WICKETED ENVELOPES WITH DETACHABLE FASTENER REGION

Abstract

A flight of wicketed envelopes includes a plurality of envelopes, and a fastener configured to engage the plurality of envelopes through a detachable region on the envelopes so that the envelopes are connected by the detachable regions and the fastener.

Claims

1. A flight of wicketed envelopes, the flight comprising: a plurality of envelopes, each of the envelopes including: a first flexible wall; and a second flexible wall overlying the first flexible wall and fixed to the first flexible wall about at least a portion of a pocket border, which pocket border encloses a pocket defined between the walls and configured and dimensioned to contain an item, at least one of the first and second flexible walls defining an envelope pocket opening extending in a transverse direction of the envelope and allowing access to the envelope pocket from an exterior of the envelope for loading the item into the envelope pocket; and a fastener configured to engage the plurality of envelopes through a detachable region on the envelopes so that the envelopes are connected by the detachable regions and the fastener, wherein: the envelope has a width in the transverse direction; and a maximum dimension of the detachable region in the transverse direction is less than the width of the envelope.

2. The flight of wicketed envelopes of claim 1, wherein the fastener is configured to secure the detachable regions to each other.

3. The flight of wicketed envelopes of claim 2, wherein the fastener is configured to prevent relative angular movement between the detachable regions.

4. The flight of wicketed envelopes of claim 1, wherein the fastener and the detachable regions of the envelopes collectively form a bundle.

5. The flight of wicketed envelopes of claim 4, wherein: the envelope further includes a tie; and the detachable region is connected to a remainder of the envelope by the tie.

6. The flight of wicketed envelopes of claim 5, wherein the tie is configured so that the bundle can be separated from a remainder of the flight.

7. The flight of wicketed envelopes of claim 5, wherein the tie is configured so that the bundle can be separated from the remainder of the flight by breaking the ties of the plurality of envelopes.

8. The flight of wicketed envelopes of claim 6, wherein the tie is configured so that the bundle can be separated manually from the remainder of the flight by the application of a predetermined force to the bundle of the detachable regions.

9. The flight of wicketed envelopes of claim 8, wherein the bundle is configured to be grasped on both sides thereof by a user.

10. The flight of wicketed envelopes of claim 8, wherein the tie is configured to break before any other portion of the envelope breaks as the detachable region is separated from the envelope.

11. The flight of wicketed envelopes of claim 6, wherein the detachable region is separated from an adjacent portion of the envelope by a line of separation.

12. The flight of wicketed envelopes of claim 11, wherein the line of separation extends continuously along an outer perimeter of the detachable region.

13. The flight of wicketed envelopes of claim 11, wherein the line of separation is a cut.

14. The flight of wicketed envelopes of claim 11, wherein: the tie further includes a first and second tie; the detachable region is connected to the remainder of the envelope by the first and second ties; the first tie extends between a first end of the line of separation and an upper edge of the envelope; and the second tie extends between a second end of the line of separation and the upper edge of the envelope.

15. The flight of wicketed envelopes of claim 14, wherein the first end of the line of separation is spaced from the upper edge of the envelope by not more than about 1/8 inch.

16. The flight of wicketed envelopes of claim 11, wherein: the envelope further includes a plurality of ties; the detachable region is connected to a remainder of the envelope by the ties; the line of separation includes a plurality of perforations; and each of the ties is separated from an adjacent one of the ties by one of the perforations.

17. The flight of wicketed envelopes of claim 1, wherein a maximum dimension of the detachable region in the transverse direction is less than 9/10 of the width of the envelope.

18. The flight of wicketed envelopes of claim 1, wherein the detachable region has an aspect ratio of a maximum dimension of the detachable region in the transverse direction to a maximum dimension of the detachable region in a direction orthogonal to the transverse direction and coinciding with a lengthwise direction of the envelope; and the aspect ratio of the detachable region is about 8:1 or less.

19. The flight of wicketed envelopes of claim 1, wherein the detachable region is spaced apart from at least one side of the envelope.

20. The flight of wicketed envelopes of claim 1, wherein the detachable region extends along not more than a portion of an upper end of the envelope.

21. The flight of wicketed envelopes of claim 1, wherein: each of the envelopes further includes a closure flap connected to and configured to rotate in relation to the first flexible wall of the envelope between an open position, and a closed position at which the closure flap covers the pocket opening; the detachable region is located on the closure flap; the closure flap has at least one hole formed therein and configured to receive a leg of a wicketed envelope holder; each of the envelopes further includes a sealing element disposed on one of the closure flap and the second flexible wall and configured to form a closure seal that fixes the closure flap to the second flexible wall when the closure flap is in the closed position.

22. The flight of wicketed envelopes of claim 1, wherein the fastener is a staple.

23. The flight of wicketed envelopes of claim 1, wherein the first flexible wall and/or the second flexible wall are made of paper.

24. A packaging unit, comprising: the flight of wicketed envelopes of claim 1; and a wicketed envelope holder configured to hold the flight of wicketed envelopes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

[0049] FIG. 1 is a perspective view of a flight of wicketed envelopes;

[0050] FIG. 2 is a perspective view of the envelope shown in FIG. 1, after being loaded and sealed;

[0051] FIG. 3 is a perspective view of the flight of wicketed envelopes shown in FIG. 1, installed on a wicketed envelope holder at a packing station;

[0052] FIG. 4 is a side view of two sheets being fixed to each outer to form a web for forming a first wall of the envelope of FIGS. 1-3;

[0053] FIG. 5 is a side view of two sheets being fixed to each other to form a second wall of the envelope of FIGS. 1-3;

[0054] FIG. 6 is a side view of the first and second walls of FIGS. 4 and 5 being fixed to each other to form the envelope of FIGS. 1-3;

[0055] FIG. 7 is a transverse cross-sectional view of the envelope shown in FIGS. 1-3, taken through the line VII-VII of FIG. 2, with the envelope in an unloaded and unsealed condition;

[0056] FIG. 8 is a longitudinal cross-sectional view of the envelope shown in FIGS. 1-3, taken through the line VIII-VIII of FIG. 1, with the envelope in an unloaded and unsealed condition;

[0057] FIG. 9 is a perspective view of an alternative embodiment of the envelope shown in FIGS. 1-3;

[0058] FIG. 10 is a perspective view of a flight of another alternative embodiment of the envelope shown in FIGS. 1-3; and

[0059] FIG. 11 is a perspective view of a flight of another alternative embodiment of the envelope shown in FIGS. 1-3.

