Flat Envelopes with Pockets and Blank for Making Same

Description

This is a Non-Provisional Patent Application and claims the benefit of Provisional Patent Application 63/536,787, filed Sep. 6, 2023.

This invention relates to flat envelopes with pockets and blanks for making the same.

As is known from Published Patent Application US2020/0189797, 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 letter-size and flat-sized pieces. To that end, the term “flat envelope” in this Patent Application means an envelope that meets the USPS regulations for a letter-size piece and a flat-sized piece.

The USPS has established certain requirements that determine if a package is suitable for USPS Letter sorting rates.

• • Not less than 5 inches long, 3½ inches high, and 0.007-inch thick.
  • Not more than 11½ inches long, or more than 6⅛ inches high, or more than ¼-inch thick.
  • Not more than 3.5 ounces
  • Rectangular, with four square corners and parallel opposite sides.
  • May not contain solid items that cause the thickness of the mailpiece to be uneven; or loose objects not affixed to the contents within the mailpiece.
  • May not be too rigid (does not bend easily when subjected to a transport belt tension of 40 pounds around an 11-inch diameter turn).

The USPS has established certain requirements that determine if a package is suitable for USPS Flat sorting rates.

• • Thickness—Flats must be under ¾″ thick.
  • Uniform Thickness—Flat-size mail pieces must be uniformly thick so that any bumps, protrusions, or other irregularities do not cause more than ¼-inch variance in thickness.
  • Flexibility—Flat-size pieces must be flexible. Mail pieces under 10 inches long must be able to flex 1 inch along the long edge and short edge of the package. For mail pieces over 1 inches long, the mail piece must be able to flex 2 inches along the long edge and short edge of the package.
  • Mailers must secure Goods to prevent shifting of more than 2 inches.
  • Flats must be more than 11½ inches long, or more than 6⅛ inches high, or more than ¼inch thick
  • Flats may not exceed 15 inches long, or more than 12 inches high, or more than ¾ inch thick.

It is an object of this invention to provide an envelope having pockets for receiving goods that qualifies as a “flat envelope”under USPS regulations.

It is another object of the invention to provide a one piece blank for making an envelope with pockets for receiving goods that qualifies as a “flat envelope” under USPS regulations.

Briefly, the invention provides a blank for making a flat envelope that comprises a front panel, a pair of side flaps, a bottom flap and a closure flap.

The front panel has a horizontally disposed score line spaced from a top edge thereof, a horizontally disposed score line spaced from a bottom edge thereof, a vertically disposed score line spaced from one side edge thereof, a vertically disposed score line spaced from another side edge thereof and a plurality of angularly disposed score lines. Each angularly disposed score line extends from an intersection of a respective horizontally disposed score line and a vertically disposed score line to a respective corner of the front panel.

The pair of side flaps extend laterally from the front panel for folding over the front panel. Each side flap includes a first section extending from the front panel, a second section extending from the first section and a score line extending between the two sections.

When the blank is folded into an envelope, the resultant envelope is characterized in being an expandable envelope construction as described in U.S. Pat. No. 6,227,444.

In addition to the above, at least one of the side flaps has an extension with a terminal section for folding under the side flap for securement to the front panel to form a pocket in the flat envelope.

The bottom flap extends longitudinally from the front panel for folding over the side flaps and the closure flap extends from the front panel on a side opposite the bottom flap for folding over the side flaps and closing the pocket.

In one embodiment, when folded, the blank forms a flat envelope having a pair of adjacent pockets for receiving goods. That is, one pocket is formed by folding under the terminal portion of the extension on one side flap and securing the terminal portion to the front panel, as by a suitable adhesive, and the second pocket is formed by folding an extension on the opposite side flap over and onto the first extension. This construction is termed a two pocket center seam construction.

In another embodiment, each of the side flaps of the blank has an extension with a terminal portion for folding under the extension for securement to the front panel to form a pocket in the flat envelope. When folded, the terminal portion of each extension is folded under and secured to the front panel to form a pair of spaced apart pockets. The spacing between the two pockets also functions as a third pocket for receiving goods. This construction is termed a three pocket side seam construction.

In still another embodiment, only one of the side flaps has an extension with a terminal portion for folding and securement to the front panel to form a pocket in the flat envelope. When folded, the terminal portion of the extension is folded under and secured to the front panel to form a pocket while the space under the opposite side flap and bottom flap forms a second pocket. This construction is termed a two pocket side seam construction.

