Flexible Mailer and Blank for Making Same

Description

This is a Non-Provisional Patent Application and claims the benefit of Provisional Patent Application 63/676,027 filed Jul. 26, 2024.

This invention relates to an expandable flat-sized flexible envelope.

As is known, envelopes have been constructed for a number of purposes, for example, for the mailing of letters, business correspondence, merchandise, such as CD carriers and the like through the mails and thus need to conform to specified size requirements. Envelopes have also been constructed for use in the filing of various types of materials and in some cases, have been constructed to expand in order to increase the capacity of the envelope. Generally, these envelopes have been glued and finished by hand. In addition, these envelopes have had an internal gusset construction which restricts the insertion of papers.

U.S. Pat. No. 6,227,444 describes an envelope that is expandable when stuffed.

U.S. Pat. No. 11,952,174 describes an insert and an envelope that conforms to the United States Postal Service (USPS) regulations (see 39 CFR Part 111) that provide standards for domestic mailing services that set forth minimum flexibility and uniform thickness criteria for flat-sized pieces.

It is an object of this invention to provide an envelope which is of an expandable nature, qualifies as a flat-sized envelope according to USPS regulations and does not require an insert to hold goods in place.

Briefly, the invention provides a blank for making an expandable flat-sized flexible envelope as well as an expandable flat-sized flexible envelope.

The blank is made of one piece of paperboard and is sized and shaped to provide a rectangular front panel, a pair of side flaps, a pair of extensions to form pockets, a back panel and a closure flap.

The rectangular front panel is provided with score lines, as described in U.S. Pat. No. 6,227,444, to impart a structural characteristic of allowing expansion of the envelope made from the blank. To this end, the score lines include a horizontally disposed score line spaced from a bottom edge, a horizontally disposed score line spaced from a top edge, a vertically disposed score line spaced from one side edge, a vertically disposed score line spaced from another side edge and a plurality of angularly disposed score lines, each of which extends from an intersection of a respective horizontally disposed score line and a vertically disposed score line to a respective corner of the panel.

The side flaps of the blank are disposed at opposite sides of the front panel and each flap is foldable over the front panel along a vertical fold line therebetween.

In one embodiment, each side flap includes a vertically disposed score line spaced from the fold line, a first section extending from a respective vertical fold line and a reduced second section extending from the first section.

Each extension extends from a respective side flap and has a plurality of contiguous sections for folding longitudinally thereof into a flattened configuration for disposition over the front panel. For example, in the first embodiment, each extension has five contiguous sections for folding into a pocket of rectangular cross-sectional shape when expanded and a perforated line separates at least one of the extensions from a respective one of the side flaps to allow the extension to be separated from the side flap. The pocket formed by each extension is open-ended so as to receive goods, such as a bar of soap, razor blade cartridge and like shapes

The back panel extends from the front panel along a horizontal fold line therebetween and has a horizontally disposed score line spaced from the fold line to define a trapezoidal section therebetween. The back panel is foldable over the front panel and the second section of each side flap to define a pocket therewith. This pocket is sized to receive goods.

The closure flap extends from the front panel along a horizontal fold line therebetween for folding over the back panel, the second section of each side flap and each pocket disposed over the back panel. The closure flap also has a horizontally disposed score line spaced from the fold line and is provided with a means for closing the pockets in place by sealing the closure flap to the back panel.

When folded, the blank forms an expandable flat-sized flexible envelope for receiving goods in the open-ended pockets as well as the pocket formed by the back panel. The envelope remains flattened for shipping in bulk with the pockets in a collapsed condition. When ready for use, the envelope is manipulated such that the pockets are erected into an opened condition to receive goods.

In particular, the envelope is folded flat and has a rectangular front panel; a pair of side flaps folded over opposite sides of the front panel, a pair of folded extensions extending from the side flaps over the front panel, a back panel folded over the side flaps to define a pocket with the front panel and a closure flap for folding over and closing the envelope.

Each side flap is folded over the front panel along a vertical fold line therebetween and includes a vertically disposed score line spaced from the fold line to define a first section extending from a respective vertical fold line and a reduced second section extending from the first section.

Each extension extends from a respective side flap and has a plurality of contiguous sections folded longitudinally thereof into a flattened pocket and disposed over the front panel.

The back panel extends from the front panel along a horizontal fold line therebetween, said back panel has a horizontally disposed score line spaced from the fold line to define a trapezoidal section therebetween. The back panel is folded over the front panel and the second section of each side flap to define a pocket therewith.

The closure flap extends from the front panel along a horizontal fold line therebetween and is folded over the back panel, the second section of each side flap and each pocket disposed on the front panel. The closure flap also has a horizontally disposed score line spaced from the fold line between the closure flap and the front panel.

