US20080290145A1 - Flat-sized flexible envelope with insert - Google Patents
Flat-sized flexible envelope with insert Download PDFInfo
- Publication number
- US20080290145A1 US20080290145A1 US11/978,466 US97846607A US2008290145A1 US 20080290145 A1 US20080290145 A1 US 20080290145A1 US 97846607 A US97846607 A US 97846607A US 2008290145 A1 US2008290145 A1 US 2008290145A1
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- US
- United States
- Prior art keywords
- envelope
- set forth
- insert
- item
- tray
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000004033 plastic Substances 0.000 claims abstract description 10
- 238000005452 bending Methods 0.000 claims description 4
- 230000002093 peripheral effect Effects 0.000 claims description 4
- 239000002984 plastic foam Substances 0.000 claims description 4
- 239000006260 foam Substances 0.000 claims 1
- 239000000853 adhesive Substances 0.000 description 9
- 230000001070 adhesive effect Effects 0.000 description 9
- 238000012360 testing method Methods 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000000123 paper Substances 0.000 description 4
- 239000002279 physical standard Substances 0.000 description 3
- 239000003292 glue Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000009172 bursting Effects 0.000 description 1
- 239000011111 cardboard Substances 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 239000010437 gem Substances 0.000 description 1
- 229910001751 gemstone Inorganic materials 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 238000010339 medical test Methods 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000011087 paperboard Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D7/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal
- B65D7/12—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal characterised by wall construction or by connections between walls
- B65D7/24—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal characterised by wall construction or by connections between walls collapsible, e.g. with all parts detachable
- B65D7/26—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal characterised by wall construction or by connections between walls collapsible, e.g. with all parts detachable with all parts hinged together
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D11/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of plastics material
- B65D11/18—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of plastics material collapsible, i.e. with walls hinged together or detachably connected
- B65D11/1833—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of plastics material collapsible, i.e. with walls hinged together or detachably connected whereby all side walls are hingedly connected to the base panel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D21/00—Nestable, stackable or joinable containers; Containers of variable capacity
- B65D21/02—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together
- B65D21/0209—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together stackable or joined together one-upon-the-other in the upright or upside-down position
- B65D21/0215—Containers with stacking feet or corner elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D25/00—Details of other kinds or types of rigid or semi-rigid containers
- B65D25/20—External fittings
Abstract
Description
- This application is a Continuation-In-Part of pending application No. 11/804,845, filed May 21, 2007.
- This invention relates to a flat-sized flexible envelope with an insert. More particularly, this invention relates to a flat-sized flexible envelope having an insert for receiving an item to be mailed that conforms to USPS requirements for flexibility and uniform thickness of flat-size pieces.
- As is known, various types of envelopes have been constructed for use in mailing items, such as digital video disks (DVDs) and compact disks (CDs). In some cases, the envelopes have been provided with padding, such as described in U.S. Pat. No. 5,662,420, wherein a macerated paper layer is sandwiched between two layers of paper.
- In still other cases, as described in U.S. Pat. Nos. 5,544,473 and 7,108,650, it has been known to provide envelopes in which a packing material is inserted to receive an item for shipping.
- Still other constructions have been known for use in shipping medical tests specimens wherein a receptacle is provided to receive a test specimen and the receptacle placed in an envelope, such as described in U.S. Pat. No. 5,620,097.
- Recently promulgated United States Postal Service (USPS) regulations (see 39 CFR Part 111) provide standards for domestic mailing services that set forth minimum flexibility and uniform thickness criteria for flat-sized pieces.
- Accordingly, it is an object of the invention to provide a package that satisfies the criteria for flat-sized pieces of the USPS.
- It is another object of the invention to provide an envelope construction with a flexible insert for shipping items of rigid or non-rigid nature.
- It is another object of the invention to provide a packaged DVD that qualifies for flat-sized piece postage in the United States.
- It is another object of the invention to be able to mail an item, such as a DVD or a CD, in a manner that qualifies as a flat-sized piece postage in the United States.