DETAILED DESCRIPTION

[0060] The inventive concepts are described with reference to the attached figures, wherein like reference numerals represent like parts and assemblies throughout the several views. Several aspects of the inventive concepts are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the inventive concepts. One having ordinary skill in the relevant art, however, will readily recognize that the inventive concepts can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the inventive concepts.

[0061] Packaging containers can include parcel packaging and other containers to package items. Packaging containers are configured to contain and hold an item, typically enclosing the item, during shipping or storage of the item. Parcel packaging is configured for shipping and/or storing products, such as for storage in warehouse or retail shelves and displays. Examples of parcel packaging include flexible shipping containers such as envelopes, which can have varying degrees of flexibility and typically are used to ship or mail small or relatively flat items or smaller items around which the walls of the envelope can conform. Flexible shipping containers such as envelopes can be padded or non-padded, can be made of materials such as paper and flexible cardboard, can be configured with or without sidewalls or gussets, and can include larger envelopes such as mailers. Examples of parcel packaging also include bags, such as paper or poly bags, which can have a self-sealing capability and are typically used to ship small to medium-sized items; boxes, which can be formed from paperboard, cardboard, wood, or plastic, and typically have a rigid or semi-rigid structure suitable for holding medium to large-size items and heavier items; and shipping tubes or tube mailers, typically used to ship documents and paper items.

[0062] Directional terms such as upper, lower, above, below, etc. are used in relation to the component orientations shown in FIG. 1. The terms longitudinal and transverse are denoted in FIG. 2 by the respective arrows L and T. These terms are used for illustrative purposes only, and are not intended to limit the scope of the claims.

[0063] FIGS. 1 and 3 depict a plurality of wicketed envelopes 10. The envelopes 10 are configured to contain and hold an item to be packaged 114, typically enclosing the item 114, while the item 114 is being mailed or shipped, or otherwise needs to be packaged in a closed container. The item 114 is depicted phantom in FIG. 2.

[0064] The envelopes 10 are configured to be held by, and dispensed from a wicketed envelope holder 100, visible in FIG. 3. As discussed below, each envelope 10 has a closure flap 16 with two holes 20 formed therein. Each hole 20 is configured to receive a corresponding leg 102 of the holder 100, so that the envelope 10 can be suspended from, or otherwise held by the holder 100 by way of rigid or semi-rigid legs 102 of the holder 100. The envelope 10 can be removed from the holder 100 manually or using automated equipment, before or after the item 114 has been loaded into the envelope 10.

[0065] The envelopes 10 are arranged in groupings, or flights 106, within which the envelopes 10 are secured to each other by a mechanical fastener, as discussed below. Each flight 106 includes twenty-five of the envelopes 10. Each flight 106 can include less, or more than twenty-five envelopes 10 in the alternative. For example, in other embodiments, each flight 106 can include fifty envelopes 10. In other embodiments each flight 106 can include, for example, ten envelopes 10.

[0066] The wicketed envelope holder 100 can have any form suitable for suspending or otherwise holding the one or more flights 106 by way of legs 102 that engage the flights 106 through the holes 20 in the envelopes 10. For example, the wicketed envelope holder 100 can be used as part of a packing station 120 shown in FIG. 3. FIG. 3 depicts the wicketed envelope holder 100 as having a backboard 122, and two legs 102 that adjoin the backboard 122. The legs 102 are configured to be fixed to the backboard 122 of the packing station 120 such that the legs 102 of the holder 100 extend outward from the backboard 122.

[0067] A packaging operator can place the flight 106 on the wicketed envelope holder 100 by aligning the holes 20 in the envelopes 10 with the legs 102, and moving the flight 106 toward backboard 122 so that the legs 102 become disposed within the holes 20. The freestanding end of each leg 102 is depicted as curving upward, to help retain the flight 106 on the wicketed envelope holder 100. The entirety of each leg 102 can be straight in alternative embodiments of the wicketed envelope holder 100. Also, the wicketed envelope holder 100 is depicted as being configured to hold one of the flights 106. Alternative embodiments of the wicketed envelope holder 100 can be configured to hold more than one of the flights 106.

[0068] As discussed below, each individual envelope 10 can be loaded with one of the items 114 while the envelope 10 is suspended from the wicketed envelope holder 100, or alternatively, after the envelope 10 has been separated from the flight 106. The packing station 120 can include a working surface 124 on which the envelope 10 can be placed while it is loaded and sealed by the packaging operator. In other applications, the envelope 10 can be loaded and sealed using automated equipment.

[0069] In other applications, the wicketed envelope holder 100 can be configured to engage and straddle the upper end of a backer board, a partition, or a short wall. In other applications, the wicketed envelope holder 100 can be configured as two rods or hooks fixed directly, and individually, to a wall, a partition, a backer board, or another supporting structure. In one such application, the backer board can be a pegboard, and the hooks can be configured to engage the holes in the pegboard. In other applications, the wicketed envelope holder 100 can be configured as a stand, the base of which can rest on or be fixed to a horizontal surface. The wicketed envelope holder 100 can have other configurations in other applications.

[0070] Each envelope 10 can be formed, in whole or in part, from paper, such as kraft paper. Examples of paper suitable for use in forming the envelopes 10 include, but are not limited to, kraft paper, fiberboard, pulp-based paper, recycled paper, newsprint, paperboard, cellulose compositions, starch compositions etc. In some applications, the paper may be an extensible paper configured to elongate, or stretch, by a percentage of its original (unstretched) length, without tearing. Parameters of the paper, including its dimensions and weight, may be varied depending upon the desired application. For example, the envelope 10 can be formed from kraft paper having a basis weight of 40 pounds per 3,000 square feet. Alternatively, the envelope 10 can be formed from paper having a basis weight greater or less than 40 pounds per 3,000 square feet. The envelope 10 can be formed from materials other than paper, such as plastic film, in alternative embodiments.

[0071] Referring to FIGS. 1 and 2, each envelope 10 comprises a flexible wall 12, and a flexible wall 14 fixed to the flexible wall 12 in the below-described manner. The walls 12, 14 define a containment region in the form of an envelope pocket 15, depicted in phantom in FIG. 2. The envelope pocket 15 is configured to receive and hold the item to be packaged 114.

[0072] In alternative embodiments, the envelope 10 can include a bottom gusset that adjoins the lower ends of the walls 12, 14 and extends transversely across the bottom of the envelope 10. The gusset further defines the envelope pocket 15 in such embodiments, and facilitates expansion of the envelope 10 by allowing relative movement between the wall 12 and the wall 14. Other alternative embodiments of the envelope 10 can include longitudinally-extending gussets positioned between the walls 12 and 14, in addition to or in lieu of the bottom gusset.

