Sealed envelope assembly with locking pockets for free insert material

Claim 2

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having lines of adhesive adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said lines of adhesive being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said lines of adhesive, said back ply having a plurality of spaced embossments located inwardly of said lines of adhesive and adjacent the periphery of said insert ply, each of said embossments comprising a tab having a base portion integrally secured to said back ply along a substantially straight deflection line and a free portion deflected towards said front ply in substantial overlapping relationship with said insert ply so as to form a locking pocket therefor, said insert ply being maintained in desired registration within said envelope during machine processing by such locking pockets, said lines of adhesive being discontinuous, the discontinuities therein occurring at least adjacent said embossments, said front and back plies having corresponding lines of weakening disposed inwardly of the deflection lines of said embossments along at least one side of said envelope whereby separation of the plies along the lines of weakening opens said envelope assembly and frees said insert ply from the locking pockets along said one side.

Claim 3

The envelope assembly of claim 1 wherein said embossments are disposed adjacent opposite peripheral edges of said insert ply, the spacing of the innermost extremities of the free portion of the tabs being less than the corresponding dimension of said insert ply.

Claim 4

The envelope assembly of claim 1 wherein said embossments comprise tabs cut from said back ply and deflected along said deflection line towards said front ply.

Claim 5

The envelope assembly of claim 3 wherein the free portions of said tabs are rectilinearly configured.

Claim 6

The envelope assembly of claim 3 wherein the free portions of said tabs are curvilinearly configured.

Claim 7

The envelope assembly of claim 1 wherein each edge of said insert ply has at least one embossment positioned adjacent thereto.

Claim 8

The envelope assembly of claim 1 wherein the free portions of said tabs have an inwardly disposed length no less than about three times the thickness of the insert ply and overlap the insert ply by no less than about 1/16 inch.

Claim 9

The envelope assembly of claim 1 including a plurality of insert plies of different size and separate embossments forming locking pockets for each different size of insert ply.

Claim 10

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having internal adhesive means adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said adhesive means being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said adhesive means, said back ply having a plurality of spaced embossments located inwardly of said adhesive means and adjacent opposite peripheral edges of said insert ply, each of said embossments comprising a rectangular tab having a base portion integrally secured to said back ply along a substantially straight deflection line and a three-sided free portion cut from said back ply and deflected towards said front ply in substantial overlapping relationship with said insert ply so as to form a locking pocket therefor, the spacing between the innermost extremities of the free portion of opposed tabs being less than the corresponding dimension of said insert ply, said insert ply being maintained in desired registration within said envelope during machine processing by the locking pockets, said adhesive means being discontinuous, the discontinuities therein occurring at least adjacent said embossments, said front and back plies each including a line of weakening disposed inwardly of the deflection lines of said embossments along one side of said envelope whereby separation of the plies along the lines of weakening removes a marginal portion of the plies, frees the insert ply from the locking pockets on the removed marginal portion, and opens said envelope assembly.

Claim 11

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having internal adhesive means adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said adhesive means being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said adhesive means, said back ply having a plurality of spaced embossments located inwardly of said adhesive means and adjacent opposite peripheral edges of said insert ply, each of said embossments comprising a rectangular tab having a base portion integrally secured to said back ply along a substantially straight deflection line and a three-sided free portion cut from said back ply and deflected towards said front ply in substantial overlapping relationship with said insert ply so as to form a locking pocket therefor, the spacing between the innermost extremities of the free portion of opposed tabs being less than the corresponding dimension of said insert ply, said insert ply being maintained in desired registration within said envelope during machine processing by the locking pockets, said adhesive means being discontinuous, the discontinuities therein occurring at least adjacent said embossments, said front and back plies each including a line of weakening disposed inwardly of the deflection lines of said embossments along one side of said envelope whereby separation of the plies along the lines of weakening removes a marginal portion of the plies, frees the insert ply from the locking pockets on the removed marginal portion, and opens said envelope assembly.

