Expandable padded parcel

Abstract

A padded mailer includes a bag formed from a front panel and a back panel, each panel including a bottom edge, a top edge, and opposite side edges. The panels are joined along their bottom edges and each side edge to define an interior space. The top edges of the panels are unjoined to form an opening into the interior space. The padded mailer also includes a cushion disposed in the interior space, the cushion including an expandable panel having a bottom edge, a top edge, and opposite side edges. The bottom edge of the expandable panel is secured proximate the bottom edges of the front and back panels, and the top edge and side edges of the expandable panel are unsecured to the front and back panels. Pulling the top edge of the expandable panel relative to the bag causes the expandable panel to expand and increase a thickness of the cushion.

Description

TECHNICAL FIELD

[0001] The present invention relates generally to the field of mailer packaging, and more specifically to a padded mailer for mailing an item. BACKGROUND

[0002] Padded mailers, such as padded envelopes, are often used to ship goods, particularly fragile goods. Padded mailers are typically made with a plastic bubble material padded inside the mailer, however, alternatives can be used such as foam, recycled fiber fluff, and paper-based cushioning materials, among others. Conventional padded mailers are subject to the limitation of being manufactured and delivered to the user in a ready-to-use state. Specifically, in their ready-to-use state, these padded mailers typically occupy the same amount of space from the manufacturing plant to the point of use during shipping. SUMMARY

[0003] The present disclosure describes a padded mailer that can be manufactured, shipped to an end user, and stored in a compact state, and then expanded to an increased cushion, higher volume state when ready for use. Thus, the padded mailer described herein allows for more efficient and less costly production and shipping of the padded mailer from its manufacturing plant to the point of use.

[0004] An exemplary padded mailer includes a bag formed of a front panel and a back panel connected at their respective bottom edges and along each of their respective opposite side edges, while remaining unconnected at their respective top edges. The padded mailer includes at least one expandable panel cushion that, in an unexpanded state, is secured to at least one of the front panel and the back panel adjacent to the respective bottom edge of the front panel and the back panel, and is unconnected at the side edges and the top edge, such that the expandable panel is free to move in a bottom-to-top direction relative to the bag. When a user receives the padded mailer in a reduced volume or unexpanded state, the user can place an item within the bag of the padded mailer and pull the expandable panel in the bottom-to-top direction such that the expandable panel expands. The expansion of the expandable panel increases the thickness of the cushion, thereby bringing the padded mailer to an increased cushion, higher volume state. When the padded mailer is closed and sealed, the expandable panel remains in the increased cushion, higher volume state during shipping from the sender to the recipient to protect the goods in transit.

[0005] An example padded mailer includes a pouch formed from a front panel and a back panel. Each panel includes a bottom edge, a top edge, and opposite side edges. The panels are connected along their respective bottom edges and along each of their respective opposite side edges to define an interior space. A direction from the bottom edge to the top edge is a bottom-to-top direction. The top edges of the panels are unconnected to form an opening into the interior space. The padded mailer additionally includes a cushion disposed in the interior space. The cushion includes at least one expandable panel that includes a bottom edge, a top edge, and opposite side edges. The bottom edge of the expandable panel is secured to at least one of the front panel and the back panel proximate the respective bottom edges of the front panel and the back panel, and the top edge and the opposite side edges of the expandable panel are unsecured to the front panel and the back panel such that the expandable panel is free to expand in the bottom-to-top direction relative to the pouch. Pulling the top edge of the expandable panel in the bottom-to-top direction relative to the pouch causes the expandable panel to expand and increase a thickness of the cushion.

[0006] One or more embodiments of the padded mailer can include one or more of the following features, such as the expandable panel includes an expandable slit sheet material. The expandable slit sheet material has a plurality of rows formed by a plurality of slits. Each row of the plurality of rows extends transverse to the bottom-to-top direction.

[0007] The expandable panel can have a relatively flat unexpanded state in which the expandable panel lies flat within a plane, and an expanded state in which the slits open to form apertures and a plurality of portions of the slit sheet material between the slits are rotated away from the plane.

[0008] The padded mailer can include a divider panel disposed in the interior space. The divider panel includes a bottom edge, a top edge, and opposite side edges. At least one of the bottom edge and the opposite side edges of the divider panel is secured to at least one of the front panel and the back panel proximate the respective edges of the front panel and the back panel.

[0009] The padded mailer can include a pull tab that extends from the top edge of the at least one expandable panel and out of the opening to make it easier for a user to pull the top edge of the expandable panel in the bottom-to-top direction relative to the pouch to cause expansion.

