Business form or mailer intermediate with protective laminate

Claim 2

A business form or mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; at least a first transverse fold line formed in said substrate perpendicular to said parallel longitudinal edges, said at least first fold line dividing said substrate into at least first and second panels; at least one base ply portion having an upper and a lower surface, said base ply portion being detachably secured to said first panel of said substrate; at least one protective laminate portion positioned opposite and in substantial alignnment with said base ply portion with respect to said first transverse fold line, said protective laminate portion having an upper surface and a lower surface, said protective laminate portion being secured to said first surface in said second panel via a releasable bond characterized by a releasable adhesive bonding strength; and a laminating adhesive provided on one or both of said upper surface of said base ply and said upper surface of said protective laminate wherein said laminating adhesive is characterized by a laminating adhesive bonding strength and wherein said laminating adhesive bonding strength exceeds said releasable adhesive bonding strength.

Claim 3

The business form or mailer intermediate as claimed in claim 1 wherein said base ply portion is a card formed in said substrate in said first panel.

Claim 4

The business form or mailer intermediate as claimed in claim 1 wherein said base ply portion is a label formed on said first surface in said first panel of said substrate.

Claim 5

The business form or mailer intermediate as claimed in claim 1 wherein multiple base ply portions are provided in said first panel and multiple protective laminate portions are provided on said second panel.

Claim 6

The business form or mailer intermediate as claimed in claim 3 further including a label adhesive disposed on said lower surface of said label.

Claim 7

The business form or mailer intermediate as claimed in claim 5 further including a liner ply disposed on said first surface of said substrate sheet, said label being releasably adhered to said liner ply by means of said label adhesive.

Claim 8

The business form or mailer intermediate as claimed claim 1 wherein said laminating adhesive is a hot-melt or pressure activatable adhesive.

Claim 9

The business form or mailer intermediate as claimed in claim 5 wherein said label adhesive is a pressure activatable adhesive.

Claim 10

The business form or mailer intermediate as claimed in claim 1 wherein said protective laminate portion further includes a film adhesive disposed on said lower surface of said protective laminate portion.

Claim 11

The business form or mailer intermediate as claimed in claim 9 wherein said film adhesive is a dry-residue fugitive adhesive.

Claim 12

The business form or mailer intermediate as claimed in claim 1 wherein said protective laminate portion includes lines of weakness thereby defining a center portion and an edge portion.

Claim 13

The business form or mailer intermediate as claimed in claim 11 wherein said lower surface of said edge portion on said protective laminate portion is provided with said film adhesive.

Claim 14

The business form or mailer intermediate as claimed in claim 12 wherein said film adhesive is a permanent adhesive.

Claim 15

The business form or mailer intermediate as claimed in claim 11 wherein a portion of said substrate lying in register with said center portion in said protective laminate portion includes a die-cut hole.

Claim 16

The business form or mailer intermediate as claimed in claim 1 wherein said protective laminate portion comprises a two-ply film having a first film and a second film releasably adhered to each other.

Claim 17

The business form or mailer intermediate as claimed in claim 15 wherein said second film is adhered to said substrate with a mounting adhesive.

Claim 18

The business form or mailer intermediate as claimed in claim 16 wherein said mounting adhesive is a permanent adhesive.

Claim 19

The business form or mailer intermediate as claimed in claim 1 further including a second transverse fold line formed in said substrate perpendicular to said parallel longitudinal edges thereby defining a third panel adjacent said first or second panels.

Claim 20

The business form or mailer intermediate as claimed in claim 18 further including lines of weakness adjacent said first and second parallel longitudinal edges defining marginal strips between said lines of weakness and said first and second parallel longitudinal edges.

Claim 21

The business form or mailer intermediate as claimed in claim 19 further including an edge adhesive disposed on said first surface on said marginal strips in at least one of said first and second panels.

Claim 22

The business form or mailer intermediate as claimed in claim 20 further including an address window disposed in one of said first, second, or third panels.

Claim 23

The business form or mailer intermediate as claimed in claim 19 further including a sealing adhesive disposed on said marginal strips on either said second surface of said second panel and said first surface of said third panel or second surface of said first panel and said second surface of said third panel.

Claim 24

The business form or mailer intermediate as claimed in claim 20 further including an end adhesive disposed adjacent said first or second opposite ends.

Claim 25

A mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; first and second transverse fold lines formed in said substrate perpendicular to said parallel longitudinal edges, said first and second fold lines dividing said substrate into first, second and third panels, said first fold line separating said first and second panels; a base ply portion having an upper and a lower surface, said base ply portion being detachably secured to one of said first or second panels of said substrate; a protective laminate portion positioned opposite and in substantial alignment with said base ply portion with respect to said first transverse fold line, said protective laminate portion having an upper surface and a lower surface, said protective laminate portion being secured to said first surface in another of said first or second panels via a releasable bond characterized by a releasable adhesive bonding strength; and a laminating adhesive provided on one or both of said upper surface of said base ply and said upper surface of said protective laminate wherein said laminating adhesive is characterized by a laminating adhesive bonding strength and wherein said laminating adhesive bonding strength exceeds said releasable adhesive bonding strength.

