Promotional one-piece mailer assembly having an integral coupon card

United States Patent [w]

Best et al.

[54] PROMOTIONAL ONE-PIECE MAILER ASSEMBLY HAVING AN INTEGRAL COUPON CARD

[75] Inventors: Scott D. Best, Troy; James F. Turner,

Farmington Hills, both of Mich.

[73] Assignee: Saxon, Inc., Ferndale, Mich.

[21] Appl. No.: 09/437,431 [22] Filed: Nov. 17, 1999

Related U.S. Application Data

[60] Provisional application No. 60/108,689, Nov. 17, 1998.

[51] Int. C I. G09B 19/00

[52] U.S. CI 283/56; 283/51; 283/116

[58] Field of Search 283/51, 56, 61,

283/62, 117, 903, 81, 100, 101, 116; 229/92.8

[56] References Cited

U.S. PATENT DOCUMENTS

1,258,922 3/1918 Marco 283/51

1,415,596 5/1922 McKinnie .

1,957,374 5/1934 Unger .

4,479,838 10/1984 Dunsirn et al 283/81 X

4,742,954 5/1988 Shishido 229/92.8

4,767,654 8/1988 Riggsbee 40/310 X

4,778,153 10/1988 Bachman et al 283/101

4,892,246 1/1990 Norman 229/92.8

4,915,287 4/1990 Volk et al 283/51 X

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[ii] Patent Number: 6,092,841 [45] Date of Patent: Jul. 25,2000

4,957,311 9/1990 Geisenheimer 283/56

5,076,490 12/1991 Dulin 229/92.8

5,100,179 3/1992 Burden et al 283/62

5,228,723 7/1993 Hertig 283/100

5,308,120 5/1994 Thompson 283/70

5,417,458 5/1995 Best et al 283/51

5,458,282 10/1995 Martin 283/56 X

5,468,021 11/1995 Ovadia 283/56

5,495,981 3/1996 Warther 283/81 X

5,571,358 11/1996 Napier et al 156/227

5,641,116 6/1997 Martin .

5,776,287 7/1998 Best et al 283/51

5,799,981 9/1998 Tung et al 283/56

5,836,622 11/1998 Fabel 283/62

Primary Examiner—-Willmon Fridie, Jr.
Attorney, Agent, or Firm—Howard & Howard

[57] ABSTRACT

A promotional one-piece mailer assembly having two layers of card stock. A release liner is sandwiched between the two layers of card stock. An integral card is formed within the first and second layers of card stock. A plurality of minicoupons are detachably cut into the integral card through the second layer of card stock. The assembly is characterized by a series of score lines cut through the first and second layers of card stock and the liner and spaced from the peripheral edges of the first and second layers of card stock to completely define the card integrally disposed within the mailer assembly and to securely maintain the card within the mailer assembly.

16 Claims, 2 Drawing Sheets

PROMOTIONAL ONE-PIECE MAILER
ASSEMBLY HAVING AN INTEGRAL
COUPON CARD

RELATED APPLICATION 5

This patent application claims priority to and all the benefits of U.S. Provisional patent application Ser. No. 60/108,689, filed on Nov. 17, 1998 and entitled "One Piece Mailer with Integral Coupon Card".

BACKGROUND OF THE INVENTION

1) Technical Field

The subject invention relates to coupon cards and in particular to a coupon card disposed within a promotional 15 mailer.

2) Description of the Prior Art

Coupon cards having a number of mini-coupons which may be removed and redeemed are well known. It is also 2Q well known to place an individual mini-coupon directly on a product for instant redemption. The mini-coupons are a popular means of attracting customers and encouraging additional sales. The prior art coupon cards and minicoupons have various constructions and are used for a ^ multitude of applications. Examples of some prior art coupon cards and mini-coupons are disclosed in U.S. Pat. Nos. 4,479,838; 4,767,654; and 5,308,120. Another prior art coupon card having a unique and superior construction is illustrated in U.S. Pat. No. 5,417,458. The '458 patent is 3Q assigned to the assignee of the subject invention and includes a novel structure of two layers of card stock sandwiching a liner with adhesive disposed between each layer of card stock and the liner. The two layers of card stock allow the mini-coupons to be removed while maintaining 3J sufficient integrity and rigidity within the card itself.