These and other objects and advantages 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 a flat envelope characterized as a two pocket center seam construction in accordance with the invention;

FIG. 2 illustrates a view of a flat envelope made from the blank of FIG. 1 with goods in two pockets;

FIG. 3 illustrates a partial view of a pocket in the flat envelope of FIG. 2;

FIG. 4 illustrates a plan view of a modified blank for making a flat envelope characterized as a three pocket side seam construction in accordance with the invention;

FIG. 5 illustrates a view of a modified flat envelope with three pockets for receiving goods;

FIG. 6 illustrates a view of the flat envelope of FIG. 5 with goods in place; and

FIG. 7 illustrates a plan view of a blank for making a flat envelope characterized as a two pocket side seam construction in accordance with the invention.

Referring to FIG. 1, a flat one piece blank 10 has a front panel 11, a pair of side flaps 12, a bottom flap 13 and a closure flap 14.

The front panel 11 has a horizontally disposed score line 15 spaced from a top edge thereof, a horizontally disposed score line 16 spaced from a bottom edge thereof, a vertically disposed score line 17 spaced from one side edge thereof, a vertically disposed score line 18 spaced from another side edge thereof and a plurality of angularly disposed score lines 19. Each angularly disposed score line 19 extends from an intersection of a respective horizontally disposed score line 15, 16 and a vertically disposed score line 17, 18 to a respective corner of the front panel 11.

The pair of side flaps 12 extend laterally from the front panel 11 for folding over the front panel via the imposition of a fold line 20 between each side flap 12 and the front panel 11

Each side flap 12 includes a first section 21 extending from the front panel 11, a second section 22 extending from the first section 21 and a score line 23 extending between the two sections 21, 22.

Each side flap 12 also includes a triangular-like tab 24 extending from one end of each section 21, 22 and a rhombic tab 25 extending from the opposite end of the sections 21, 22.

As illustrated, an extension 26 extends from each of the side flaps 12 and is of a lesser height than a side flap 12.

One of the extensions 26 is sized for securement to the front panel 11 to form a pocket and, to this end, the extension 26 has a foldable terminal portion 27 that includes a line of weakening 28, such as a cut-crease combo, to define a pair of mutually foldable sections 29, 30 and a score line 31 separating the pair of mutually foldable sections 29, 30 from a third section 32 thereof.

The bottom flap 13 extends longitudinally from the front panel 11 for folding over the side flaps 12 via the imposition of a fold line 33 between the bottom flap 13 and the front panel 11. As illustrated, the bottom flap 13 has a score line 34 separating the flap 13 into a trapezoidal section 35 and a rectangular section 36.

The bottom flap 13 is of a height less than the height of the extensions 26 of each side flap 12.

The closure flap 14 extends from the front panel 11 on a side opposite the bottom flap 13 for folding over the side flaps 12 via the imposition of a fold line 37 between the closure flap 14 and the front panel 11 and closing the pocket formed by the extension 27. As illustrated, the closure flap 14 has a score line 38 separating the flap 13 into a trapezoidal section 39 and a rectangular section 40 with a tear-open strip 41, as is known.

Referring to FIG. 2, in use, the blank 10 is folded into a flat envelope 42. In this regard, as a first step, the side flap 12 with the extension 26 having the terminal portion 27 is folded via the fold line 20 over the front panel 11.

Next, the terminal portion 27 is folded under as indicated in FIG. 3 so that the end section 32 can be secured to the front panel 11, as by a suitable adhesive, while the mutually foldable sections 29, 30 flex inwardly or outwardly of the thus formed pocket 43.

Thereafter, the other side flap 12 is folded via the fold line 20 over the front panel 11 and the extension 26 extending therefrom is secured onto the pocket 43, as by a suitable adhesive, thereby forming a second pocket 44.

As illustrated in FIGS. 2 and 3, the flat envelope 42 has two pockets, each of which is able to receive goods 45, for example, packets of seeds. The pockets serve as compartments of limited size for maintaining the received goods 45 in a confined manner thereby limiting shifting of the goods 45 and conforming to USPS regulations for a letter-sized piece or a flat-sized piece.

After folding over of the side flaps 12, the bottom flap 13 is folded via the fold line 33 over the side flaps 12 to close off the bottom of the envelope 42 and the closure flap 14 is folded via the fold line 37 to close the envelope 42. In this latter regard, the closure flap 14 may be provided with a strip of adhesive (not shown) for sealing purposes and a tear-off strip 46 (See FIG. 2) covering over the strip of adhesive.

