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. In one embodiment, the insert is provided with a cutout that is asymmetrical to one side of the insert and envelope to matingly receive the item being shipped. In another embodiment, the insert is a thin plastic tray having a recess to receive the item being shipped and a plurality of cavities interconnected by thin webs that impart flexibility to the package.

1 . A flat-sized package comprising
 an item to be mailed disposed within the package; and   a flexible insert disposed within the package to prevent said item from shifting within the package, said insert being flexible within the area occupied by said insert under a bending force imposed on at least one side of the package.   
     
     
         2 . A flat-sized package as set forth in  claim 1  wherein said insert has a cut-out of predetermined shape for receiving said item. 
     
     
         3 . A flat-sized package as set forth in  claim 2  wherein said insert is made of foam plastic. 
     
     
         4 . A flat-sized package as set forth in  claim 1  wherein said insert is a tray having a recess receiving said item. 
     
     
         5 . A flat-sized package as set forth in  claim 4  wherein said tray includes a pattern of cavities disposed in spaced apart relation and a plurality of thin webs interconnecting said cavities to allow each said cavity to pivot toward an adjacent cavity. 
     
     
         6 . A flat-sized package as set forth in  claim 1  further comprising an an envelope receiving said item and said insert and wherein said package has a uniform thickness of not more than ¾ inch. 
     
     
         7 . A tray for a mailer comprising
 a thin plastic body;   a recess disposed in asymmetric relation within said body for receiving an item to be mailed;   a plurality of cavities disposed in said body on at least two sides of said recess, at least some of said cavities being disposed in spaced apart relation to each other to define a thin web therebetween in said body.   
     
     
         8 . A tray as set forth in  claim 7  wherein said recess is of rectangular shape having a floor, a plurality of walls upstanding from said floor, and at least one projection on at least one of said walls projection into said recess for retaining an item therein. 
     
     
         9 . A tray as set forth in  claim 8  wherein each said cavity has a floor coplanar with said floor of said recess, a plurality of upstanding walls, and a plurality of ribs on each said wall for rigidifying said wall. 
     
     
         10 . A tray as set forth in  claim 7  wherein each said cavity has a floor, a peripheral wall upstanding from said floor with a pair of parallel side walls therein and a plurality of ribs extending within and between said pair of parallel side walls and said floor for rigidifying said cavity. 
     
     
         11 . A tray as set forth in  claim 7  wherein said cavities are disposed in a pair of rows on each of two sides of said recess. 
     
     
         12 . In combination
 a tray comprising a thin plastic body; a recess disposed in asymmetric relation within said body for receiving an item to be mailed; a plurality of cavities disposed in said body on at least two sides of said recess, at least some of said cavities being disposed in spaced apart relation to each other; and a plurality of thin webs in said body interconnecting said cavities;   an item in said recess of said tray; and   an envelope receiving said tray and said item.   
     
     
         13 . The combination as set forth in  claim 12  wherein said envelope has a pocket for receiving said tray and a closure flap for closing over said pocket. 
     
     
         14 . The combination as set forth in  claim 12  where said envelope is prescored with an expandable pocket for receiving said tray. 
     
     
         15 . The combination as set forth in  claim 11  wherein said envelope is a sleeve receiving said tray in slide fit relation. 
     
     
         16 . The combination as set forth in  claim 11  wherein said envelope is a wrapper enveloping said tray and said item. 
     
     
         17 . In combination
 an envelope having a pocket;   an item to be mailed in said pocket; and   a flexible insert within said pocket having a cut-out of predetermined shape receiving said item and being of a height and width to substantially fill the remainder of said pocket and to be shipped in said envelope.   
     
     
         18 . The combination as set forth in  claim 17  wherein said insert is secured to said envelope. 
     
     
         19 . The combination as set forth in  claim 17  wherein said insert is made of self-supporting plastic foam. 
     
     
         20 . The combination as set forth in  claim 17  wherein said insert is of L-shape and said cut-out is disposed asymmetrically to one side of said insert. 
     
     
         21 . The combination as set forth in  claim 17  wherein said envelope has a closure flap for closing over said pocket. 
     
     
         22 . The combination as set forth in  claim 17  wherein said envelope is a sleeve receiving said insert and said item in slide fit relation. 
     
     
         23 . The combination as set forth in  claim 17  wherein said envelope is a wrapper enveloping said insert and said item. 
     
     
         24 . The combination as set forth in  claim 17  wherein said envelope has a dimension of at least ten inches on one side thereof. 
     
     
         25 . The combination as set forth in  claim 17  wherein said insert has a thickness of from 1/16 inches to 1¼ inches. 
     
     
         26 . The combination as set forth in  claim 17  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. 
     
     
         27 . The combination as set forth in  claim 26  wherein said item is rigid. 
     
     
         28 . The combination as set forth in  claim 27  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. 
     
     
         29 . The combination as set forth in  claim 28  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. 
     
     
         30 . The combination as set forth in  claim 29  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.