One-piece promotional mailers are also well known in the art. These mailers are typically sent through the postal service system under a bulk rate postage. The postal service system requires a particular size and format in order to 40 receive the bulk rate postage discount. The standardized size and format for the mailers is needed because of the high volume and speed in which these mailers pass through the postal service's sorting machines.

The mailers usually have advertisements, informational 45 messages and other like promotional verbiage imprinted thereon. There may also be an index card, such as Rolodex® type business card, at least partially attached to the mailer. Specifically, the index cards are at least partially die cut from the mailer. A user then tears the index card out of the mailer. 50 Examples of promotional mailers having removable index cards are disclosed in U.S. Pat. Nos. 4,957,311 and 5,076, 490. The prior art mailers, however, are formed of a single sheet of paper material such that the structural integrity of the mailers is in question. In addition, the die cuts reduce the 55 rigidity of the mailers. During the high speed processing of the mailers, the index cards may become detached or deform about the die cuts such that the mailers become destroyed, mutilated, or otherwise damaged.

Accordingly, there is a need for a promotional mailer 60 having sufficient structural integrity to support a removable item disposed within the mailer. In addition, it would be desirable to incorporate the advantages and popularity of the mini-coupons into the convenience of a bulk rate promotional mailer. Finally, it would be even more desirable to 65 incorporate an entire coupon card, having a plurality of mini-coupons, into a structurally sound mailer.

SUMMARY OF THE INVENTION AND
ADVANTAGES

A promotional one-piece mailer assembly comprising a first layer of card stock having an exterior surface and an interior surface with a plurality of outer peripheral edges. A liner is adhered to the interior surface of the first layer of card stock. A second layer of card stock, having an exterior surface and an interior surface with a plurality of outer peripheral edges, is aligned with the peripheral edges of the first layer of card stock. The interior surface of the second layer of card stock is adhered to the liner to sandwich the liner between the first and second layers of card stock. An integral card is formed within the first and second layers of card stock. A plurality of mini-coupons are detachably cut into the integral card through the second layer of card stock. The assembly is characterized by a series of score lines cut through the first and second layers of card stock and the liner and spaced from the peripheral edges of the first and second layers of card stock to completely define the card integrally disposed within the mailer assembly and to securely maintain the card within the mailer assembly.

Accordingly, the promotional mailer of the subject invention has a double card stock layer construction for providing adequate structural integrity and rigidity to the mailer. In addition, the card, which is a coupon card having a plurality of mini-coupons, is completely disposed within the mailer such that the score lines do not intersect the peripheral edges. Hence, this also increases the structural integrity of the mailer.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a promotional mailer assembly incorporating the novel aspects of the subject invention;

FIG. 2 is a perspective view of the mailer assembly with an integral coupon card detachably spaced therefrom;

FIG. 3 is a cross-sectional view of the mailer assembly taken along line 3—3 of FIG. 2; and

FIG. 4 is a top view of a series of mailer assemblies during the manufacturing thereof.

DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENT

Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a promotional one-piece mailer assembly is generally shown at 10 in FIGS. 1 and 2. As discussed in the background section, the one-piece mailer assembly 10 is preferably used as a promotional device sent through the postal service system under a bulk rate postage.

Referring also to FIG. 3, the structure of the mailer assembly 10 comprises a first layer of card stock 12 having an exterior surface and an interior surface with a plurality of outer peripheral edges 14, 16, 18, 20. A liner 22 is adhered to the interior surface of the first layer of card stock 12. A second layer of card stock 24, having an exterior surface and an interior surface with a plurality of outer peripheral edges 14, 16, 18, 20, is aligned with the peripheral edges 14, 16, 18, 20 of the first layer of card stock 12. The interior surface of the second layer of card stock 24 is adhered to the liner