Flat-sized flexible envelope with insert

Abstract

The flat oversize mail piece includes an envelope of expandable nature, a flexible insert within the pocket of the envelope and an item that may be rigid or non-rigid. The insert is provided with a cutout that is asymmetrical to one side of the insert an envelope to matingly receive the item being shipped.

1 . In combination,
 a flat envelope including a front panel, a back panel, a pair of side flaps disposed in folded relation relative to said front panel and said back panel to define a pocket therewith and a closure flap for closing over said pocket; and   a flexible insert within said pocket of said envelope, said insert being of a height and width to substantially fill said pocket, said insert having a cut-out of predetermined shape for receiving an item to be shipped in said envelope.   
     
     
         2 . The combination as set forth in  claim 1  wherein said insert is secured to at least one of said panels. 
     
     
         3 . The combination as set forth in  claim 1  wherein said insert is made of self-supporting plastic foam. 
     
     
         4 . The combination as set forth in  claim 1  wherein said insert is of L-shape and said cut-out is disposed asymmetrically to one side of said insert. 
     
     
         5 . The combination as set forth in  claim 1  wherein said envelope has a dimension of at least ten inches on one side thereof. 
     
     
         6 . In combination
 an expandable envelope construction comprising   a pair of panels folded over each other along a horizontal fold line;   at least a first panel of said panels having a horizontally disposed score line spaced from a bottom edge thereof, a horizontally disposed score line spaced from a top 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 said angularly disposed score line extending from an intersection of a respective horizontally disposed score line and a vertically disposed score line to a respective corner of said first panel;   a pair of side flaps at opposite sides of one of said pair of panels, each said flap being folded over said one panel along a vertical fold line therebetween and being secured to the other of said pair of panels to form a pocket; and   a closure flap extending from said one of said pair of panels along a horizontal fold line therebetween for folding over the other of said pair of panels to close said pocket, said closure flap having a horizontally disposed score line spaced from said fold line between said closure flap and said one of said pair of panels whereby upon insertion of materials into said pocket, said panels are expandable from each other to enlarge the thickness of said pocket while said pocket is maintained in a sealed condition; and   a flexible insert within said pocket of said envelope, said insert extending between said score lines of said first panel, said insert having a cut-out of predetermined shape for matingly receiving an item to be shipped in said envelope, said cut-out being disposed asymmetrically of said insert.   
     
     
         7 . The combination as set forth in  claim 6  wherein each said flap has a vertical score line spaced from said first panel and wherein the other of said panels is secured to each said side flap between said score lines thereof to seal said pocket at at least each of two corners of said envelope construction. 
     
     
         8 . The combination as set forth in  claim 6  wherein said insert is secured to at least one of said flaps. 
     
     
         9 . The combination as set forth in  claim 6  wherein said insert has a thickness of from 1/16 inches to 1¼ inches. 
     
     
         10 . In combination,
 an envelope including a front panel, a back panel, a pair of side flaps disposed in folded relation relative to said front panel and said back panel to define a pocket therewith and a closure flap closing over said pocket;   a flexible insert within said pocket of said envelope, said insert having a predetermined thickness and being of an overall height and width to substantially fill said pocket, said insert having a cut-out of predetermined shape disposed asymmetrically of said insert; and   an item matingly disposed in said envelope within said cut-out of said insert, said item having a shape corresponding to said predetermined shape of said cut-out and a thickness corresponding to said predetermined thickness of said insert.   
     
     
         11 . The combination as set forth in  claim 10  wherein said item is flexible. 
     
     
         12 . The combination as set forth in  claim 11  wherein, with an uppermost half of said envelope supported on a horizontal plane, a lowermost half of said envelope is bendable relative to said horizontal plane about a longitudinal axis located at mid-height thereof to deflect a lowermost edge thereof for a vertical distance of at least one inch from said horizontal plane. 
     
     
         13 . The combination as set forth in  claim 10  wherein said item is rigid. 
     
     
         14 . The combination as set forth in  claim 13  wherein, with an uppermost half of said envelope supported on a horizontal plane, a lowermost half of said envelope is bendable relative to said horizontal plane about a longitudinal axis located at mid-height thereof to deflect a lowermost edge thereof for a vertical distance of at least one inch from said horizontal plane. 
     
     
         15 . The combination as set forth in  claim 14  wherein, with one side of said envelope supported on said horizontal plane and five inches of the opposite side of said envelope projecting in an unsupported manner, said opposite side of said envelope is bendable relative to said horizontal plane to deflect an edge thereof for a vertical distance of at least two inches from said horizontal plane. 
     
     
         16 . The combination as set forth in  claim 15  wherein, with said opposite side of said envelope supported on said horizontal plane and five inches of said one side of said envelope projecting in an unsupported manner, said one side of said envelope is bendable relative to said horizontal plane to deflect an edge thereof for a vertical distance of at least two inches from said horizontal plane. 
     
     
         17 . The combination as set forth in  claim 10  wherein said item is a CD holder. 
     
     
         18 . The combination as set forth in  claim 10  wherein said item is a DVD. 
     
     
         19 . The combination as set forth in  claim 10  wherein said insert is made of self-supporting plastic foam. 
     
     
         20 . The combination as set forth in  claim 10  wherein said insert is of L-shape and said cut-out is disposed to one side of said insert to prevent shifting of said item in said envelope. 
     
     
         21 . The combination as set forth in  claim 10  wherein said insert and said item are of equal thickness. 
     
     
         22 . In combination,
 a flat envelope having a dimension of at least ten inches on one side thereof and including a front panel, a back panel, a pair of side flaps disposed in folded relation relative to said front panel and said back panel to define a pocket therewith and a closure flap closing over said pocket;   a flexible insert within said pocket of said envelope, said insert having a predetermined thickness and being of an overall height and width to substantially fill said pocket, said insert having a cut-out of predetermined shape; and   an item matingly disposed within said cut-out of said insert, said item having a shape corresponding to said predetermined shape of said cut-out and a thickness corresponding to said predetermined thickness of said insert.   
     
     
         23 . The combination as set forth in  claim 22  wherein said cut-out is disposed asymmetrically of and to one side of said envelope and said item is rigid. 
     
     
         24 . The combination as set forth in  claim 22  wherein said insert is of L-shape.