[0073] A lower end of the closure flap 16 adjoins an upper end of the wall 12. A score line 29 is provided at the interface between the closure flap 16 and the wall 12. The score line 29 causes the underlying portion of the envelope 10 to act as a living hinge that allows the closure flap 16 to rotate from an open position shown in FIG. 1, to a closed position shown in FIG. 2. When in the open position, the closure flap 16 provides access to the envelope pocket 15 so that the item 114 can be placed in the envelope pocket 15. When in the closed position, the closure flap 16 is positioned over the outward-facing surface of the wall 14, so that the closure flap 16 closes the envelope pocket 15 and thereby retains the item 114 within the envelope pocket 15.

[0074] A sealing element in the form of a strip of adhesive 48 is disposed on the surface of the closure flap 16 that folds onto the wall 14. The adhesive 48 can be covered by a release strip 49, as shown in FIGS. 1 and 3, until the envelope 10 is ready to be closed. The adhesive 48 forms a closure seal between the closure flap 16 and the wall 14 when the closure flap 16 is in the closed position, thereby securing the closure flap 16 in the closed position.

[0075] The adhesive 48 can be a pressure sensitive (cold) adhesive. Sealing elements other than the cold adhesive 48 can be used in alternative embodiments. For example, a cohesive material, a heat sealable material, or a hot-melt adhesive can be used as the sealing element in lieu of the cold adhesive.

[0076] The release strip 49 can include a material, in the form of a release coating, for example, that allows the release strip to lightly adhere to the adhesive 48. In some embodiments, the release strip 49 can include silicone or a silicone-based material. In other embodiments, the release strip 49 can include a UV curable release material. In other embodiments, the release strip 49 can include a UV-curable cationic release silicone. In other embodiments, the release strip 49 can include a UV-curable silicon release material such as Elkeem UV POLY 206. The release coating can be formed from other materials and other compositions in other alternative embodiments.

[0077] As noted above, the closure flap 16 has two holes 20 formed therein. Referring to FIGS. 1 and 3, each hole 20 receives a respective leg 102 of the wicketed envelope holder 100, so that each envelope 10 is suspended from the holder 100 by way of its closure flap 16. The holes 20 can be disposed symmetrically about the longitudinal centerline of the envelope 10. The holes 20 can be disposed non-symmetrically about the longitudinal centerline of the envelope 10 in alternative embodiments.

[0078] The holes 20 can be positioned above the strip of adhesive 48, from the perspective of FIG. 1. The uppermost portion of each hole 20 can be offset from the upper edge of the closure flap 16 by a distance about equal to, or less than the diameter of the hole 20, to reduce the potential for the closure flap 16 to be torn and/or separated from the wicketed envelope holder 100 unintentionally. The holes 20 can be spaced from the upper edge of the closure flap 16 by other distances in alternative embodiments.

[0079] Referring to FIG. 1, the envelopes 10 within each flight 106 can be held together by one or more mechanical fasteners that extend through the closure flap 16 of each envelope 10. The fasteners can be, for example, staples 112. Other types of fasteners can be used in lieu of the staples 112 in alternative embodiments. For example, barbed fasteners, screws, rods, bolts, etc. can be used in lieu of the staples 112.

[0080] A discontinuous region is formed in the closure flap 16, proximate the location at which the staple 112 is inserted though the closure flap 16. The discontinuous region permits a relatively small portion of the closure flap 16 surrounding the staple 112, referred to herein after as a detachable region 18, to separate from the remainder of the closure flap 16 when an individual envelope 10 is removed from the wicketed envelope holder 100 and its associated flight 106.

[0081] The detachable region 18 includes a major region 24. The major region 24 is the portion of the closure flap 16 that is bordered by the discontinuous region. The discontinuous region can be provided, for example, by perforations 22, visible in FIG. 1. In alternative embodiments, the discontinuous region can be provided by features other than the perforations 22. For example, the discontinuous region can be provided by a cut, as shown in FIG. 10, in lieu of the perforations 22. In alternate embodiments, the discontinuous region can be provided by a score line configured to have sufficient weakness to separate or break from the discontinuous region. The ties 21 between the perforations 22 are configured to tear or otherwise break as the individual envelope 10 is pulled off the wicketed envelope holder 100 and detached from its associated flight 106. In particular, the perforations 22 and their associated ties 21 are sized so that the ties 21 tear or otherwise break before the restraining effect of the staple 112 begins to cause any tearing or ripping at any other locations on the closure flap 16 or the remainder of the envelope 10, so that the closure flap 16 remains intact, other than for the controlled separation or detachment of the detachable region 18 which occurs due to the breaking of the ties 21. The length of the perforations 22 and the spacing between the perforations 22 and the staple 112 can be chosen to help ensure that the ties 21 between the perforations 22 break before the material located between the perforations 22 and the staple 112 begins to tear.

[0082] The length of each perforation 22, and the distance between each perforation 22 and its adjacent perforations 22 are applicant-dependent, and can vary with factors such as the type, thickness, and tear resistance of the paper or other material from which the envelopes 10 are formed, the desired level of force needed to separate the detachable region 18 from the remainder of the closure flap 16, etc. The separation of the detachable region 18 results in a gap 19 in the closure flap 16, as can be seen in FIG. 2.

[0083] The line of perforations 22 extends in a semi-circle, with the ends of the semi-circle coinciding with the upper edge of the closure flap 16 (from the perspective of FIG. 1). Thus, because the perforations 22 define the detachable region 18, the detachable region 18 has the shape of a half circle. The perforations 22 can be arranged in other patterns, and the detachable region 18 can have a shape other than a half circle, in alternative embodiments. For example, the shape of the detachable region 18 can be of any suitable shape, including, for example, U-shaped, C-shaped, semi-circular, or a shape having a curvilinear border. The envelopes 10 can be assembled into a flight of the envelopes 10a secured to each other by one of the staples 112, as discussed above in relation to the envelopes 10.

[0084] Referring to FIGS. 4-6, the construction of the envelope 10 now will be discussed in more detail, beginning with the construction of a two-layer web 23 from which the wall 12 and the closure flap 16 can be formed. Each layer of the two-layer web 23 is made of a single ply 28a of paper. The wall 14 likewise can be formed from two layers, with each layer being formed by a single ply 28b of paper. The wall 14 can be fixed to the web 23 in the below-described manner, to form the assembled envelope 10.