[0010] The pull tab can include a pull tab adhesive layer covered by a pull tab removable release pad.

[0011] Any of the front panel and the back panel, the expandable panel, or the divider panel can be made of paper.

[0012] The back panel of the pouch can have a greater length in the bottom-to-top direction than the front panel such that when the bottom edges of the front panel and the back panel are aligned, the top edge of the back panel extends beyond the top edge of the front panel in the bottom-to-top direction to form a pouch cover.

[0013] The back panel can include a fold line adjacent to the top edge of the front panel to facilitate folding the bag flap over the top edge of the front panel to close the opening.

[0014] The bag flap can include a bag flap adhesive layer on an inner surface of the back panel adjacent to the top edge of the back panel. The inner surface of the back panel faces the interior space of the bag.

[0015] The bag flap adhesive layer can be covered by a bag flap removable release pad.

[0016] The front panel can include a front panel adhesive layer on an outer surface of the front panel adjacent to the top edge of the front panel. The outer surface of the front panel faces the exterior of the bag.

[0017] The front panel adhesive layer can be covered by a front panel removable release pad.

[0018] The bag can include a mechanical fastener adjacent to the top edge of each of the front panel and the back panel for closing the opening of the bag.

[0019] The bag can include a sealant adjacent to the top edge of each of the front panel and the back panel for closing the opening of the bag.

[0020] The bag can include at least one gusset, wherein the front panel is connected to the back panel along each of the bottom edges of the front panel and the back panel and the opposite side edges of the front panel and the back panel.

[0021] An example method of packaging an item for shipment includes the step of providing a padded mailer. The method also includes the steps of inserting the item into the interior space of the bag and pulling the top edge of the expandable panel to cause the expandable panel to expand and increase the thickness of the cushion. The method then includes the step of securing the top edge of the expandable panel to the bag after the pulling step. The method then includes the step of closing the opening of the bag.

[0022] An example method of making a padded parcel includes the steps of providing a front panel and a back panel oriented in a face-to-face relationship. Each panel includes their respective bottom edges, their respective top edges, and their opposite side edges. The method further includes the step of joining the front panel and the back panel along their respective bottom edges and along each of their respective opposite side edges to define an interior space. The top edges of the panels remain unjoined to form an opening into the interior space. The method then includes the step of placing a cushion in the interior space. The cushion includes at least one expandable panel that includes a bottom edge, a top edge, and opposite side edges. The method then includes the step of securing the bottom edge of the expandable panel to the bag proximate the bottom edges of the front and back panels. The top edge and the opposite side edges of the expandable panel are free to move relative to the front and back panels of the bag. Pulling the top edge of the expandable panel in a bottom-to-top direction relative to the bag causes the expandable panel to expand and increase a thickness of the cushion. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is a perspective view of an example padded parcel in a reduced volume state;

[0024] Figure 2 is a perspective view of an example padded parcel in a higher volume state of Figure 1

[0025] Figure 3 is a perspective view of an example padded parcel in a partially unassembled, open face arrangement of Figure 1

[0026] Figure 4 is a perspective view of an example padded parcel in a partially unassembled, partially open face arrangement of Figure 1

[0027] Figure 5 is a perspective view of an example padded parcel in a partially unassembled, closed face arrangement of Figure 1

[0028] Figure 6A and Figure 6B are schematic views of an example slit sheet material used as an expandable panel in a padded parcel of Figure 1 in an unexpanded state and an expanded state, respectively;

[0029] Figure 7 is a perspective view of an example padded parcel;

[0030] Figure 8A and Figure 8B are schematic views of an example padded parcel; and

[0031] ​​​​Figures 9A-9D is Figure 1 a continuous perspective view of an exemplary padded mailer, illustrating steps that a user can take in packaging an item therein. DETAILED DESCRIPTION

[0032] Turning now to the drawings, an exemplary padded mailer 10 is configured to be manufactured, shipped to an end user, and stored in a reduced volume and compact state, as depicted in Figure 1 . The padded mailer 10 is configured to be expanded to an increased cushioning, higher volume state when ready for use, as depicted in Figure 2 . For example, a user can receive the padded mailer 10 in a reduced volume, compact state. When the user is ready to package an item therein for shipment, the user can insert the item into the padded mailer 10 and expand the padded mailer 10 to an increased cushioning, higher volume state prior to shipping the item packaged therein.