- Briefly, the invention provides a package that conforms to the requirements of a flat-sized piece for USPS requirements. The package is made to hold the item to be mailed and a flexible insert that occupies the inside of the package in a manner that allows the package to flex. The item to be received within the envelope may be of rigid nature or non-rigid nature.
- In one embodiment, the insert has a cut-out of predetermined shape for receiving an item to be shipped in the package so that the item is prevented from shifting within the package. In another embodiment, the insert is in the form of a tray that has a recess for receiving the item in a manner to prevent the item from shifting within the package.
- In each embodiment, the flexible insert and the item being packaged can be inserted into a pocket of a paper envelope of standard or an expandable construction, as described in U.S. Pat. No. 6,227,444, and a flap of the envelope can be folded over to close the pocket. In each embodiment, the flexible insert is of a height and width to substantially fill the pocket. Alternatively, the flexible insert and the item may be inserted in a sleeve, plastic bag, shrink-wrapped in plastic, or wrapped with a web of paper or plastic or the like to form the package for mailing purposes. Further, the envelope may be pre-lined with padding to protect fragile items.
- The insert may be fixed within an envelope by a glue or adhesive or the insert may be slidably mounted within the envelope in an unsecured condition.
- In the first embodiment, the insert is made of any suitable material, such a self-supporting plastic foam, corrugated paper board or the like. Typically, the cut-out in the insert is made asymmetrical and to one side of the insert. For example, the insert is made of L-shape. Where the envelope has a dimension of at least 10 inches on one side, the cut-out in the insert may be located symmetrically within the insert and still meet the criteria of the USPS for flat-sized pieces with a rigid insert.
- When the insert is in place, the package may be flexed or bent in the area occupied by the flexible insert and particularly in a manner that allows the package to conform to the above noted regulations of the USPS.
- In the second embodiment, the tray is made of a body of thin thickness of plastic that is shaped, as by molding, with a cut-out in the form of a recess that is sized to receive the item to be mailed. For example, the item may be a DVD holder, a CD holder, a pen, a cassette holder and the like. In any event, the recess is typically disposed asymmetrically within the tray and the tray is provided with a pattern of wells or cavities to impart a flexibility to the tray as well as rigidity.
- The cavities are disposed in the tray in spaced apart relation and are connected to each adjacent cavity by a thin web of the tray body as well as to the recess that holds the item to be mailed. The thinness of the interconnecting web allows a cavity to pivot toward an adjacent cavity or the recess, if adjacent the recess, under a flexing or bending force imposed on the package. Where the cavities are disposed in parallel rows, the insert can be flexed or bent along a line that passes within a web in parallel between each two adjacent rows.
- When the tray is in place, the package may be flexed or bent in the area occupied by the cavities and particularly in a manner that allows the package to conform to the above noted regulations of the USPS.