When ready to be stuffed, the side flaps of the envelope are flexed outwardly from the back panel thereby causing the flattened extensions to expand into open-ended pockets with a rectangular cross-section suitable for receiving goods.

In another embodiment, the blank is constructed such that each side flap includes a vertically disposed score line spaced from the fold line, an upper section extending from the vertical fold line and a lower section extending from the fold line.

In this embodiment, each extension extending from the upper section of a side flap has four contiguous sections for folding into a pocket of rectangular cross-sectional shape with the upper section. In like manner, each extension extending from the lower section of a side flap has four contiguous sections for folding into a pocket of rectangular cross-sectional shape with the lower section. Where the pockets formed in part by the upper sections of the flaps are intended to receive goods, the pockets formed in part by the lower sections of the flaps are intended to impart a uniform thickness to an envelope stuffed with goods in the upper part.

Also, in this embodiment, each pair of extensions extending from a side flap has a central section of the contiguous sections for folding into parallel with the front panel that are connected to each other. Thus, when an envelope made by the blank is being stuffed with goods, opening of the pockets in the upper half of the envelope will cause the pockets in the lower half to follow along and vice versa.

In all embodiments, the score lines provided on the front and back panels, the side flaps and the closure flap allow for expansion of the pockets within the envelope and the envelope while maintaining the flat appearance of the envelope.

Typically, the pockets provided by the extensions have a rectangular cross-section with a one half (0.500) inch thickness.

The envelope may be made with a front panel that does not include score lines.

The envelope construction is such that, upon insertion of materials into the pockets, the front and back faces expand from each other while the two sides and the bottom of the envelope construction collapse inwardly about the respective pairs of score lines adjacent the fold lines on each edge of the envelope construction. For example, for an envelope construction intended to have a thickness capacity of one-half inch, the score lines are spaced one-half inch from the adjacent fold line. The envelope may then be expanded from an empty flat condition to one in which the pockets are one-half inch thick while retaining a flat appearance.

After materials have been introduced into the pockets of the envelope construction, the closure flap is folded over the back panel to close the pockets. To this end, where the means for closing the pockets includes an adhesive strip along an inside edge of the closure flap and a removable barrier strip over the adhesive strip, the barrier strip is removed to expose the adhesive strip and the adhesive strip is pressed against the back panel.

The closure flap may also include a horizontally disposed tear strip which, upon removal, unseals the remainder of the closure flap from the back panel of the envelope so that the contents of the pockets may be removed. In order to facilitate removal of the tear strip, a stub is provided at each end of the tear strip to extend beyond the closure flap for manual gripping.

Unlike corrugated paper, paperboard is bendable. The blank is constructed from 8 pt to 18 pt paperboard, though most often in the 12 pt to 15 pt range. The blank is not rigid.

The USPS requires that Flats be flexible through the middle of the package along the length and width. Accordingly, the envelope formed by the blank is such that rigid goods (merchandise) do not pass through the middle of the envelope.

These and other objects of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:

FIG. 1 illustrates a plan view of a blank for making an expandable flat-sized flexible envelope in accordance with the invention;

FIG. 2 illustrates a view of an envelope in an open condition as made in accordance with the blank of FIG. 1;

FIG. 3 illustrates a view of the envelope of FIG. 2 with goods in the pockets in accordance with the invention;

FIG. 4 illustrates a view of the envelope of FIG. 2 with the closure flap in a closed position in accordance with the invention;

FIG. 5 illustrates a plan view of a second embodiment of a blank for making an expandable flat-sized flexible envelope in accordance with the invention:

FIG. 6 illustrates a perspective view of an envelope made from the blank of FIG. 5 with goods stuffed in the pockets of the upper portion; and

FIG. 7 illustrates a perspective view of the envelope of FIG. 6 in a closed condition.

Referring to FIG. 1, the blank 10 is made of one piece of paper or cardboard and is sized and shaped to provide a rectangular front panel 11, a pair of side flaps 12, a pair of extensions 13 to form pockets, a back panel 14 and a closure flap 15.

The rectangular front panel 11 has a horizontally disposed score line 16 spaced from a bottom edge thereof, a horizontally disposed score line 17 spaced from a top edge thereof, a vertically disposed score line 18 spaced from one side edge thereof, a vertically disposed score line 19 spaced from another side edge thereof and a plurality of angularly disposed score lines 20, each of which extends from an intersection of a respective horizontally disposed score line 16,17 and a vertically disposed score line 18,19 to a respective corner of the front panel 11.