Claim 12

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having internal lines of adhesive adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said lines of adhesive being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said lines of adhesive, said back ply having a plurality of spaced tabs located inwardly of said lines of adhesive and adjacent opposite peripheral edges of said insert ply, each of said tabs comprising a base portion secured to said back ply and a free portion deflected towards said front ply in overlapping relationship with said insert ply so as to form a locking pocket therefor, the spacing between the innermost extremities of the free portion of opposed tabs being less than the corresponding dimension of said insert ply, said insert ply being maintained in desired registration within said envelope during machine processing by such locking pockets, said lines of adhesive being discontinuous, the discontinuities therein occurring at least adjacent said tabs, said front and back plies each including a line of weakening disposed inwardly of the deflection lines of the tabs along one side of said envelope whereby separation of the plies along the lines of weakening removes a marginal portion of the plies, opens said envelope assembly and frees said insert ply from the locking pockets on the removed marginal portion.

Claim 13

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having internal lines of adhesive adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said lines of adhesive being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said lines of adhesive, said back ply having a plurality of spaced tabs located inwardly of said lines of adhesive and adjacent opposite peripheral edges of said insert ply, each of said tabs comprising a base portion secured to said back ply and a free portion deflected towards said front ply in overlapping relationship with said insert ply so as to form a locking pocket therefor, the spacing between the innermost extremities of the free portion of opposed tabs being less than the corresponding dimension of said insert ply, said insert ply being maintained in desired registration within said envelope during machine processing by such locking pockets, said lines of adhesive being discontinuous, the discontinuities therein occurring at least adjacent said tabs, said front and back plies each including a line of weakening disposed inwardly of the deflection lines of the tabs along one side of said envelope whereby separation of the plies along the lines of weakening removes a marginal portion of the plies, opens said envelope assembly and frees said insert ply from the locking pockets on the removed marginal portion.

Claim 14

The envelope assembly of claim 10 wherein each of said tabs, as defined by the deflection line and the free edges of said free portion, is rectangular.

Claim 15

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having internal adhesive means adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said adhesive means being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said adhesive means, said back ply having a plurality of spaced embossments located inwardly of said adhesive means and adjacent opposite peripheral edges of said insert ply, each of said embossments comprising a rectangular tab having a base portion integrally secured to said back ply along a substantially straight deflection line and a free portion cut from said back ply and deflected towards said front ply in substantial overlapping relationship with said insert ply so as to form a locking pocket therefor, the spacing between the innermost extremities of the free portion of opposed tabs being less than the corresponding dimension of said insert ply, said insert ply being maintained in desired registration within said envelope during machine processing by such locking pockets, said adhesive means being discontinuous, the discontinuities therein occurring at least adjacent said tabs, said front and back plies each including a line of weakening disposed inwardly of the deflection lines of the embossments along one side of said envelope whereby separation of the plies along the lines of weakening removes a marginal portion of the plies, opens said envelope assembly and frees said insert ply from the locking pockets on the removed marginal portion.

Claim 16

A stuffed, sealed envelope assembly comprising an envelope having front and back plies and at least one insert ply between said front and back plies, said envelope having internal adhesive means adjacent the peripheral edges of said front and back plies for uniting said front and back plies to form a generally sealed assembly, said adhesive means being spaced from the periphery of said insert ply so that said insert ply lies wholly within the enclosure of said envelope bounded by said adhesive means, said back ply having a plurality of spaced embossments located inwardly of said adhesive means and adjacent opposite peripheral edges of said insert ply, each of said embossments comprising a rectangular tab having a base portion integrally secured to said back ply along a substantially straight deflection line and a free portion cut from said back ply and deflected towards said front ply in substantial overlapping relationship with said insert ply so as to form a locking pocket therefor, the spacing between the innermost extremities of the free portion of opposed tabs being less than the corresponding dimension of said insert ply, said insert ply being maintained in desired registration within said envelope during machine processing by such locking pockets, said adhesive means being discontinuous, the discontinuities therein occurring at least adjacent said tabs, said front and back plies each including a line of weakening disposed inwardly of the deflection lines of the embossments along one side of said envelope whereby separation of the plies along the lines of weakening removes a marginal portion of the plies, opens said envelope assembly and frees said insert ply from the locking pockets on the removed marginal portion.