[0033] With additional reference to Figures 3-5 , the padded mailer 10 includes a bag 12 formed at least from a front panel 14, a back panel 16, and a cushion 18. Figure 3 depicts the bag 12 in a partially unassembled, open-faced arrangement, which is intended to more clearly illustrate the arrangement of the front panel 14, the back panel 16, and the cushion 18 relative to one another. For the same purpose, Figure 4 depicts the bag 12 in a partially unassembled and partially open-faced arrangement, and Figure 5 depicts the bag 12 in a partially unassembled, closed-faced arrangement.

[0034] Each of the front panel 14, the back panel 16, and the cushion 18 includes a bottom edge 14a, 16a, 18a, a top edge 14b, 16b, 18b, and opposite side edges 14c, 16c, 18c, respectively. The direction from the bottom edge 14a, 16a, 18a to the top edge 14b, 16b, 18b is referred to herein as a bottom-to-top direction 20 with respect to the bag 12, and the direction from the face of the front panel 14 to the face of the back panel 16 is referred to herein as a thickness direction 21.

[0035] As Figure 1 and Figure 2As depicted, the bottom edge 14a of the front panel 14 and the opposite side edge 14c are attached to the bottom edge 16a of the back panel 16 and the opposite side edge 16c, respectively, to form the interior space 22 of the assembled bag 12. The bottom edges 14a, 16a and the opposite side edges 14c, 16c can be attached to one another using, for example, an adhesive, mechanical fasteners, or fold lines. The bag 12 can include at least one gusset in which the front panel 14 and the back panel 16 are attached to one another along each of their respective bottom edges 14a, 16a and their respective opposite side edges 14c, 16c for reinforcement of the bag 12. The top edge 14b of the front panel 14 and the top edge 16b of the back panel 16 remain unconnected to one another to form an opening 24 into the interior space 22 of the bag 12 for insertion of the items to be packaged therein.

[0036] The cushion 18 is disposed in the interior space 22 and can pad all or a portion of the front panel 14 and the back panel 16 in the interior space 22. The cushion 18 includes at least one expandable panel 19 in an unexpanded state. In the depicted embodiment, the cushion 18 includes two expandable panels 19, each in an unexpanded state. A bottom edge 18a of the cushion 18 is secured to at least one of the front panel 14 and the back panel 16 proximate the respective bottom edges 14a, 16a of the front panel 14 and the back panel 16. The bottom edge 18a of the cushion 18 can be secured to the front panel 14 or the back panel 16 by, for example, an adhesive, mechanical fasteners, or fold lines. The top edge 18b and the opposite side edges 18c of the cushion 18 are unconnected to the front panel 14 and the back panel 16 such that the cushion 18 is free to expand in the bottom-to-top direction 20 relative to the bag 12. As will be described more fully hereinafter, pulling the top edge 18b of the at least one expandable panel 19 of the cushion 18 in the bottom-to-top direction 10 relative to the bag 12 causes the at least one expandable panel 19 to expand and increase the thickness of the cushion 18 in the thickness direction 21.

[0037] The front panel 14 and the back panel 16 are made of a mailing material such as paper. Depending on the particular application or environment in which the cushioned mailing bag 10 is to be used, the mailing material can be any type and grade of paper such as kraft paper, etc. The mailing material can have any different basis weight and can be made from 0 to 100% recycled material. In some embodiments, the mailing material can be laminated or can include any other suitable material such as another paper, a plastic sheet, a metal foil, or any other combination thereof, etc. Wax or other coatings and chemical treatments can be added to the mailing material to add or improve desired properties such as moisture and heat resistance for cold chain applications, etc.

[0038] In Figures 3-5In the embodiment depicted in the middle, the bag 12 is formed by layering the cushion 18 over the pieces of mailing material (the front piece 14 and the back piece 16) and folding the cushion 18 and the mailing material at the fold 32, which thereby forms the bottom edges 14a, 16a, 18a of the front piece 14, the back piece 16, and the cushion 18, respectively. The bottom edge 18a of the cushion 18 is thereafter secured to at least one of the front piece 14 and the back piece 16 adjacent the respective bottom edges 14a, 16a of the front piece 14 and the back piece 16. Further, the respective opposite side edges 14c, 16c of the front piece 14 and the back piece 16 are thereafter attached to each other to form the interior space 22.

[0039] In another embodiment, however, the front piece 14 and the back piece 16 can be provided as separate pieces of mailing material, and their respective bottom edges 14a, 16a and respective opposite side edges 14c, 16c can be attached to each other to form the interior space 22 of the bag 12. In this embodiment, the cushion 18 can be inserted separately and its bottom edge 18a secured to at least one of the front piece 14 and the back piece 16 adjacent the respective bottom edges 14a, 16a of the front piece 14 and the back piece 16.