The pair of side flaps 12 are disposed at opposite sides of the front panel 11 and each is foldable over the front panel 11 along a vertical fold line 21 therebetween. Each side flap 12 includes a vertically disposed score line 22 spaced from the fold line 21 to define a first section 23 extending from a respective vertical fold line 21 and a reduced second section 24 extending from the first section.

Each extension 13 extends from a side flap 12 and has a plurality of contiguous sections 25, 26, 27, 28. 29 for folding longitudinally thereof and for disposition over the front panel 11.

The back panel 14 extends from the front panel 11 along a horizontal fold line 30 therebetween and has a horizontally disposed score line 31 spaced from the fold line 30 to separate a trapezoidal section 32 from a rectangular section 33 with a curvilinear upper edge 34. The back panel 14 is foldable over the front panel 11 and the second section 24 of each side flap 12 to define a pocket (not shown) therewith.

The closure flap 15 extends from the front panel 11 along a horizontal fold line 35 therebetween for folding over the back panel 14, the second section 24 of each side flap 12 and each pocket (not shown). The closure flap 15 has a horizontally disposed score line 36 spaced from the fold line 35 to separate a trapezoidal section 37 from a rectangular section 38.

The closure flap 15 also includes an adhesive strip 39 along an inside edge and a removable barrier strip 40 over the adhesive strip 39 to act as a means for securing the closure flap 15 to the back panel 14 in order to close the envelope.

The closure flap 15 also has a horizontally disposed tear strip 41 at an intermediate point which, upon removal, unseals the remainder of the closure flap 15 from the back panel 14.

Referring to FIG. 2, wherein like reference characters indicate like parts as above, when folded, the blank 10 forms an envelope 42 characterized in having a pocket 43 between the front panel 11 and back panel 14 and a pair of open-ended collapsed pockets 44 overlying the front panel 11.

During folding of the blank 10, the sections 25, 26, 27, 28. 29 of each extension 13 as shown in FIG. 1 are folded over each other to form a collapsed pocket 44 and the outermost section 29 is secured, as by an adhesive (not shown), to the foremost section 25. Suitable fold lines 45 are provided between the sections 25-29 to facilitate folding while a line of weakening, such as a perforation 46, is provided between the foremost section 25 and a side flap 12 to allow a pocket 44 to be removed from the envelope 42. After folding of the extensions 13 to form the pockets 44, each side flap 12 is folded over the front panel 11 thereby positioning the collapsed pockets 44 over the front panel 11.

Next, the back panel 14 is folded over the second sections 24 of the side flaps 12 short of the pockets 44. A suitable adhesive (not shown) applied to the side edges of the back panel 12 is used to secure the back panel 14 to the side flaps 12.

The back panel 14 and front panel 11 thus form a pocket with the curvilinear edge 34 of the back panel 14 forming an entry mouth to the pocket.

When in an open condition, as viewed, the envelope 42 is flattened for shipment in bulk. In this regard, the pockets 44 are flattened to lie against the front panel 11.

Referring to FIG. 3, wherein like reference characters indicate like parts as above, when placed in use, a good 47, such as, a bar of soap, is slid into each pocket 44 of the envelope 42 thereby expanding the pocket 44. In addition, another good 48 or filler is slid into the pocket 43 between the back panel 12 and the front panel 11 to expand the pocket.

Next, referring to FIG. 4, the barrier strip 40 is removed from the closure flap 15 and the closure flap 15 positioned over the pockets 43, 44 (not shown) and secured to the back panel 14 to close the pockets 43, 44 (not shown) to the outside environment.

Referring to FIG. 1, the blank 10 is dimensioned to form an envelope that can be used to ship goods via the USPS as an expandable flat-sized flexible envelope without the need for a separate insert to hold the goods.

By way of example, an envelope as illustrated in FIG. 4 has dimensions of 6.750 inches in length and 6.375 inches in width. The front panel 12 of the blank 10 of FIG. 1 has the same dimensions with the side flaps 12 having a first section 23 of a width of 0.625 inches and a second section 24 of a width of 0,500 inches. Each extension 13 has a height, as viewed, of 2,250 inches with sections 25, 27 of a length of 1.75 inches, intermediate sections 26, 28 of 0.5 inches in length and an end section 29 of 0.5 inches in length.

The pockets 44 formed in the envelope of FIG. 2 thus have a size of 1.75 inches by 0.5 inches with open ends.

Referring to FIG. 5, wherein like reference characters indicate like parts as above, the blank 10′ is made of one piece of paper or cardboard and is sized and shaped to provide a rectangular front panel 11, a pair of side flaps 12′, a pair of extensions 13′ extending from each side flap 12, a back panel 14 and a closure flap 15.