[0085] Referring to FIGS. 4-8, the plies 28a of the web 23 are fixed to each other by two longitudinal inter-ply seals 30a, two closure flap inter-ply seals 31, and two transverse inter-ply seals 32a visible in FIGS. 7 and 8. FIGS. 7 and 8 are diagrammatic representations that are not shown to scale for illustrative purposes only. As mentioned previously, the longitudinal and transverse directions are denoted in FIG. 2 by the respective arrows L and T. The longitudinal, closure flap, and transverse inter-ply seals 30a, 31, 32a are formed from a sealing element in the form of an adhesive material 34. The adhesive material 34 is applied to a first of the plies 28a as shown in FIG. 4. The other ply 28a is aligned with the first ply 28a and brought into contact with the adhesive material 34, as denoted by the arrow 39 in FIG. 4, to form the longitudinal, closure flap, and transverse inter-ply seals 30a, 31, 32a, thereby fixing the plies 28a to each other to form the web 23.

[0086] In alternative embodiments, the web 23 can be formed as part of a continuous webbing containing multiple webs 23. The individual plies 28a within the webbing can be formed from two continuous sheets of paper fixed to each other by the adhesive material 34 applied to the sheets of paper so as to form the longitudinal and transverse inter-ply seals 30a, 32a when the sheets are aligned and brought into contact with each other. Each individual web 23 can be cut from the webbing before, or after the web 23 is joined with a corresponding web to form an envelope 10.

[0087] Each longitudinal inter-ply seal 30a is located along a corresponding longitudinal, or side edge of the web 23, and extends along the entire length of the web 23. Each longitudinal inter-ply seal 30a can be offset from the corresponding side edge of the web 23 in alternative embodiments. The longitudinal inter-ply seals 30a are continuous. The longitudinal inter-ply seals 30a can be non-continuous in alternative embodiments.

[0088] The transverse inter-ply seals 32a are located along the upper and lower edges of the web 23, and extend substantially in a transverse direction, between the longitudinal inter-ply seals 30a. The transverse inter-ply seals 32a can be offset from the upper and lower edges of the web 23 in alternative embodiments.

[0089] The transverse inter-ply seals 32a are continuous. The transverse inter-ply seals 32a can be non-continuous in alternative embodiments. In other alternative embodiments, the transverse inter-ply seals 32a can extend across the entire width of the web 23, and the longitudinal inter-ply seals 30a can extend between the transverse inter-ply seals 32a.

[0090] As depicted diagrammatically in FIG. 8, each closure flap inter-ply seal 31 is located along a respective side edge of the closure flap 16. The closure flap inter-ply seals 31 extends at an angle in relation to the longitudinal and transverse directions (to follow the taper of the side edge of the closure flap 16), between the inter-ply seals 30a, 32a. For example, the closure flap inter-ply seals 31 can extend at an angle of about 45 degrees in relation to the longitudinal and transverse directions. Each closure flap inter-ply seal 31 can be offset from the corresponding side edge of the closure flap 16 in alternative embodiments. The closure flap inter-ply seals 31 are continuous, but can be non-continuous in alternative embodiments. In other alternative embodiments, the closure flap inter-ply seals 31 can extend along the entire length of the side edges of the closure flap 16, and the upper transverse inter-ply seal 32a can extend between the closure flap inter-ply seals 31. In other alternative embodiments, the web 23 can be formed without the closure flap inter-ply seals 31. The closure flap 16 can be substantially rectangular (without tapering) in alternative embodiments, so that the longitudinal seals 30a extend to the transverse seals 32a at a corner of the closure flap 16, negating the need for the closure flap inter-ply seals 31.

[0091] The adhesive material 34 can be a cold glue. Other types of adhesive materials, and other types of sealing elements can be used in lieu of a cold glue in alternative embodiments. For example, the sealing element can be a cohesive material, a heat sealable material, and/or a hot-melt adhesive in alternative embodiments.

[0092] The sealing element, e.g., the adhesive material 34, can be applied directly to the exposed surface of the first ply 28a, by suitable known methods. Alternatively, the sealing element can be applied as a tape, such as a double-sided tape, or by other suitable methods.

[0093] The adhesive 34 can be, for example, a liquid adhesive or a pressure-sensitive adhesive. Pressure sensitive adhesives stick to create the bond upon the application of a slight, initial, external pressure to the adhesive. Pressure sensitive adhesives includes water-based, acrylic, pressure sensitive adhesives. Specific examples of such adhesives include RHOPLEX N-1031 Emulsion, RHOPLEX N-580 Emulsion, and RHOPLEX N-619 Emulsion. Other emulsion polymers or acrylic polymer blend adhesives are also known, and other suitable types of adhesives and/or contact adhesives can be used. Pressure sensitive adhesives also include dry adhesives, which typically require no activation with water, solvent or heat, and firmly adhere to many dissimilar surfaces.

[0094] In the alternative, the sealing element can be, for example, a cohesive material. A cohesive material includes a bonding material that causes one surface to stick to an opposing surface by coming into contact with the same or a complimentary cohesive substance to form the bond between the two surfaces. Cohesives do not stick to other substances sufficiently to adhere to those other substances, or in some cases stick very weakly compared to the bond they form from sticking to each other.

[0095] In the alternative, the sealing element can be, for example, a heat-sealable material. Heat-sealable materials typically are pre-applied on the opposing surfaces of the substrates that are to be sealed together, typically as a coating applied to each surface. In some embodiments, the heat sealable material can be applied as a tape. The heat sealable material, after application, typically is solid in form.

[0096] An example of a heat-sealable coating material is a weldable polymer provided in a thickness and with a composition such that upon applying sufficient heat to the coating and pressure to the substrates to pressure the opposing coatings against each other, the heat-sealable material of the coatings melts and becomes welded together upon cooling, thereby forming a heat-seal of one substrate to the other. Typical heat sealable coatings are made of thermoplastics. The heat-sealable material on the opposing surfaces of the substrates typically is identical. In some embodiments, non-identical materials can be used in the coating provided the materials are similar enough such that the materials can melt and combine to become welded together upon cooling.

[0097] In some embodiments, the heat-sealable material can include emulsion-based polymers and polymer dispersions. The one or more polymers can include one or more of vinyl acetate ethylene, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetate copolymers, polyvinyl alcohol copolymers, dextrin stabilized polyvinyl acetate, vinyl acetate copolymers, ethylene copolymers, vinylacrylic, styrene acrylic, acrylic, styrene butyl rubber, polyurethane, polyolefins, and biodegradable materials (e.g., cellulose and starch). For example, the heat-activatable material can be a polyvinyl alcohol (PVOH) coating on surfaces of the sheets 28a, 28b. In some applications, the PVOH can be coated with polyethylene (PE) or polylactic acid (PLA) to prevent the PVOH from sticking, or from absorbing moisture which causes sticking.