- These and other objects and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:
-
FIG. 1 illustrates a perspective view of an envelope construction in accordance with the invention; -
FIG. 2 illustrates a view taken on line 2-2 ofFIG. 1 ; -
FIG. 3 illustrates a view of a blank for making the envelope ofFIG. 1 with an insert secured in place in accordance with the invention; -
FIG. 4 illustrates an exploded view of a package for mailing a DVD or like cassette; -
FIG. 5 illustrates a top view of a tray employed in the package ofFIG. 4 ; -
FIG. 6 illustrates a left side view of the tray ofFIG. 5 ; -
FIG. 7 illustrates a front side view of the tray ofFIG. 5 ; -
FIG. 8 illustrates an exploded view of a package employing a modified tray and an expandable envelope in accordance with the invention; -
FIG. 9 illustrates a top view of the tray ofFIG. 8 ; -
FIG. 10 illustrates a left-side view of the tray ofFIG. 9 ; -
FIG. 11 illustrates a front view of the tray ofFIG. 9 ; -
FIG. 12 illustrates a perspective view of a modified tray in accordance with the invention; -
FIG. 13 illustrates a top view of a modified tray similar to the tray ofFIG. 12 ; -
FIG. 14 illustrates a side view of the tray ofFIG. 13 ; -
FIG. 15 illustrates a front view of the tray ofFIG. 13 and -
FIG. 16 illustrates a cross-sectional view taken on line 16-16 ofFIG. 13 . - Referring to
FIGS. 1 and 3 , theenvelope 10 is an expandable envelope constructed in a manner as described in U.S. Pat. No. 6,227,444 from a flat blank 11. - Referring to
FIG. 3 , the blank 11 includes afront panel 12 of rectangular shape and aback panel 13 that is secured to thefront panel 12 along ahorizontal fold line 14. In addition, thefront panel 12 is provided with a rectangular array ofscore lines 15; each spaced inwardly from the respective edge of thepanel 12 to define a rectangle within thepanel 12 and diagonally disposedscore lines 16 that connect the corners of the rectangle ofscore lines 15 with the corners of thepanel 12. - The
back panel 13 has ascore line 17 spaced parallel to thefold line 14 to separate atrapezoidal section 18 located between thefold line 14 andscore line 17 from arectangular section 19. - The blank 11 also includes a pair of
side flaps 20 each of which is separated from thefront panel 12 by afold line 21 and each of which includes ascore line 22 at an intermediate point parallel to thefront panel 12. - Each
side flap 20 has arounded end 23 at each end as well as ascore line 24 that extends from thescore line 22 on aside flap 20 to the corner of thefront panel 12. - Each
flap 20 is to be folded over thefold line 21 into folded over relation to thefront panel 12. Theback panel 13 is sized to be secured, as by an adhesive, to the folded overside flaps 20 to extend to and between thescore lines 21 of theflaps 20. - The blank 11 also has a
closure flap 25 that is secured to thefront panel 12 along a horizontal fold line (as viewed) 26 and that includes ascore line 27 spaced from thefold line 26 to separate atrapezoidal section 28 from a rectangular section 29. - Referring to
FIGS. 1 and 3 , theclosure flap 25 includes a strip of adhesive orglue 30, such as a gummed or latex adhesive, for closing onto theback panel 13 as well as aremovable strip 31 that covers over the adhesive 30 until the adhesive 30 is ready for use. - Referring to
FIG. 3 , eachside flap 20 is provided with a line of adhesive (not shown) on the underside (as viewed) of the section between thescore line 22 and the free edge of theflap 20 for securement to the underside of theback panel 13. - In order to form the
envelope 10 ofFIG. 1 , the blank 11 ofFIG. 3 is manipulated manually and/or mechanically in an automated manner in the following manner. - First, the side flaps 20 are folded along the fold lines 21 over the
front panel 12. Next, theback panel 13 is folded about thefold line 14 onto the exposed adhesive on the side flaps 20. In this respect, theback panel 13 is of a width to extend to and between the score lines 22 of the side flaps 20, as indicated inFIG. 1 . At this time, thetrapezoidal section 18 of theback panel 13 covers over the lower ends 23 of the side flaps 20 in an overlapping manner and completely seals the two lower corners of theenvelope 10. Also, the two upper corners of theback panel 13 lie over the rounded ends 23 of the side flaps 20 to leave the uppermost rounded ends 23 of the side flaps 20 exposed. - Once the
back panel 13 is secured in place as shown inFIG. 1 , a pocket is formed within theenvelope 10. - Referring to
