A liquid sample bulk mailing packaging device includes a paperboard envelope blank assembled to form a hermetically sealed leakproof containment pocket such that a moisture resistant coating on one of the paperboard surfaces will prevent leakage in the event an enclosed liquid containing packette fa
A liquid sample bulk mailing packaging device includes a paperboard envelope blank assembled to form a hermetically sealed leakproof containment pocket such that a moisture resistant coating on one of the paperboard surfaces will prevent leakage in the event an enclosed liquid containing packette fails during mail processing, while the other paperboard surface will absorb the moisture from the packette. The device meets the US Postal Service requirements for machinable and automation letters.
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1. An envelope blank comprising: paperboard having a first side, a second opposite side, a top edge, a bottom edge, a first lateral edge, and an opposite second lateral edge;the paperboard coated on the first side with a semi-permeable coating to form a printable surface;print media placed on at lea
1. An envelope blank comprising: paperboard having a first side, a second opposite side, a top edge, a bottom edge, a first lateral edge, and an opposite second lateral edge;the paperboard coated on the first side with a semi-permeable coating to form a printable surface;print media placed on at least a portion of the printable surface;a moisture resistant coating overlying the print media and semi-permeable coating;a first panel extending from the top edge having a picture frame cutout with a non-permeable window adhered to the second side; anda second panel extending from the first panel with the second side having a liquid packette mounting area, with at least a portion of the paperboard in the liquid packette mounting area uncoated such that the uncoated portion is absorbent. 2. The envelope blank of claim 1 wherein the paperboard has a Cobb value of at least about 50 gm/square meter. 3. The envelope blank of claim 2 further comprising ink applied to color the liquid packette mounting area. 4. The envelope blank of claim 1 wherein the non-permeable window is formed from the group consisting of plastic and metalized plastic films. 5. The envelope blank of claim 4 wherein the non-permeable window is adhered to the second side by a permanent glue encircling the periphery of the picture frame cutout. 6. The envelope blank of claim 1 wherein the paperboard comprises solid bleached sulfate (SBS) paperboard and the semi-permeable coating is a clay coating. 7. The envelope blank of claim 1 wherein the moisture resistant coating is an aqueous coating. 8. The envelope blank of claim 1 die-cut in a substantially rectangular shape for folding into an envelope having a length, a height, and a thickness when enclosing a sample liquid packette, further comprising: a third panel extending from the second panel towards the bottom edge;a fourth panel extending from the third panel to the bottom edge;a first fold line between the first panel and the second panel;a second fold line between the third panel and the fourth panel;a third fold line between the second panel and the third panel;a first tab cut along the first lateral edge in the first panel proximate the first fold line;a second tab opposite the first tab and cut along the second lateral edge in the first panel proximate the first fold line; anda tear string having a tensile strength greater than the paperboard tensile strength, the tear string adhered to the second side of the first panel extending from the first tab to the second tab. 9. The envelope blank of claim 8 wherein the tear string comprises a flat polyester ribbon, the tear string adhered by a permanent glue. 10. The envelope blank of claim 8 wherein the print media presents: the first panel having an attractive display for the nonpermeable window area;the second panel having an attractive and informational graphic presentation, appropriate marking for presorted bulk mail treatment by the United States Postal Service including a marking indicating a liquid sample is enclosed, and a blank area for subsequent address and barcode information; andattractive and informational graphic presentations in the third and fourth panels. 11. The envelope blank of claim 10 further comprising a fugitive glue applied to the second side of the second panel and a sample liquid packette adhered to the envelope blank by the fugitive glue. 12. The envelope blank of claim 11 wherein the sample liquid packette has a burst strength of at least about 1500 psi. 13. The envelope blank of claim 11 further comprising: a line of permanent glue applied to the second side of the second panel around the sample liquid packette, from proximate the first fold line at a point inward of the first tab extending substantially diagonally outward, towards the first lateral edge, then extending towards the third fold line, then extending towards the second lateral edge, then extending towards the first fold line, then extending substantially diagonally inward to a point inward of the second tab; andpermanent glue applied to the second side of the third panel proximate to and parallel with the third fold line, the second fold line, the first lateral edge, and the second lateral edge. 14. The envelope blank of claim 13 wherein: the second side of the first panel is folded along the first fold line and glued to the second panel forming a leakproof containment pocket around the sample liquid packette, andthe second side of the fourth panel is folded along the second fold line and glued to the third panel. 15. The envelope blank of claim 14 further comprising a coupon having a coupon barcode uniquely identifying the coupon, the coupon releasably adhered to the first side of the fourth panel by a fugitive glue. 16. A liquid sample bulk mailing packaging device formed from the envelope blank of claim 15, wherein the packaging device is formed from the envelope blank further comprising: fugitive glue applied to spots on the first side of the first panel proximate the first lateral edge, the first fold line, and the second lateral edge;the first side folded along the third fold line and glued to the first side of the fourth panel; anda targeted address and address barcode printed in the address area, wherein the coupon barcode is associated by a computer database with the address barcode. 17. The liquid sample bulk mailing packaging device of claim 16 forming an envelope having: a length between 5 and 11.5 inches,a height between 3.5 and 6.125 inches,a thickness no greater than 0.25 inches, anda weight no greater than 3.5 ounces,wherein an aspect ratio of the length divided by the height is between 1.3 and 2.5; andwherein the liquid sample bulk mailing packaging device has flexibility sufficient to bend around an 11 inch diameter drum when subjected to a transport belt tension of 40 pounds. 