[0098] In some embodiments, the heat-sealable material can include a polyolefin-based dispersion. The polyolefin dispersion can include polyethylene and/or polypropylene, thermoplastic polymers, polymeric stabilizing agents including at least one polar polymer, water, and/or other suitable polyolefin dispersions. A suitable polyolefin dispersion can include, for example HYPOD, from Dow Chemical, or other suitable polyolefin dispersions.

[0099] In some embodiments, the heat-sealable material can be water-based. The water-based heat-sealable material may include a water-based polymer. The use of a water-based heat-sealable material can enhance the recyclability of the packaging material 12, since the water-based heat-sealable material can be dissolved and separated easily from the paper pulp during the recycling process.

[0100] In the alternative, the adhesive 34 can be, for example, a hot-melt adhesive. Hot-melt adhesives are thermoplastic polymers that are solid at room temperature, become molten when heated to a temperature above their softening point, and resolidify by loss of heat, increasing in strength as they resolidify. Most hot-melt adhesives, upon melting into a molten state and re-solidifying, do not undergo any chemical reaction such as cross-linking or removal of a carrier, e.g., evaporation of water. Thus, hot-melt adhesives typically can be re-activated, i.e., re-melted and re-solidified, after initially being applied to a substrate.

[0101] The hot-melt adhesive, upon application to a substrate, is in a low-tackiness state in which it has a low, or no tackiness in a lower range of temperatures. The hot-melt adhesive is reactivatable. More specifically, the hot-melt adhesive is applied hot, and cools and cures in the converting process. It will not stick to other surfaces when cold because it has no, or minimal tackiness until it is reactivated, i.e., re-heated up to a sealable temperature above the lower range of temperatures at which the hot-melt adhesive initially is in a low-tackiness state. This lower range of application temperatures includes room temperature, and in some embodiments is below about 140 F. In other embodiments, the lower range of temperatures is below about 120 F., below about 125 F., or below about 130 F.

[0102] The re-heating of the hot-melt adhesive to the activation temperature causes the hot-melt adhesive to become molten. The subsequent cooling of the hot-melt adhesive, in combination with the application of pressure, causes the hot-melt adhesive to bond to the contacting surface.

[0103] As shown in FIGS. 7 and 8, the longitudinal, closure flap, and transverse inter-ply seals 30a, 31, 32a border, and help to define an interlayer region, or inter-ply space 36a between the two plies 28a of the wall 12 and the closure flap 16, initially formed as part of the web 23. The plies 28a face each other each other across the inter-ply space 36a, but are not adhered to each other in the inter-ply space 36a. Also, the inter-ply space 36a is sufficiently empty such that the plies 28a can abut and otherwise contact each other within the inter-ply space 36a, and can slide in relation to each other within the inter-ply space 36a. For example, the inter-ply space 36a can be completely empty, i.e., the inter-ply space 36a can be completely devoid of any filler or other material.

[0104] In alternative embodiments, a cushioning, padding, and/or thermally-insulating material, or other types of expandable and non-expandable materials can be disposed in the inter-ply space 36a. For example, a foam padding material can be disposed in the inter-ply space 36a. As another example, an expansion material can be disposed in the inter-ply space 36a, and can be adhered to one or both of the plies 28a. The expansion material is configured to assume an expanded configuration upon activation by an expansion initiator. The expansion initiator can be, for example, thermal, mechanical, and/or chemical, and/or can include other suitable initiating properties for activating the expansion material. The expansion material, in its expanded state, can provide the envelope 10 with cushioning, thermally-insulative, or other properties.

[0105] One or more of the plies 28a can include one or more functional layers positioned thereon. Examples of functional layers can include, but are not limited to, waterproofing layers configured to reduce permeability of water therethrough, an airtight layer configured to reduce permeability of air therethrough, other suitable material layers, and/or a combination thereof.

[0106] In other alternative embodiments, the plies 28a can be adhered to each other in their entirety, so that there is no inter-ply space 36a between the plies 28a. In other alternative embodiments, the plies 28a can be adhered to each other at locations other than, or in addition to the outer peripheries of the plies 28a.

[0107] In other alternative embodiments, the web 23 can have more than one inter-ply space 36a defined therein. For example, an alternative embodiment of the web 23 can have two inter-ply spaces 36a defined by three longitudinal inter-ply seals 30a. Two of the longitudinal inter-ply seals 30a can be located along the longitudinal edges of the web 23. The third longitudinal inter-ply seal 30a can be located at the approximate mid-point of the web 23, i.e., about halfway between the longitudinal edges of the web 23, thereby dividing the space between the plies 28a into two inter-ply spaces 36a.

[0108] In other alternative embodiments, the web 23 can have more than three longitudinal inter-ply seals 30a, so that more than two inter-ply spaces 36a are defined within the web 23. In other alternative embodiments, the web 23 can have more than two transverse inter-ply seals 32a, to similarly divide the space between the plies 28a into more than one inter-ply space 36a. In other alternative embodiments, one or more of the inter-ply seals can extend in a direction other than the longitudinal and transverse directions. In other alternative embodiments, a small strip or dot of adhesive located between the plies 28a, and inward of the longitudinal, lower, and upper edges of the web 23, can be used to further adhere the plies 28a to each other while still permitting some relative movement between the plies 28a. In other alternative embodiments, the web 23 can be formed from a single piece of paper folded over onto itself to form the two plies 28a, and sealed along its three exposed edges.

[0109] The plies 28b of the wall 14 are fixed to each other by two longitudinal inter-ply seals 30b (shown in FIG. 7), and two transverse inter-ply seals 32b (shown in FIG. 8). The longitudinal and transverse inter-ply seals 30b, 32b are formed from the adhesive material 34. The adhesive material 34 is applied to a first of the plies 28b as shown in FIG. 6. The other ply 28b is aligned with the first ply 28b and brought into contact with the adhesive material 34, as denoted by the arrow 41 in FIG. 6, to form the longitudinal and transverse inter-ply seals 30b, 32b, thereby fixing the plies 28b to each other to form the wall 14.

[0110] Each longitudinal inter-ply seal 30b is located along a corresponding longitudinal, or side edge of the wall 14. In alternate embodiments, the upper end of each longitudinal inter-ply seal 30b can be offset from the upper edge of the wall 14. The offset distance can be, for example, about inch to about inch. The longitudinal inter-ply seals 30b are continuous. The longitudinal inter-ply seals 30b can be non-continuous in alternative embodiments. The longitudinal inter-ply seals 30b can be offset from the side edge of the wall in alternative embodiments.