FIG. 3 , aflexible insert 32 is secured to thefront panel 12, for example by a suitable adhesive. As illustrated, theinsert 32 is of L-shape and defines a cut-out located asymmetrically to one side of theinsert 32 for receiving an item 33 (seeFIG. 1 ) to be shipped in the completedenvelope 10. - The
insert 32 is made of any suitable material, such as a self supporting plastic foam, cardboard or the like. Preferably, a lightweight plastic foam is used. - As indicated in
FIG. 3 , theinsert 32 extends width-wise to and between thevertical score lines 15 of thefront panel 12 and extends height-wise to and between thehorizontal score lines 15 of thefront panel 12 in order to substantially fill the pocket of theenvelope 10. - Referring to
FIG. 2 , theinsert 32 has a thickness of from 1/16 inches to 1¼ inches and preferably a thickness of ½ inch. The thickness of theinsert 32 may be up to ¾ of an inch. - Alternatively, the
insert 32 need not be secured to either thefront panel 13 or theback panel 13. In this case, theinsert 32 may be slid into the pocket of theenvelope 10 after the envelope has been fabricated. For example, theinsert 32 may be inserted into the envelope by a user when theitem 33 is being inserted. - Further, the
insert 32 may be dropped onto a die cut flat sheet and then the sheet closed around theinsert 32 and rigid inserteditem 33 creating an envelope. - When the
insert 32 is in place, the pocket of theenvelope 10 is expanded into the condition as indicated inFIG. 2 . As viewed, theinsert 32 extends to and between thevertical score lines 15 of thefront panel 12 and to and between the score lines 22 of the side flaps 20. Also, the edges of thefront panel 12 beyond thevertical score lines 15 bend downwardly, as viewed, and the sections of eachside flap 20 between therespective fold line 21 and scoreline 22 bend upwardly, as viewed, to define V-shaped side edges to theenvelope 10. A similar V-shaped bottom edge to theenvelope 10 is also formed. As a result, theinsert 32 being of a thickness equal to the largest width of the V-shaped side and bottom edges of theenvelope 10 is restrained from shifting sideways or vertically, and particularly, no more than 1 inch in anenvelope 10 of a 9 inch×12 inch size withscore lines 15 on thefront panel 12 being spaced ¼ inch from the edges of thefront panel 12 and theinsert 32 being ½ inch in thickness. - Insertion of the
insert 32 may be accomplished manually or automatically through suitable mechanical equipment. - Referring to
FIG. 1 , theitem 33 may be rigid, such as a DVD holder or a CD holder, or the item may be non-rigid, i.e. flexible. In either case, theitem 33 is matingly disposed within the cut-out of theinsert 32. In this respect, theitem 33 has a shape corresponding to the shape of the cut-out and a thickness corresponding to the thickness of theinsert 32. - The
item 33 may be inserted into the cut-out of theinsert 32 within the pocket of theenvelope 10 manually or automatically. Further, theitem 33 and insert 32 may be inserted in the same operation by any suitable means. After theitem 33 has been inserted into the cut-out of theinsert 32, theremovable cover strip 31 is removed and theclosure flap 25 folded via thefold line 26 over theback panel 13 in order to close the pocket and seal theitem 33 therein. - Upon closing over of the
closure flap 25, thetrapezoidal section 28 of theclosure flap 25 over lies the rounded ends 23 of the side flaps 20 to seal the two upper corners of theenvelope 10. At the same time, the remainder of theclosure flap 25 is of a width equal to the width of theback panel 13 to form a neat closure herewith. - The
envelope 10 may be of any suitable size. For example, for shipping a DVD holder, the envelope, when closed, has a width of 12-½″ and a height of 10″. In addition, theinsert 32 is of ½″ thickness and theDVD holder 33 has a corresponding ½″ thickness, a width of 7.5″ and a height of 5.25″. - The
envelope 10 with theinsert 32 therein conforms to the recently promulgated United States Postal Service (USPS) requirements for minimum flexibility criteria for flat-size pieces. As of Jul. 15, 2007, USPS regulation 301 (Physical Standards) found at http://pe.usps.gov/text/dmm300/301.htm provides: - 1.0 Physical Standards for Flats
- 1.1 General Definition of Flat Size Mail
- Flat-size mail other than that in 3.0, Physical Standards for Automation Flats, is:
-
- a. More than 11-½ inches long, or more than 6-⅛ inches high, or more than ¼ inch thick.
- b. Not more than 15 inches long, or more than 12 inches high, or more than ¾ inch thick, except for Periodicals mail under 707.26.0.