The pair of side flaps 12′ are disposed at opposite sides of the front panel 11 and each is foldable over the front panel 11 along a vertical fold line 21 therebetween. Each side flap 12 includes a vertically disposed score line 49 spaced from the fold line 21 to define a first section 23, an upper section 50 extending from the vertical fold line 49 and a lower section 51 extending from the fold line 21.

As illustrated, the upper section 50 of each side flap 12′ has a rectangular portion 52 extending from the score line 49 that is sized to fold over the front panel 11 and a curved portion 53 extending from the score line 49 adjacent the rectangular portion 52.

The extension 13′ extending from the upper section 50 of each side flap 12 has four of contiguous sections 26, 27, 28, 29 for folding into a pocket of rectangular cross-sectional shape with the upper section 50.

The lower section 51 of each side flap 12′ has three portions, namely, a rectangular portion 54 extending from the score line 49 that is sized to fold over the front panel 11; a triangular portion 55 extending from the score line 49 and main portion 54 to the rectangular portion 52 of the upper section 50 and an elongated portion 56 extending from the score line 49 and main portion 54,

The extension 13′ extending from the lower section 51 of a side flap 12′ has four contiguous sections 57,58,59,60 for folding into a pocket of rectangular cross-sectional shape with the lower section 51.

As illustrated, the rectangular portion 54 of the lower section 51 is spaced from the rectangular portion 52 of the upper section 50 and the first of the contiguous sections 26 and 57 are spaced from each other to provide an access opening into the pocket formed by the lower section 51 when forming an opened envelope.

In like manner, the last two 59, 60 of the contiguous sections of the lower section 51 are spaced from the last two, 28, 29 of the contiguous sections of the upper section 50 to complete the access opening into the pocket.

As illustrated, each extension 13′ has a central section 27, 58 for folding into parallel with the front panel 11. These central sections 27, 58 are connected to each other.

The upper end of the first section 23 and the upper end of the curved portion 53 of each side flap 12′ are provided with score lines, as is known, to facilitate folding in of the upper ends of the side flaps 12′ when an envelope from which the blank 10′ is made is being stuffed and closed.

Referring to FIG. 6, wherein like reference characters indicate like parts as above, when folded, the blank 10′ forms an envelope 61 characterized in having a pair of open-ended expanded pockets 62 in an upper portion and overlying the front panel 11 for receiving goods 63. The envelope 61 is also characterized in having a pair of open-ended expanded pockets 64 in a lower portion to act as a filler for imparting a uniform thickness to the envelope 61 when stuffed with the goods 63.

Referring to FIG. 5, during folding of the blank 10′ into the envelope 61, the four contiguous sections 26-29 and 57-60 of the two extensions 13′ on each side flap 12′ are folded over each other and the outermost section 29, 60 of each is secured, as by an adhesive (not shown), to the rectangular portion 52 of the upper section 50 and the rectangular portion 54 of the lower section 51 to thereby form a pair of collapsed pockets 62

Suitable fold lines 65 are provided between the sections 25-29; 57-60 to facilitate folding.

After folding of the extensions 13′, each side flap 12′ is folded over the front panel 11 thereby positioning the collapsed pockets 62 over the front panel 11.

Next, the back panel 14 is folded over the rectangular portion 54 of the lower section 51 of each side flap 12′ and secured thereto by an adhesive (not shown). applied to the side edges of the back panel 14.

Next, the closure panel 15 is folded over the side flaps 12′ and back panel 14 without being secured in place. The resulting envelope 61 thus remains in a flattened condition for shipment in bulk and with the pockets 62 flattened to lie against the front panel 11.

In order to use an envelope 61, the closure panel 15 is folded back and the back panel 14 is moved away from the front panel 11, for example, manually, so as to expand the envelope in thickness while moving the side flaps 12′ and opening access to the pockets 62 in the upper half to receive the goods 63. During this time, the contiguous sections 26-29; 57-60 of the extensions 13′ unfold from a flattened collapsed condition to an erected expanded condition thus allowing the pockets 62 to be formed in the upper half.

Referring to FIG. 7, after stuffing of the pockets 62, the barrier strip 40 is removed from the closure panel 15 and the closure panel 15 is folded over and adhesively secured, via the adhesive strip shown in FIG. 5, to the back panel 14.

The invention thus provides a flat-sized envelope according to USPS regulations that does not require an insert to hold goods in place. In this respect, the flat-sized envelope is characterized in having self-contained pockets for receiving and mailing of goods.

The flat-sized envelope is also characterized in being bendable longitudinally and laterally in accordance with USPS regulations.

The invention also provides a blank of unique construction for forming an envelope that can be expanded to receive and to be mailed via the USPS as a flat-sized piece.