[0111] One of transverse inter-ply seals 32b is located along the lower edge of the wall 14, and extends between the longitudinal inter-ply seals 30b. The transverse inter-ply seal 32b can be offset from the lower edge of the wall 14 in alternative embodiments. The other transverse inter-ply seal 32b can be offset from the upper edge of the wall 14, and extends between the longitudinal inter-ply seals 30b. The offset distance can be about equal to the offset distance of the longitudinal inter-ply seals 30b from the upper edge of the wall 14, e.g., about inch to about inch. An offset of the longitudinal and transverse inter-ply seals 30b, 32b from the upper edge of the wall 14 allows the upper portion of the wall 14 to be folded downward into the envelope pocket 15. In the illustrated embodiment, the offset distance of the transverse inter-ply seal 32b and the longitudinal inter-ply seals 30b from the upper edge of the wall 14 is about zero, with no folding of the upper portion of the wall 15 into the envelope pocket 15.

[0112] The transverse inter-ply seals 32b are continuous. The transverse inter-ply seals 32b can be non-continuous in alternative embodiments. In other alternative embodiments, the transverse inter-ply seals 32b can extend across the entire width of the wall 14, and the longitudinal inter-ply seals 30b can extend between the transverse inter-ply seals 32b.

[0113] As shown in FIGS. 7 and 8, the longitudinal and transverse inter-ply seals 30b, 32b border, and help to define an interlayer region, or inter-ply space 36b between the two plies 28b of the wall 14.

[0114] The plies 28b face each other other across the inter-ply space 36b, but are not adhered to each other in the inter-ply space 36b. Also, the inter-ply space 36b is sufficiently empty such that the plies 28b can abut and otherwise contact each other within the inter-ply space 36b, and can slide in relation to each other within the inter-ply space 36b. For example, the inter-ply space 36b can be completely empty, i.e., the inter-ply space 36b can be completely devoid of any filler or other material. The above discussion of possible alternative embodiments of the web 23 applies equally to the wall 14.

[0115] The inter-ply seals 30a, 32a, 30b, 32b of the web 23 and the wall 14 can extend in directions other than the longitudinal and transverse directions in alternative embodiments. Also, the inter-ply seals 30a, 32a, 30b, 32b can extend non-linearly in alternative embodiments. The closure flap inter-ply seal of the wall 23 can extend at various angles other than about 45-degrees in alternative embodiments.

[0116] The multi-ply construction of the web 23 and the wall 14, and the absence of a fixed mechanical connection between the plies 28a, 28b within the respective inter-ply spaces 36a, 36b can enhance the ability of the envelope 10 to withstand tearing or puncturing. More specifically, in the event of a tear or puncture in one of the plies 28a, 28b, the underlying envelope pocket 15 of the envelope 10, and the item 114 residing in the envelope pocket 15, will remain enclosed due to the presence of the intact, i.e., undamaged, ply 28a, 28b in the same wall 12, 14.

[0117] Also, although the tear or puncture may propagate along the damaged ply 28a, 28b, it will not necessarily propagate to the intact ply 28a, 28b because the longitudinal inter-ply seals 30a, 30b and/or the transverse inter-ply seals 32a, 32b will act as a stop that prevents the tear or puncture from propagating past, or through the longitudinal inter-ply seals 30a, 30b or the transverse inter-ply seals 32a, 32b. Thus, the envelope pocket 15 will remain intact and the item 114 held therein will remain in the envelope pocket 15 even when the tear or puncture propagates across most or all of the damaged ply 28a, 28b.

[0118] Also, the multi-ply configuration of the web 23 and the wall 14 can facilitate the use of lower basis-weight paper than otherwise would be possible, providing the web 23 and the wall 14 with greater flexibility than they otherwise might have, while maintaining the strength and tear resistance needed for a particular application. For example, the plies 28a, 28b of the respective web 23 and wall 14 can be formed from relatively low basis-weight paper, such as two plies of 40-pound paper, in lieu of a single ply of 90-pound paper.

[0119] Referring to FIG. 6, assembly of the web 23 and the wall 14 into the envelope 10 will now be discussed. The web 23 and the wall 14 can be fixed to each other as follows, to form the assembled envelope 10. A sealing element in the form of an adhesive material 35 is applied to the outer surface of one of the plies 28a of the web 23, along the side edges thereof, as shown in FIG. 6. The adhesive material 35 extends between the lower edge of the web 23, and a position corresponding to the lower edge of the closure flap 16 on the assembled envelope 10. The adhesive material 35 also is applied along the lower edge of the ply 28a.

[0120] The adhesive material 35 can be the same as or different from the adhesive material 34. For example, the adhesive material 35 can be a cold glue. Other types of adhesive materials, and other types of sealing elements can be used in lieu of a cold glue in alternative embodiments. For example, a cohesive material, a heat sealable material, and/or a hot-melt adhesive can be used as the sealing element in alternative embodiments.

[0121] Following application of the adhesive material 35, the wall 14 is positioned so that the lower edge of the wall 14 aligns with the lower edge of the web 23, and each longitudinal edge of the wall 14 aligns with a corresponding longitudinal edge of the web 23. The wall 14 is then brought into contact with the web 23, as denoted by arrow 43, to form the envelope 10. The adhesive material 35 extending along the lower edge of the web 23 contacts the portion of the wall 14 adjacent the lower edge of the wall 14, forming a transverse inter-wall seal 40 between the web 23 and the wall 14. The transverse inter-wall seal 40 is depicted in phantom in FIG. 2 and in FIG. 8. Also, the adhesive material 35 extending along the sides of the web 23 contacts the side edge portions of the wall 14, forming longitudinal inter-wall seals 42 between the wall 12 and the wall 14. The longitudinal inter-wall seals 42 are visible in FIG. 7 and are depicted in phantom in FIG. 2. At this point, the wall 14 has been fixed to the web 23. The wall 14 opposes the wall 12 and is fixed to the wall 12 by the longitudinal inter-wall seals 42. The longitudinal inter-wall seals 42 and the transverse inter-wall seals 40 border the pocket 15 defined by the walls 12, 14, and thus define a containment border.

[0122] The holes 20 and the perforations 22 can subsequently be formed in the closure flap 16. Alternatively, the holes 20 and/or the perforations 22 can be formed prior to assembly of the web 23 and the wall 14 into the envelope 10.

[0123] The score line 29, visible in FIGS. 1, 3, and 6, and shown diagrammatically in FIG. 8, can be formed in the web 23 between the upper end of the wall 12 and the lower end of the closure flap 16. The diagrammatic depiction of the score line 29 in FIG. 8 is not to scale and is only for illustrative purposes. The sealing element, in the form of the strip of adhesive 48, is placed on the surface of the closure flap 16 that folds onto the wall 14. The strip of adhesive 48 can be positioned beneath the holes 20, as shown in FIG. 1.