18. A liquid sample bulk mailing packaging device comprising: an envelope blank comprising paperboard having a semi-permeable coated first side forming a printable surface, print media placed on at least a portion of the printable surface, a moisture resistant coating overlying the print media and semi-permeable coating, and an uncoated second side providing a moisture absorbing surface, the envelope blank having a first panel extending from a top edge and a second panel adjacent the first panel;a sample liquid packette comprising a cover film laminated to a backing film and containing a volume of sample liquid, the sample liquid packette having a burst strength and providing a primary sealing means for containing the sample liquid during mailing, the sample liquid packette adhered to a packette mounting area on the second side of the second panel by a fugitive glue; anda permanent glue applied to the perimeter of the packette mounting area from a fold line between the first panel and the second panel, such that the sample liquid packette is encircled by the fold line and the permanent glue, the first panel folded to and glued to the second panel packette mounting area forming a hermetic seal around the sample liquid packette, the hermetic seal providing a secondary sealing means to prevent leakage of liquid from the sample liquid packette from the liquid sample bulk mailing packaging device;wherein the liquid sample bulk mailing packaging device is not greater than ¼ inch thick and is within the United States Postal Service requirements for Automation letters. 19. The liquid sample bulk mailing packaging device of claim 18 wherein the paperboard comprises solid bleached sulfate (SBS) paperboard capable of absorbing the moisture contained within the sample liquid packette. 20. The liquid sample bulk mailing packaging device of claim 18 wherein the paperboard has a Cobb value of at least about 50 gm/square meter. 21. The liquid sample bulk mailing packaging device of claim 20 wherein the burst strength exceeds 1000 psi as defined by ASTM testing method F-1140. 22. The liquid sample bulk mailing packaging device of claim 18 further comprising: a third panel extending from the second panel and a fourth panel extending from the third panel, the second side of the fourth panel folded to and glued to the second side of the third panel; andthe first panel having a picture frame cut-out with a nonpermeable window adhered to the second side. 23. The liquid sample bulk mailing device of claim 22 further comprising: a first tab cut along a first lateral edge and a second tab cut along an opposite second lateral edge in the first panel proximate the fold line between the first panel and the second panel, anda tear string comprising a string material having a tensile strength greater than a tensile strength of the paperboard, the tear string adhered to the second side of the first panel by a permanent glue and extending from the first tab to the second tab. 24. The liquid sample bulk mailing packaging device of claim 18 wherein the sample liquid is selected from the group comprising liquids, creams, lotions, color cosmetics, gels, paste, and other fluid products. 25. The liquid sample bulk mailing packaging device of claim 18 wherein the sample liquid is selected from the group comprising aromatics, fragrances, and other volatile products in any form. 26. A method of assembling a liquid sample bulk mailing packaging device comprising: providing an envelope blank formed from paperboard clay coated on a first side and uncoated on the opposite second side, preprinted with print media on the clay coated side providing attractive and informational graphic presentations in a first, second, third, and fourth panel area, having a moisture resistant coating overlying the print media, and having the first panel including a non-permeable window adhered to the second side by a permanent glue, the envelope blank having a top edge, a bottom edge, a first lateral edge, and an opposite second lateral edge;cutting a first tab along the first lateral edge in the first panel, proximate a fold line between the first panel and the second panel, and a second tab opposite the first tab along the second lateral edge, and adhering a string to the second side extending from the first tab to the second tab with a permanent glue;applying a fugitive glue to the second side of the second panel;placing a sample liquid packette on the fugitive glue in the second panel;applying a line of permanent glue to the second side of the second panel around from a first fold line between the first and second panels at a point inward of the first tab extending around the sample liquid packette to a point inward of the second tab;applying permanent glue to the second side of the third panel proximate to and parallel with the third fold line, a fourth fold line, the first lateral edge, and the second lateral edge;folding the second side of the first panel towards the second panel and pressing the periphery of the first panel to adhere a first panel to the second panel with the permanent glue;folding the second side of the fourth panel towards the third panel and pressing the periphery of the fourth panel to adhere the fourth panel to the third panel with the permanent glue;applying a fugitive glue to the first side of the first panel;folding the first side of the first panel towards the fourth panel and adhering the panels together with the fugitive glue; andprinting address the information in an address area on the first side of the second panel. 27. The method of claim 26 further comprising adhering a coupon to the first side of the fourth panel with fugitive glue. 28. The method of claim 27 further comprising correlating the coupon to addressee information in a computer database. 29. A liquid sample bulk mailing packaging device comprising: an envelope blank comprising paperboard having a semi-permeable coated first side forming a printable surface, print media placed on at least a portion of the printable surface, and an uncoated second side providing a moisture absorbing surface, the envelope blank having a first panel extending from a top edge and a second panel adjacent the first panel;a sample liquid packette comprising a cover film laminated to a backing film and containing a volume of sample liquid, the sample liquid packette having a burst strength and providing a primary sealing means for containing the sample liquid during mailing, the sample liquid packette adhered to a packette mounting area on the second side of the second panel; anda permanent glue applied to the perimeter of the packette mounting area from a fold line between the first panel and the second panel, such that the sample liquid packette is encircled by the fold line and the permanent glue, the first panel folded to and glued to the second panel packette mounting area forming a hermetic seal around the sample liquid packette, the hermetic seal providing a secondary sealing means to prevent leakage of liquid from the sample liquid packette from the liquid sample bulk mailing packaging device;wherein the liquid sample bulk mailing packaging device is not greater than ¼ inch thick and is within the United States Postal Service requirements for Automation letters.
Baker, Ronald; Galarneau, Steven J.; Farrell, Gary S.; Griffith, Paul E.; Wood, Charles E., Mail flat assembly for automated processing and method of distributing promotional items using same.
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