- c. Rectangular with four square corners or with finished corners that do not exceed a radius of 0.125 inch (⅛ inch).
- 1.3 Minimum Flexibility for Flat-Size Pieces provides a test as follows:
-
- 1. Place the piece with the length parallel to the edge of the flat surface and extend piece half way off the surface;
- 2. Press down on the piece at a point 1 inch from the outer edge, in the center of the piece's length, exerting steady pressure;
- 3. The piece is not flexible if it cannot bend at least 1 inch vertically without being damaged;
- 4. The piece is flexible if it can bend at least 1 inch vertically without being damaged and it does not contain a rigid insert.
- If the piece is a flat 10 inches or longer and contains a rigid insert, the following tests are to be conducted:
-
- 1. Place the piece with the length perpendicular to the edge of a flat surface and extend the piece 5 inches off the surface;
- 2. Press down on the piece at a point 1 inch from the outer edge, in the center of the piece's length, exerting steady pressure;
- 3. Turn the piece around and repeat
steps 1 and 2. The piece is flexible if both ends can bend at least 2 inches vertically without being damaged.
- The following test is for flats less than 10″ and that contains a rigid insert:
-
- 1. Place the piece with the length perpendicular to the edge of a flat surface and extend the piece one-half of its length off the surface;
- 2. Press down on the piece at a point one inch from the outer edge, in the center of the piece's width, exerting steady pressure;
- 3. Turn the piece around and repeat
steps 1 and 2; the piece is flexible if both ends can bend at least 1 inch vertically without being damaged.
- The USPS requirements (1.4) for uniform thickness are:
- Flat-size mailpieces must be uniformly thick so that any bumps, protrusions, or other irregularities do not cause more than ¼-inch variance in thickness. When determining variance in thickness, exclude the outside edges of a mailpiece (1 inch from each edge) when the contents do not extend into those edges. Also, exclude the selvage of any polywrap covering (see 3.3) from this determination. Mailers must secure nonpaper contents to prevent shifting of more than 2 inches within the mailpiece if shifting would cause the piece to be nonuniform in thickness or would result in the contents bursting out of the mailpiece.
- The
envelope 10 as shown inFIG. 1 that is stuffed with aDVD holder 33 as described above and being of a size of 12½″ wide and 10″ high passes the minimum flexibility criteria for flat-sized pieces of the USPS forflats 10 inches or longer that contain a rigid insert. - An envelope having dimensions of 9⅞ inches wide and 8 inches high with a CD holder 5⅞ inches wide×4⅞ inches high asymmetrically to one side of the cut-out in the
insert 32 also passes the USPS minimum flexibility criteria for flats less than 10 inches long and that contain a rigid insert. - The combination of envelope, flexible insert and packaged item may have different relative sizes in order to pass the flexibility tests of the USPS. For example, the envelope may have a maximum size of 12 inches high and 15 inches wide.