Claim 26

A mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; first and second transverse fold lines formed in said substrate perpendicular to said parallel longitudinal edges, said first and second fold lines dividing said substrate into first, second and third panels, said first fold line separating said first and second panels; a base ply portion having an upper and a lower surface, said base ply portion being detachably secured to one of said first or second panels of said substrate; a protective laminate portion positioned opposite and in substantial alignment with said base ply portion with respect to said first transverse fold line, said protective laminate portion having an upper surface and a lower surface, said protective laminate portion being secured to said first surface in another of said first or second panels via a releasable bond characterized by a releasable adhesive bonding strength; and a laminating adhesive provided on one or both of said upper surface of said base ply and said upper surface of said protective laminate wherein said laminating adhesive is characterized by a laminating adhesive bonding strength and wherein said laminating adhesive bonding strength exceeds said releasable adhesive bonding strength.

Claim 27

The mailer intermediate as claimed in claim 24 wherein said base ply portion is a card formed in said substrate.

Claim 28

The mailer intermediate as claimed in claim 24 said base ply portion is a label formed on said first surface of said substrate.

Claim 29

The mailer intermediate as claimed in claim 24 wherein multiple base ply portions are provided in said first panel and multiple protective laminate portions are provided on said second panel.

Claim 30

The mailer intermediate as claimed in claim 24 further including lines of weakness adjacent said first and second parallel longitudinal edges defining marginal strips between said lines of weakness and said first and second parallel longitudinal edges.

Claim 31

The mailer intermediate as claimed in claim 28 further including an edge adhesive pattern disposed on said first surface of said marginal strips in at least one of said first and second panels.

Claim 32

The mailer intermediate as claimed in claim 29 further including a sealing adhesive disposed on said marginal strips on either said second surface of said second panel and said first surface of said third panel or said second surface of said first panel and said second surface of said third panel.

Claim 33

The mailer intermediate as claimed in claim 24 further including an address window disposed in one of said first and second panels.

Claim 34

The mailer intermediate as claimed in claim 24 further including an end adhesive disposed adjacent said first or second opposite ends.

Claim 35

The business form or mailer intermediate as claimed in claim 1 wherein said base ply portion is a tag formed in said substrate or on said first surface of said substrate.

Claim 36

The business form or mailer intermediate as claimed in claim 1 wherein lines of weakness are provided in said substrate to define said base ply portion.

Claim 37

A business form or mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; at least a first transverse fold line formed in said substrate perpendicular to said parallel longitudinal edges, said at least first fold line dividing said substrate into at least first and second panels; at least one label having an upper and a lower surface, said label being formed on said first surface in said first panel of said substrate; at least one protective laminate portion having an upper surface and a lower surface, said protective laminate portion being provided on said first surface in said second panel, said protective laminate portion being positioned opposite to and in substantial alignment with said label with respect to said first transverse fold line; a label adhesive disposed on a lower surface of said label; a liner ply disposed on said first surface of said substrate sheet, said label being releasably adhered to said liner ply by means of said label adhesive; and a laminating adhesive provided on one or both of said upper surface of said label and said upper surface of said protective laminate wherein when said substrate is folded about said at least first fold line said protective laminate portion adheres to said label.

Claim 38

A business form or mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; at least a first transverse fold line formed in said substrate perpendicular to said parallel longitudinal edges, said at least first fold line dividing said substrate into at least first and second panels; at least one label having an upper and a lower surface, said label being formed on said first surface in said first panel of said substrate; at least one protective laminate portion having an upper surface and a lower surface, said protective laminate portion being provided on said first surface in said second panel, said protective laminate portion being positioned opposite to and in substantial alignment with said label with respect to said first transverse fold line; a label adhesive disposed on a lower surface of said label; a liner ply disposed on said first surface of said substrate sheet, said label being releasably adhered to said liner ply by means of said label adhesive; and a laminating adhesive provided on one or both of said upper surface of said label and said upper surface of said protective laminate wherein when said substrate is folded about said at least first fold line said protective laminate portion adheres to said label.

Claim 39

A business form or mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; at least a first transverse fold line formed in said substrate perpendicular to said parallel longitudinal edges, said at least first fold line dividing said substrate into at least first and second panels; at least one base ply portion having an upper and a lower surface, said base ply portion being provided in said substrate in said first panel or on said first surface in said first panel; at least one protective laminate portion having an upper surface and a lower surface, said protective laminate portion being provided on said first surface in said second panel, opposite to and in substantial alignment with said base ply portion with respect to said first transverse fold line, wherein said protective laminate portion further includes a film adhesive disposed on said lower surface; and a laminating adhesive provided on one or both of said upper surface of said base ply and said upper surface of said protective laminate wherein when said substrate is folded about said at least first fold line said protective laminate portion adheres to said base ply portion.

Claim 40

A business form or mailer intermediate comprising: a substrate sheet having first and second surfaces, first and second parallel longitudinal edges and first and second opposite ends; at least a first transverse fold line formed in said substrate perpendicular to said parallel longitudinal edges, said at least first fold line dividing said substrate into at least first and second panels; at least one base ply portion having an upper and a lower surface, said base ply portion being provided in said substrate in said first panel or on said first surface in said first panel; at least one protective laminate portion having an upper surface and a lower surface, said protective laminate portion being provided on said first surface in said second panel, opposite to and in substantial alignment with said base ply portion with respect to said first transverse fold line, wherein said protective laminate portion further includes a film adhesive disposed on said lower surface; and a laminating adhesive provided on one or both of said upper surface of said base ply and said upper surface of said protective laminate wherein when said substrate is folded about said at least first fold line said protective laminate portion adheres to said base ply portion.