[0040] Alternatively, the bottom edge 18a of the cushion 18 can be secured between the bottom edge 14a of the front piece 14 and the bottom edge 16a of the back piece 16. In particular, a method of manufacturing the padded mailing bag 10 includes the step of providing a front piece 14 and a back piece 16 oriented in a face-to-face relationship. Each of the front piece 14 and the back piece 16 includes their respective bottom edges 14a, 16a, top edges 14b, 16b, and opposite side edges 14c, 16c arranged adjacent the respective edges of the other of the front piece 14 and the back piece 16. The method can then include the step of connecting the front piece 14 and the back piece 16 along their respective bottom edges 14a, 16a and along each of their respective opposite side edges 14c, 16c to define an interior space 22. The top edges 14b, 16b remain unconnected to form an opening 24 into the interior space 22. The method then includes the step of placing a cushion 18 in the interior space 22. The cushion 18 includes at least one expandable piece 19 including a bottom edge 18a, a top edge 18b, and an opposite side edge 18c. The method then includes the step of securing the bottom edge 18a of the expandable piece to the bag 12 adjacent the bottom edges 14a, 16a of the front piece 14 and the back piece 16, respectively. The top edge 18b and the opposite side edge 18c of the expandable piece 19 are free to move relative to the front piece 14 and the back piece 16 of the bag 12. Thus, the step of pulling the top edge 18b of the expandable piece 19 in the bottom-to-top direction 20 relative to the bag 12 causes the expandable piece 19 to expand and increase the thickness of the cushion in the thickness direction 21.

[0041] Turn now Figures 6A-6B At least one expandable sheet 19 of the pad 18 is made of slotted sheet material 26. Specifically, Figure 6A The slit sheet material 26 of at least one expandable sheet 19 in an unexpanded state is shown, and Figure 6B The slit sheet material 26 in an expanded state is shown. The slit sheet material 26 has a plurality of slits 28 arranged in rows 30 that are longitudinally spaced (i.e., along the length L of the slit sheet material 26) and laterally extended (i.e., along the width W of the slit sheet material 26). When disposed in the interior space 22 of the bag 12, the length L of the slit sheet material 26 extends in the bottom-to-top direction 20 of the bag 12, and the plurality of rows 30 and slits 28 extend laterally in the bottom-to-top direction 20 of the bag 12.

[0042] The slot sheet material 26 can have any one or different sheet thicknesses from a number of alternative arrangements of the slot 28 (i.e., in Figures 6A-6B (Dimensions perpendicular to the paper in the perspective view shown). Different arrangements of slits 28 may include any one or more of the following: different arrangements of rows 30 relative to each other, slits 28 of different sizes, different intervals between slits 28, different slit shapes, or slit positioning (such as angular positioning relative to adjacent slits 28). Slits 28 may be formed by intermittent perforations (such as by cutting) across the width W of the slit sheet material 26 or by other means that weaken the slit sheet material 26.

[0043] The rows 30 of these slits 28 are generally parallel to each other and are generally periodically and typically equally spaced longitudinally. The slits 28 are intermittently but periodically distributed within the rows 30, and the slits 28 of each row 30 typically intersect with the slits 28 of the directly adjacent rows 30. On each row 30 of slits 28, there may be a combined slit region with a length longer than the combined length of the non-slit regions disposed between each slit 28, thereby providing optimal expansion of the slit sheet material 26.

[0044] The expandable sheet 19 has a relatively flat unexpanded state in which it lies flat within the plane of the slit sheet material 26. The slit sheet material 26 is configured to expand in one or more dimensions to an expanded state in which the slits 18 open to form apertures 29 and the portions of the slit sheet material 26 between the slits 28 are rotated out of the plane. For example, when a tensile force is applied to the slit sheet material 26 in the lengthwise direction (i.e., relative to the bottom-to-top direction 20 of the bag 12), the length of the slit sheet material 26 increases in the lengthwise direction, the width decreases in the widthwise direction, and the thickness increases in a direction transverse to both the lengthwise and widthwise directions, thereby increasing the volume of the slit sheet material 26. In particular, with reference to Figure 6B pulling the top edge 18b of the gusset 18 (slit sheet material 26) causes the areas of the slit sheet material 26 on either side of the slits 28 in the longitudinal direction L to be pulled away from each other and causes the slits 28 to open and form apertures 29 in the slit sheet material 26. As the slits 28 open, the portions of the slit sheet material 26 between the slits 28 rotate out of the previously linear plane of the slit sheet material 26. Because the rotated areas of the slit sheet material 26 extend or protrude beyond the previously linear plane of the slit sheet material 26, this causes the thickness of the slit sheet material 26 to also increase. Thus, when stretched in this manner, the thickness of the slit sheet material 26 in the expanded state can be an order of magnitude or more greater than the thickness of the slit sheet material 26 in the unexpanded state.