- Further, the
insert 32 may have one or more cutouts for receiving rigid items other than rectangular items, such as DVD holders and CD holders. For example, for a large size envelope, the insert may have a cut-out that is symmetrically placed. Further, such a cut-out may be of any suitable shape such as rectangular, circular, or otherwise, to receive a circular item or otherwise. Further, theinsert 32 may be provided with a slit in order to receive a slender item, such as a pencil. - As noted above, the envelope may be pre-lined with padding. In such an embodiment, the
insert 32 may be fixed or not in place. - Referring to
FIG. 4 , apackage 33 is formed of aninsert 34 in the form of a rectangular tray and a wrapper or sleeve 35 that envelopes thetray 34. - As illustrated, the
tray 34 is made of a thin thickness of plastic that is shaped, as by molding, with a cut-out in the form of arecess 36 that is sized to receive anitem 37 to be mailed. For example, in the illustrated embodiment, the item may be a DVD holder or the like. Therecess 36 is disposed within thetray 34 asymmetrically of the X and Y axes of thetray 34 as viewed. - Referring to
FIG. 5 , therecess 36 is located in an upper left-hand corner of thetray 34. In addition, therecess 36 is of rectangular shape and is defined by aflat floor 38 and fourflat side walls 39 that extend upwardly from thefloor 38. One ormore projections 40 extend centrally from eachside wall 39 into therecess 36 in order to hold the DVD holder (not shown) between thefloor 38 and the underside of eachprojection 40. - In addition, each
side wall 39 has anenlarged section 41 at each end outside the plane of theside wall 39 to form anenlarged corner 42 of therecess 36 for forming and protection. - The
floor 38 of therecess 36 may be smooth and flat or may be formed with a depressed design such as described below to impart rigidity and to receive the DVD holder (not shown) in a manner in which the DVD holder can be more easily removed. - The
tray 34 is provided with a pattern of cavities orwells 43 to impart a thickness to thetray 34 as well as rigidity. Thesecavities 43 are spaced apart and are arranged in rows. As shown, there are two rows ofcavities 43 along the front of thetray 34 and three rows ofcavities 43 along the right-hand side of thetray 34 as viewed. - Each
cavity 43 is of rectangular shape with aflat floor 46 and fourupstanding walls 47, each of whichwalls 47 is formed with vertical flutes orribs 48, as viewed, in order to impart rigidity to the cavity 45. As illustrated, the cavities may be of different sizes. - Referring to
FIGS. 6 and 7 , the underside of theflat floor 46 of eachcavity 43 is co-planar with the underside of thefloor 38 of therecess 36 and thewalls 47 of eachcavity 43 is of the same height as thewalls 39 of therecess 36. - A
thin web 49 connects eachcavity 43 with anadjacent cavity 43 and therecess 36 and each row of cavities with an adjacent row ofcavities 43. The connectingwebs 49 allow thetray 34 to flex between adjacent rows ofcavities 43, between therecess 36 and the adjacent row ofcavities 43 and between each pair ofcavities 43 in a row. In this regard, thethin web 49 allows the bottoms of twoadjacent cavities 43 to pivot toward each other. - A small
flat flange 50 extends about the entire periphery of thetray 34 - The
tray 34 can be of any suitable size. For example, thetray 34 may have outside dimensions of 8.375 inches by 11.0 inches and a thickness of 0.671 inches. Thewebs 49 may have a length of 0.30 inches between the flutes orribs 48 ofadjacent cavities 43. - Referring to
FIG. 4 , once the item 37 (e.g. a DVD holder) has been placed in therecess 36, either manually or automatically by suitable equipment, thetray 34 may be slipped into the sleeve 35 with the side having the front rows ofcavities 43 being inserted first and the ends of the sleeve closed in conventional manner to form a package suitable for mailing as a flat-sized piece in conformance with United States Postal Service (USPS) regulations (see 39 CFR Part 111). - When packaged, a flexing or bending force imposed on the side of the package occupied by the rows of
cavities 43 causes thetray 34 to flex between the rows ofcavities 43 as well as between therecess 36 and the adjacent row ofcavities 43 and, particularly, in a manner to conform with the above described United States Postal Service requirements for flat-sized packages. - Referring to
FIG. 8 , wherein like reference characters indicate like parts as above, thepackage 51 may be made with atray 34′ of a smaller size than the tray described above and anenvelope 10 as described above in the embodiment ofFIG. 1 . - The
