Postal mailers with adjustable dimensions

Abstract

Mailers for securing and protecting stress-sensitive or frangible articles for safe processing by automated postal processing equipment. The mailer may include a first panel adhesively bonded with a second panel to define a pocket between the first and second panels. The pocket is configured to receive an article. The second panel has a first edge and a second edge spaced from the first edge by a height of the second panel or a length of the second panel. The mailer further includes a flap with a first section attached along a fold line to the first edge of the second panel, a second section, and a line of weakening between the first and second sections. The first section is configured to fold along the line of weakening relative to the second section. The first and second sections are configured to fold along the fold line relative to the second panel.

1 . A mailer for an article, the mailer comprising:
 a first panel;   a second panel adhesively bonded with the first panel to define a pocket between the first and second panels, the pocket configured to receive the article, and the second panel having a first edge and a second edge spaced from the first edge by a height of the second panel or a length of the second panel; and   a flap including a first section attached along a fold line to the first edge of the second panel, a second section, and a line of weakening between the first section and the second section, the first section configured to fold along the line of weakening relative to the second section, and the first and second sections configured to fold along the fold line relative to the second panel.   
   
   
       2 . The mailer of  claim 1  wherein the first section has a first height measured orthogonal to the fold line, the second section has a second height measured orthogonal to the fold line, and the first height of the first section is shorter than the second height of the second section. 
   
   
       3 . The mailer of  claim 2  wherein a sum of the first height of the first section and the height of the second panel is greater than  6   1 / 8  inches, and the height of the second panel is 6⅛ inches or less. 
   
   
       4 . The mailer of  claim 2  wherein a sum of the first height of the first section and the height of the second panel is greater than a maximum height for United States Postal Service regulations governing automation-compatible mailpieces, and the height of the second panel is less than or equal to the maximum height for United States Postal Service regulations governing automation-compatible mailpieces. 
   
   
       5 . The mailer of  claim 1  wherein the mailer is a letter-sized mailpiece under United States Postal Service regulations when the first section of the flap is folded relative to the fold line, and the mailer is a flat mailpiece under the United States Postal Service regulations when the second section of the flap is folded relative to the line of weakening. 
   
   
       6 . The mailer of  claim 1  wherein the second section of the flap includes an adhesive region configured to adhesively bond the second section of the flap to the first panel when the first and second sections of the flap are folded about the fold line or when the second section is folded about the line of weakening such that the adhesive region on the second section of the flap contacts the second panel. 
   
   
       7 . The mailer of  claim 6  wherein the adhesive is a pressure-sensitive adhesive, and further comprising:
 a removable protective barrier covering the pressure-sensitive adhesive.   
   
   
       8 . The mailer of  claim 1  wherein the pocket has an access opening accessible along the first edge of the second panel, and the flap is configured to fold about the fold line or about the line of weakening to close the access opening. 
   
   
       9 . The mailer of  claim 8  wherein the second section of the flap includes an adhesive region configured to adhesively bond the second section of the flap to the first panel when the first and second sections of the flap are folded about the fold line or when the second section is folded about the line of weakening such that the adhesive region on the second section of the flap contacts the second panel. 
   
   
       10 . The mailer of  claim 1  wherein the second section of the flap has a larger surface area than the first section of the flap. 
   
   
       11 . The mailer of  claim 1  wherein the first panel has a first surface, the second panel has a second surface, and the pocket is disposed between the first surface and the second surface, and further comprising:
 a plurality of adhesive portions configured to adhesively bond the first surface of the first panel with the second surface of the second panel, at least one of the adhesive portions positioned between the first edge and the pocket to define a false bottom between the article and the first edge.   
   
   
       12 . A method for changing the height of a mailer including a first panel, a second panel, and a flap, the flap including a first section attached along a fold line to an edge of the second panel, a second section, and a line of weakening between the first section and the second section, the method comprising:
 placing an article inside a pocket between the first and second panels;   optionally folding the second section of the flap about the line of weakening relative to the first section so that the second section of the flap contacts the first panel; and   if the second section of the flap is not folded about the line of weakening, folding the first and second sections of the flap about the fold line relative to the second panel so that the second section of the flap contacts the first panel.   
   
   
       13 . The method of  claim 12  wherein the first and second sections of the flap are folded about the fold line after the second section of the flap is optionally folded about the line of weakening 
   
   
       14 . The method of  claim 12  further comprising:
 adhesively bonding the second section of the flap with the first panel.   
   
   
       15 . The method of  claim 12  further comprising:
 if the second section of the flap is not folded about the line of weakening, placing the mailer inside an envelope.   
   
   
       16 . The method of  claim 15  further comprising:
 removing the mailer from the envelope;   folding the second section of the flap about the line of weakening; and   adhesively bonding the second section of the flap with the first panel when the second section of the flap is folded into contact with the first panel.   
   
   
       17 . The method of  claim 16  wherein the envelope includes an original address and the first panel or the second panel includes a return address. 
   
   
       18 . An assembly for mailing an article, comprising:
 an envelope;   a mailer adapted to be inserted into the envelope, the mailer including a first panel, a second panel, a pocket positioned between the first and second panels, an access opening to the pocket, and a flap attached to the first panel and movable relative to the second panel for closing the access opening to the pocket; and   a sleeve positioned inside the pocket of the mailer, the sleeve including a first panel, a second panel joined to the first panel to define a first edge and a second edge, a pocket between the first and second panels, an access opening along a portion of the second edge for accessing the pocket to insert and remove the article, and a false bottom adapted to space the pocket from the first edge.   
   
   
       19 . The assembly of  claim 18  wherein the mailer includes an original address and the envelope includes a window, the original address being visible through the window when the mailer is inserted into the envelope. 
   
   
       20 . The assembly of  claim 10  wherein the flap includes an original address and the envelope includes a window, the original address being visible through the window when the mailer is inserted into the envelope.