[0045] When a tensile force is applied to the slit sheet material 26 in the longitudinal direction and the slit sheet material 26 expands to the expanded state, the slit sheet material 26 is deformed nonelastically. This deformation causes the slit sheet material 26 to remain in the expanded state and reduces the tendency of the slit sheet material 26 to return to its previously unexpanded state. In other words, the applied tensile force is sufficient to expand the slit sheet material 26 beyond its elastic limit. In some embodiments, the deformation can not be completely permanent, which can result in the slit sheet material 26 having a tendency to spring back and partially return to a flatter state.

[0046] The slit sheet material 26 can include paper, such as Kraft paper or the like, and typically includes a single layer of Kraft paper. Suitable Kraft paper can have a variety of basis weights, such as, for example, 20 pound or 40 pound, or the like. The paper itself can be made from 0 to 100% recycled material. In some embodiments, the slit sheet material 26 can be laminated or can include any other suitable material, such as another paper, a plastic sheet, a metal foil, or any other combination thereof, or the like. Embossing, perforations, or other features can be added to the slit sheet material 26 to define predetermined points of deformation, reduce the force required to expand the slit sheet material 26, and reduce the force required to maintain an expanded state. Waxes or other coatings and chemical treatments can be added to the liner to add or improve desirable properties, such as moisture and heat resistance for cold chain applications, or the like.

[0047] Referring to Figure 7 The padded mailer 10 can include a pull tab 46 extending from the top edge 18b of the liner 18, specifically from the top edge 18b of the at least one expandable panel 19, and out from the opening 24 of the bag 12. The pull tab 46 is configured to make it easier for a user to pull the top edge 18b of the expandable panel 19 in the bottom-to-top direction 20 relative to the bag 12 to cause expansion. The pull tab 46 can include a pull tab adhesive layer 48 to secure the at least one expandable panel 19 to at least one of the front panel 14 and the back panel 16 after the expandable panel 19 has been expanded and to prevent the expandable panel 19 from springing back and returning to a less expanded state. A pull tab removable release pad 50 can cover the pull tab adhesive layer 48 to prevent the pull tab 46 from adhering to any objects before the pull tab removable release pad 48 is removed.

[0048] The padded mailer 10 can additionally include at least one divider panel disposed in the interior space 22. The at least one divider panel also includes a top edge, a bottom edge, and opposite side edges. At least one of the bottom edge and the opposite side edges of the divider panel can be secured to at least one of the front panel and the back panel proximate the respective edges of the front panel and the back panel. For example, the bottom edge and the opposite side edges of the divider panel can be secured to the front panel and the back panel by adhesive or mechanical fasteners. Alternatively, the divider panel can not be secured within the interior space 22.

[0049] The divider panel can be made of paper, such as tissue paper or the like. For example, suitable paper can have a variety of basis weights, such as 20 pound or 40 pound, or the like. The paper itself can be made from 0 to 100% recycled material. In some embodiments, the divider panel can be laminated or can include any other suitable material, such as another paper, a plastic sheet, a metal foil, or any other combination thereof, or the like.

[0050] Turning now to Figure 8A and Figure 8BThe back panel 16 of the bag 12 may have a greater length in the bottom-to-top direction 20 than the front panel 14, such that when the bottom edges 14a, 16a of the front panel 14 and the back panel 16 are aligned and attached to each other, the top edge 16b of the back panel 16 extends beyond the top edge 14b of the front panel 14 in the bottom-to-top direction 20 to form a flap 34. The flap 34 may be folded to close the opening 24 of the bag 12 and may be secured to the front panel 14 to seal the padded parcel 10 for shipment. The back panel 16 may include a fold line 36 on the flap 34 adjacent to the top edge 14b of the front panel 14 to facilitate folding of the flap 34 above the top edge 14b of the front panel 14 to close the opening 24 after an item has been inserted.