tray 34′ being of a smaller size, for example, having arecess 36 for receiving a jewel case and with overall dimensions of 7 inches by 8.875 inches, a lesser number of rows ofcavities 43 is required. In addition, the overall thickness of thetray 34′ may be made smaller such as with a height of 0.548 inches. Likewise, the size of thecavities 43 may be different and the spacing betweencavities 43 may be greater or less, e.g. with thewebs 49 having a length of 0.25 inches between theflutes 48 of thecavities 43. - As illustrated, two rows of
cavities 43 are disposed to each of two sides of therecess 36. In addition, thecavity 36 is formed with adepression 52 in the floor of the recess that has a pattern as shown inFIG. 9 with acircle 53 with four radiatingchannels 54. - Referring to
FIG. 12 wherein like reference characters indicate like parts as above, thetray 55 may be modified to have arecess 56 for shipping items other than CDs and DVDs. For example, the item might be an elongated pen (not shown) or any other suitably shaped structure. - In addition, the
tray 55 is molded of a one-piece body to have a plurality of elongated cavities orwells 57 in a pattern wherein two rows of spaced apart cavities 57 extend from one side of therecess 56. Where therecess 56 is disposed angularly, as shown, to one side of thetray 55, one row of cavities has one more cavity than the other row to lie closer to therecess 56. In addition, asingle cavity 57 is disposed on the opposite side of therecess 56 in line with the row having the lesser number of cavities. That is to say, therecess 56 is disposed angularly across the two rows ofcavities 57 rather than being in parallel with acavity 57. - Each
cavity 57 has a rounded bottom 58 and an upstanding peripheral wall defining a pair ofopposed side walls 60 and a pair ofsemi-circular end walls 61 connecting the twoside walls 60. In addition, a plurality offlutes 62, i.e. semi-circular grooves) extend across the bottom 58 of eachcavity 57 and into each of the twoopposed side walls 60. - The
flutes 62 may be angularly disposed across eachside wall 60 as shown inFIG. 12 or may be vertically disposed acrossside wall 60 as shown inFIG. 13 . - The
recess 56 has a flat bottom 63 coplanar with the bottom 58 of eachcavity 57 and aperipheral wall 64 upstanding from the bottom 63. As illustrated, theperipheral wall 64 is of an ovate shape having a pair ofparallel side walls 65 and a pair ofsemi-circular end walls 66 connecting theside walls 65. In addition, one ormore projections 67 are provided on each of theside walls 65 for retaining an item within therecess 56. - In this embodiment, the
recess 56 has a width of 0.701 inches between theside walls 65 to receive a pen or the like. Thetray 55 may have outside dimensions of 6.0 inches by 8.50 inches and an overall thickness of 0.580 inches. - As illustrated, the
recess 56 is asymmetrically disposed within thetray 55, i.e. to one side of thetray 55. In addition, at least onecavity 57 is disposed to one side of therecess 56 and two rows ofcavities 57 are provided on the opposite side of therecess 56. - As above, a
thin web 68 extends betweenadjacent cavities 57 and between therecess 56 and theadjacent cavities 57 to impart flexibility to thetray 55. In addition, athin flange 69 extends about the periphery of thetray 52. - Referring to
FIGS. 13 to 16 , wherein like reference characters indicate like parts as above, therecess 56 may have a rounded bottom 70 that is coplanar with the bottoms of thecavities 57 and that is shaped to accommodate the item, e.g. a pen, to be inserted into therecess 57. Likewise, eachprojection 67 is formed out of aside wall 65 of therecess 57 and is shaped to retain the item within therecess 53. - When the
tray 55 is placed in an envelope, sleeve or wrapper, the section of thetray 57 containing the multiple rows ofcavities 57 is able to flex under a bending force in a manner to conform to the above described United States Postal Service requirements for flat-sized packages. In addition, the left-hand section of the tray with thesingle cavity 57 is able to flex relative to therecess 56 along a line parallel to the axis of therecess 56. - The trays in each of the above described embodiments is made of a plastic material that may be clear, translucent or opaque. Also, each tray may be placed in an envelope of conventional structure, an expandable envelope as described in U.S. Pat. No. 6,227,444 or a wrapper or sleeve.
- The invention thus provides an insert or tray that is able to receive and retain rigid or non-rigid items within an envelope or wrapper to form a package that can be mailed as a flat-sized piece as defined by the USPS.
- The envelope and insert satisfies the USPS requirement that a flat-sized mail piece be uniformly thick so that any bumps, protrusions or other irregularities do not cause more than ¼″ variance in thickness.