[0124] Alternatively, the holes 20, the perforations 22 and/or the strip of adhesive 48 can be applied to the web 23 prior to assembly of the web 23 and the wall 14 into the envelope 10. Likewise, the score line 29 can be formed in the web 23 prior to assembly of the web 23 and the wall 14 into the envelope 10. In other alternative embodiments, the closure flap 16 can be a substantially rectangular shape and cut to appear as depicted in FIGS. 1, 2, 3, 4, and 6 prior to or subsequently to assembly of the web 23 and the wall 14 into the envelope 10.

[0125] The web 23 and the wall 14 have been described as having a two-ply configuration for illustrative purposes only. One, or both of the web 23 and the wall 14 can have a one-ply (single-ply) configuration in alternative embodiments. In other alternative embodiments, the web 23 and the wall 14 can be formed unitarily from a single one-ply or two-ply webbing that is folded onto itself so that the wall 14 overlies the web 23. One longitudinal inter-wall seal 42 can be used to fix the overlying longitudinally-extending edges of the webbing to each other. One transverse inter-wall seal 40 likewise can be used to fix the overlying transversely-extending edges of the webbing to each other at the bottom end of the envelope.

[0126] The assembled envelopes 10 can be grouped into the flight 106 as discussed above, with the envelopes 10 secured to each other by the staples 112 or other types of mechanical fasteners as discussed above. As can be seen in FIG. 3, due to the flat configuration of the envelopes 10, the flights 106 have a relatively compact footprint that permits the flights 106 to be shipped to the packaging facility in an efficient manner.

[0127] Upon reaching the packing facility, the flights 106 can be placed on the wicketed envelope holder 100 individually, or with one or more other flights 106, as needed by the packaging operator. Each envelope 10 can be loaded manually by the packaging operator, while the envelope 10 is on the wicketed envelope holder 100. To load the envelope 10, the packaging operator can pull the top of the wall 14 away from the wall 12, thereby expanding the envelope 10 from its flat state. The expansion of the envelope 10 causes the envelope pocket 15 to become defined between the walls 12, 14, with the upper edge of the wall 14 and the adjacent portion of the wall 12 defining an opening to the envelope pocket 15.

[0128] The packaging operator can insert the item to be packaged 114 into the envelope pocket 15 by way of the opening to the envelope pocket 15. The packaging operator then removes the envelope 10 from the flight 106 by pulling the envelope 10 outward, away from the adjacent envelope 10, so as to break the ties 21 between the perforations 22. As discussed above, the ties 21 between the perforations 22 are configured to break or tear before any other portion of the closure flap 16 (or the envelope 10) begins to tear due to the restraining effect of the staple 112, thereby avoiding any tearing of the closure flap 16 that could adversely affect the integrity of the closure seal formed from the strip of adhesive 48. Once the ties 21 between the perforations 22 have broken, the envelope 10 can freely slide off of the legs 102 of the wicketed envelope holder 100 as the envelope 10 is pulled outward by the packaging operator, with the detachable region 18 of the envelope 10 remaining attached to the detachable regions 18 of the other envelopes 10 in the flight 106 by way of the staple 112.

[0129] Alternatively, the envelope 10 can be removed from the wicketed envelope holder 100 before the item 114 is loaded into the envelope 10.

[0130] After the envelope 10 has been loaded and removed from the wicketed envelope holder 100, the packaging operator can close and seal the envelope 10. In particular, the packaging operator can remove the release strip 49 from the strip of adhesive 48 on the closure flap 16. The packaging operator then can rotate the closure flap 16 about the score line 29, so that the closure flap 16, and the adhesive strip 48 thereon, rotate over and onto the outwardly-facing surface of the wall 14 as shown in FIG. 2. The folding of the closure flap 16 closes the opening to the pocket 15. The adhesive strip 48 fixes the closure flap 16 to the wall 14, so that the envelope pocket 15 remains closed and the packaged item 114 is retained therein. The closure flap 16 should have a height that is sufficient to allow the closure flap 16 to cover the opening in the expanded envelope 10, and to allow the adhesive strip 48 to land on the outwardly-facing surface of the wall 14.

[0131] The envelope 10 need not be loaded, removed from the wicketed envelope holder 100 and sealed by a packaging operator. In other applications, the envelope 10 can be loaded, removed from the wicketed envelope holder 100, and sealed using automated equipment.

[0132] As noted above, the web 23 and the wall 14 have been described as having a two-ply configuration for illustrative purposes only. One, or both of the web 23 and the wall 14 can have a one-ply (single-ply) configuration alternative embodiments.

[0133] In other alternative embodiments, the web 23 and the wall 14 can be formed unitarily from a single one-ply or two-ply webbing that is folded onto itself so that the wall 14 overlies the web 23. One longitudinal inter-wall seal 42 can be used to fix the overlying longitudinally-extending edges of the webbing to each other. One transverse inter-wall seal 40 likewise can be used to fix the overlying transversely-extending edges of the webbing to each other at the bottom end of the envelope.

[0134] FIG. 9 depicts an alternative embodiment of the envelope 10 in the form of an envelope 10a. The envelope 10a is similar to the envelope 10, with the exception that the envelope 10a does not include a closure flap. More specifically, the envelope 10a comprises a wall 14a fixed to a wall 12a. The wall 14a can be substantially identical to the wall 14 of the envelope 10. The wall 12a can be substantially identical to the wall 12 of the envelope 10, with the exception that the wall 12a is not connected to a closure flap.

[0135] The holes 20 that accommodate the legs 102 of the wicketed envelope holder 100 (or variants thereof) are formed in both the wall 12a and the wall 14a, proximate the respective upper edges thereof. The sealing element in the form of the strip of adhesive 48 is disposed on an inwardly-facing surface of the wall 12a of the envelope 10a, near the top of the wall 12a, and can form a closure seal that fixes the wall 14a to the wall 12a after the envelope 10a has been loaded, to close and seal the envelope pocket within the envelope 10a. The detachable regions 18 can be formed in both of the walls 12a, 14a, to facilitate separation of the envelope 10a from its associated flight as discussed above in relation to the envelope 10.