Of note, the tabs 24, 25 on the side flaps 12 serve, in a known manner, to facilitate closing of the corners of the envelope 42.

The various score lines 15-19, 23,34, 38 in the one piece blank 10 allow the envelope 42 to expand in thickness to accommodate the thickness of the goods 45, for example as described in U.S. Pat. No. 6,227,444.

Typically, in order to meet USPS regulations for a flat-sized piece, the envelope 42 when stuffed with the goods 45 will have a uniform thickness of more than ¼ inch and less than ¾ inch. Also, the envelope 42 will have a length of from 11½ inches to 15 inches and a height of from 6⅛ inches to 12 inches.

In order to meet USPS regulations for a letter-sized piece, the envelope 42 when stuffed will have a uniform thickness not greater than ¼ inch

Referring to FIG. 4, wherein like reference characters indicate like parts as above, the one piece blank 47 is formed with each of the side flaps 12 having an extension 48 for folding under the respective side flap 12 for securement to the front panel 11 to form a pocket.

Each side flap 12 is also formed with a triangular-like tab 25 at each end of the sections 21, 22 while omitting the use of a rhombic tab.

Each extension 48 has a foldable terminal portion 49 that includes a pair of lines of cut-crease combo 50 to define two pairs of mutually foldable sections 51, 52, a first score line 53 separating the two pairs of mutually foldable sections and a second score line 54 separating a third section 55 from the two pairs of mutually foldable sections 51, 52.

The blank 47 also has a bottom flap 13′ with a rectangular section 34′ of a height such that the upper edge of the bottom flap 13′ is even with the upper edge of each extension 48 of each side flap 12.

When folded, the terminal portion 49 of each extension 48 of each side flap 12 is folded under and secured to the front panel 11 to form a pair of spaced apart pockets. The spacing between the two pockets also functions as a third pocket for receiving goods.

When the side flaps 12 of the blank 47 are folded over the front panel 11 and the extensions 48 folded under, the two pairs of mutually foldable sections 51, 52 flex in or out in accordion-like manner to accommodate different thicknesses of the goods being received. The three scores allow the envelope to lay flat but expand to a limited maximum capacity. In the instance of the USPS regulations, capacity would be limited to ¾ inch thickness.

Referring to FIG. 5, wherein like reference characters indicate like parts as above, a flat envelope 56 may be made from a blank wherein each side flap 12 has an extension 48′ without fold lines. In this embodiment, the extension 48′ extends from the side flap 12 and the terminal portion 49′ is folded under via a fold line (not shown) without intermediate lines of cut-crease combo and/or fold lines and is secured to the front panel 11 via a suitable adhesive.

Referring to FIGS. 5 and 6, as above, the flat envelope 56 has a bottom flap 13′ with a rectangular section 34′ of a height such that the upper edge of the bottom flap 13′ is even with the upper edge of the extension 48′ (see FIG. 5) of each side flap 12.

Referring to FIG. 6, the envelope 56 has three pockets which can accommodate goods 57, such as flat packets of audio cards, in a manner that limits shifting of the goods 57. When stuffed with the goods 57, the envelope will have dimensions similar to those of the envelope 42 of FIG. 2.

Referring to FIG. 7, wherein like reference characters indicate like parts as above, the one piece blank 10′, as above, has a front panel 11, a pair of side flaps 12, a bottom flap 13 and a closure flap 14. However, only one of the side flaps 12 has an extension 26 with a terminal portion 27 for folding under and securement to the front panel 11 to form a pocket in the flat envelope. As above, the extension 26 has a foldable terminal portion 27 that includes a line of weakening 28, such as a cut-crease combo, to define a pair of mutually foldable sections 29, 30 and a score line 31 separating the pair of mutually foldable sections 29, 30 from a third section 32 thereof.

When folded, the terminal portion 27 of the extension 26 is folded under and secured to the front panel 11 to form a pocket while the space under the opposite side flap 12 forms a second pocket. This construction is termed a two pocket side seam construction.

The invention thus provides an envelope having pockets for receiving goods that Qualifies as a “letter envelope” or a “flat envelope” under USPS regulations. Further, the invention provides a one piece blank for making an envelope with pockets for receiving goods that qualifies as a “letter envelope” or a “flat envelope” under USPS regulations.