- Excluding the outside edges of a mail piece, i.e., one inch from the edge, when determining variance in thickness, the insert secures the item within the cutout of the
insert 32 so as to prevent shifting of more than 2 inches within the envelope.
Claims (30)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/978,466 US20080290145A1 (en) | 2007-05-21 | 2007-10-29 | Flat-sized flexible envelope with insert |
CA 2641639 CA2641639C (en) | 2007-10-29 | 2008-10-23 | Flat-sized flexible envelope with insert |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/804,845 US20080290144A1 (en) | 2007-05-21 | 2007-05-21 | Flat-sized flexible envelope with insert |
US11/978,466 US20080290145A1 (en) | 2007-05-21 | 2007-10-29 | Flat-sized flexible envelope with insert |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/804,845 Continuation-In-Part US20080290144A1 (en) | 2007-05-21 | 2007-05-21 | Flat-sized flexible envelope with insert |
Publications (1)
Publication Number | Publication Date |
---|---|
US20080290145A1 true US20080290145A1 (en) | 2008-11-27 |
Family
ID=40071477
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/978,466 Abandoned US20080290145A1 (en) | 2007-05-21 | 2007-10-29 | Flat-sized flexible envelope with insert |
Country Status (1)
Country | Link |
---|---|
US (1) | US20080290145A1 (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080245695A1 (en) * | 2007-03-07 | 2008-10-09 | Ronald Baker | Mail flat assembly for automated processing and method of distributing promotional items using same |
US20090121000A1 (en) * | 2006-01-20 | 2009-05-14 | Daniel Goller | Envelope |
US20110049224A1 (en) * | 2009-09-03 | 2011-03-03 | Consolidated Graphics, Inc. | Automated Flat Mail Piece |
US20130192170A1 (en) * | 2012-01-31 | 2013-08-01 | Gary Dellert | Method and Tray For Mailing Small Objects |
US20140001252A1 (en) * | 2012-06-28 | 2014-01-02 | Marvin A. Makofsky | Blank for Making a Mailer and Mailer Made Thereby |
US20140326621A1 (en) * | 2013-05-03 | 2014-11-06 | Au Optronics Corporation | Carton |
US9475335B2 (en) * | 2012-06-28 | 2016-10-25 | Comformer Products, Inc. | Expandable file holder |
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US20140001252A1 (en) * | 2012-06-28 | 2014-01-02 | Marvin A. Makofsky | Blank for Making a Mailer and Mailer Made Thereby |
US9004345B2 (en) * | 2012-06-28 | 2015-04-14 | Conformer Products, Inc. | Blank for making a mailer and mailer made thereby |
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Legal Events
Date | Code | Title | Description |
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AS | Assignment |
Owner name: CONFORMER EXPANSION PRODUCTS, INC., NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MAKOFSKY, MARVIN A;REEL/FRAME:020073/0810 Effective date: 20071029 |
|
AS | Assignment |
Owner name: CONFORMER PRODUCTS, INC.,NEW YORK Free format text: CHANGE OF NAME;ASSIGNOR:CONFORMER EXPANSION PRODUCTS, INC.;REEL/FRAME:024128/0152 Effective date: 20091201 Owner name: CONFORMER PRODUCTS, INC., NEW YORK Free format text: CHANGE OF NAME;ASSIGNOR:CONFORMER EXPANSION PRODUCTS, INC.;REEL/FRAME:024128/0152 Effective date: 20091201 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |
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AS | Assignment |
Owner name: PAMA ENTERPRISES, INC., NEW YORK Free format text: MERGER;ASSIGNOR:CONFORMER PRODUCTS, INC.;REEL/FRAME:029389/0175 Effective date: 20121019 Owner name: CONFORMER PRODUCTS, INC., NEW YORK Free format text: CHANGE OF NAME;ASSIGNOR:PAMA ENTERPRISES, INC.;REEL/FRAME:029395/0848 Effective date: 20121031 |