[0136] FIG. 10 depicts another alternative embodiment of the envelope 10 in the form of an envelope 10b. The envelope 10b is substantially the same as the envelope 10, with the exception of the following differences. The envelopes 10b can be arranged in a flight 106b in the same or substantially the same manner as the envelopes 10 are arranged in the flight 106. Each envelope 10b includes a wall 12b, a wall 14b, a closure flap 16b extending from the wall 12b, and a detachable region 18b on the closure flap 16b. The walls 12b, 14b can be identical or substantially identical to walls 12 and 14, respectively. The closure flap 16b can be substantially identical to closure flap 16, with the exception that the closure flap 16b has a detachable region 18b thereon. The detachable region 18b is formed by making a continuous cut 22b in the closure flap 16b in lieu of perforations 22 formed in the closure flap 16. The collective group of detachable regions 18b in the flight 106b form a bundle 17 of detachable regions 18b. The detachable region 18b includes a major region 24b and two ties 25. The major region 24b is the resulting graspable flap that is formed by the continuous cut 22b. The ties 25 refer to the intact (uncut) portions of the detachable region 18b that tie the major region 24b to the envelope 10.

[0137] Because the ties 25 are left intact, the major region 24b can be lifted or manipulated without detaching entirely from the envelope 10b. In alternate embodiments, the continuous cut 22b can be a score line configured to have sufficient weakness to separate or break from the detachable region 18b.

[0138] The two ties 25 are shown in FIG. 10. Alternative embodiments can be formed with only one tie 25. The continuous cut 22b extends from a first of the ties 25 to a second of the ties 25. As with the perforations 22, the continuous cut 22b defines the shape of the detachable region 18b. In alternate embodiments, the continuous cut 22b can resemble different shapes than the C-shape in FIG. 10. For example, the continuous cut 22b can resemble an oval, a triangle, a circle, an arc, any other suitable shape, or a U-shape as shown in FIG. 11 and discussed further below. The ties 25 tie the major region 24b of the detachable region 18b to the upper edge portion of the closure flap 16b. The ties 25 are sized so as to allow the bundle 17 of detachable regions 18b to be removed collectively from the flight 106b in response to a force on the major region 24b by, for example, pulling or twisting the major region 24b manually. In addition, the ties 25 are sized so that the bundle 17 of detachable regions 18b is sufficiently robust so as to minimize the potential for the bundle 17 to be separated inadvertently or otherwise unintentionally from the flight 106b. Thus, the detachable regions 18b, in general, will remain attached to their respective envelopes 10b prior to a force being exerted on the bundle 17 to tear the ties 25 and thereby separate the bundle 17 from the flight 106b.

[0139] In some embodiments, the ties 25 can have of thickness of less than about inch. This thickness of the ties 25 is denoted in FIGS. 10 and 11 by the reference 26. In some embodiments, the ties 25 can have a thickness of about 1/32 inch to about 1/8 inch. In some embodiments, the ties 25 can have a thickness of about 1/16 inch to about 1/8 inch. The optimal thickness of the ties 25 is application dependent and can vary with factors such as the tear resistance and other characteristics of the paper from which the envelopes 10b are formed. The thickness of the ties 25 can lie outside of the above-noted ranges in other embodiments.

[0140] FIG. 11 depicts another alternative embodiment of the envelope 10 in the form of an envelope 10c. The envelope 10c is substantially the same as the envelope 10, with the exception of the following differences. The envelopes 10c can be arranged in a flight 106c in the same or substantially the same manner as the envelopes 10 are arranged in the flight 106. Each envelope 10c includes a wall 12c, a wall 14c, a closure flap 16c extending from the wall 12c, and a detachable region 18c on the closure flap 16c. The walls 12c, 14c can be identical or substantially identical to walls 12 and 14, with the exception that the walls 12c, 14c include cuts 44 formed in the upper corners of the walls 12c, 14c. The cuts 44 extend through the score line 29 about which the closure flap 16c rotates. The cuts 44 provide stress relief for the adjoining walls 12c, 14c when the envelope 10c is opened, i.e., when the wall 14c is pulled away from the wall 12c to access the inside of the envelope 10c. The closure flap 16c can be substantially identical to closure flap 16, with the exception that the closure flap 16c has a detachable region 18c thereon. The detachable region 18c is formed by making a continuous cut 22c in the closure flap 16c in lieu of perforations 22 formed in the closure flap 16. The detachable region 18c includes a major region 24c and two ties 25.

[0141] As with the envelope 10b shown in FIG. 10, the continuous cut 22c extends from a first of the ties 25 to a second of the ties 25. The ties 25 perform substantially the same function with envelope 10c as described above with envelope 10b. As with the perforations 22, the continuous cut 22b defines the shape of the detachable region 18b. The detachable region 18c resembles a U-shape. In alternate embodiments, the detachable region 18c can resemble other shapes, such as an oval, a triangle, a circle, an arc, or any other suitable shape.

[0142] Referring to the envelopes 10b, 10c shown in FIGS. 10 and 11, the presence of the detachable region 18b, 18c defined by the continuous cut 22b, 22c can make it easier to remove the individual envelopes 10b, 10c from the envelope holder 100 because the operator can collectively remove all of the detachable regions, i.e., the bundle 17, from the flight 106b, 106c immediately before or after the flight 106b, 106c is loaded onto holder 100. Therefore, the operator, when removing an individual envelope 10b, 10c from the flight 106b, 106c, does not need to tear or otherwise break any portion of the envelope 10b, 10c. In addition, because the ties 25 are configured to break before any other portion of the envelope 10b, 10c, the detachable regions 18b, 18c can be removed in a controlled manner along with the staple 112 without the potential for uncontrolled tearing to propagate from the staple 112 to other areas of the closure flap 16b, 16c.

[0143] The bundle 17 of detachable regions 18b, 18c may be removed from the flight 106b, 106c at a customer facility or other location that is different from the location of manufacture of the envelopes 10b, 10c. More specifically, the envelopes 10b, 10c may be held together within the flight 106b, 106c by the detachable regions 18b, 18c and the staple 112 during shipment to the user's facility, and up until the point of at which the flight 106b, 106c is to be loaded onto the envelope holder 100. Immediately prior to loading the flight 106b, 106c onto the envelope holder 100, the user may remove the bundle 17, along with the staple 112, from the remainder of the flight 106b, 106c by grasping the bundle 17 from either side and pulling, twisting, or otherwise manipulating the bundle 17 to collectively break the ties 25, thereby decoupling the individual envelopes 10b, 10c within the flight 106b, 106c from each other. The operator then can place the flight 106b, 106c, absent the bundle 17, onto the envelope holder 100.

[0144] Alternatively, the flight 106b, 106c can be placed on the envelope holder 100 prior to the bundle 17 being removed. The user subsequently can remove the bundle 17 prior to removing the first envelope 10b, 10c from the flight 106b, 106c. In another alternative technique, the flight 106b, 106c can be placed on the envelope holder 100 prior to the bundle 17 being removed, and the ties 25 on each envelope 10b, 10c can be broken on an individual basis (as opposed to collectively) as each envelope 10b, 10c is removed individually from the envelope holder 100.

[0145] Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.