[0051] exist Figure 8A In the embodiment specifically depicted, the flap 34 may include a flap adhesive layer 38 adjacent to the top edge 16b of the rear panel 16 on the inner surface of the rear panel 16 (the inner surface of the top panel 14 facing the interior space 22 of the bag 12) to seal the padded parcel 10 for shipment. When the flap 34 is folded over the top edge 14b of the front panel 14, the flap 34 can adhere to the outside of the front panel 14, thereby closing the opening 24 and sealing the padded parcel 10. The flap adhesive layer 38 may be covered by a flap removable release pad 40 to prevent the flap 34 from adhering to any object before the flap removable release pad 40 is removed, thus allowing the flap 34 to be folded over and adhered to the front panel 14.

[0052] exist Figure 8B In the embodiment specifically depicted, the front sheet 14 includes a front sheet adhesive layer 42 adjacent to the top edge 14b of the front sheet 14 on its outer surface (the outer surface of the front sheet 14 facing the outside of the bag 12) for sealing the padded parcel 10 for shipment. Thus, when the bag flap 34 is folded over the top edge 14b of the front sheet 14, the bag flap 34 can adhere to the outside of the front sheet 14, thereby closing the opening 24 and sealing the padded parcel 10. The front sheet adhesive layer 42 may be covered by a removable front sheet release pad 44 to prevent the outside of the front sheet 14 from adhering to any object before the removable front sheet release pad 44 is removed.

[0053] In addition to or instead of the flap adhesive layer 38 and the front panel adhesive layer 42, the bag 12 may include mechanical fasteners adjacent to the respective top edges 14b, 16b of the front panel 14 and the rear panel 16 (e.g., on the flap 34) for closing the opening of the bag. The bag 12 may also, or alternatively, include sealant adjacent to the respective top edges 14b, 16b of the front panel 14 and the rear panel 16 (e.g., on the flap 34) for closing the opening of the bag 12.

[0054] Turn now Figures 9A-9DA method of using the padded mailer 10 to package an item for shipment is depicted in successive steps. Specifically, as depicted in Figure 9A the method includes the steps of providing the above-described padded mailer 10 and inserting the cargo into the interior space 22 of the bag 12. As shown in Figure 9B the method further includes pulling the top edge 18b of the cushion 18, and in particular the at least one expandable panel 19, to cause the at least one expandable panel 19 to expand and increase the thickness of the cushion 18 in the thickness direction 21. The pulling step can be facilitated by the presence of the pull tab 46, as described above. As depicted in Figure 9C then, the method includes the step of securing the top edge 18b of the cushion 18 to the bag 12 after the pulling step. This securing step can be accomplished using the pull tab adhesive layer 48. Accordingly, the method can additionally include the step of removing the pull tab removable release pad 50 prior to securing the top edge 18b of the cushion 18 to the bag 12. Finally, as shown in Figure 9D the method can include the step of closing the opening 24 of the bag 12, for example, using the bag closure 34 described above.

[0055] In summary, the described padded mailer 10 includes a bag 12 formed from a front panel 14 and a back panel 16, each including a bottom edge 14a, 16a, a top edge 14b, 16b, and opposite side edges 14c, 16c. The panels 14, 16 are connected along each of their bottom edges 14a, 16a and their side edges 14c, 16c to define an interior space 22. The top edges 14b, 16b of the panels are unconnected to form an opening 24 into the interior space 22. The padded mailer 10 further includes a cushion 18 disposed in the interior space 22, the cushion including an expandable panel 19 having a bottom edge 18a, a top edge 18b, and opposite side edges 18c. The bottom edge 18a of the expandable panel 19 is secured proximate the bottom edges 14a, 16a of the front and back panels 14, 16, and the top edge 18b and side edges 18c of the expandable panel 19 are unsecured to the front and back panels 14, 16. Pulling the top edge 18b of the expandable panel 19 relative to the bag 12 causes the expandable panel 19 to expand and increase the thickness of the cushion 18.

[0056] While one embodiment is shown and described, those skilled in the art, upon reading and understanding this specification and the attached drawings, will conceive of equivalent alternatives and modifications. In particular, with respect to the different functions performed by the integers (components, assemblies, devices, compositions, etc.) described above, unless otherwise indicated, the terminology used to describe such integers, including references to "means," is intended to refer to any integer that performs the specified function (i.e., is functionally equivalent) of the described integer, even if structurally not equivalent to the disclosed structure performing the function in the illustrated example embodiment.

Claims

1. A padded parcel (10), comprising: A bag (12) formed of a front piece and a back piece (14, 16), wherein each piece includes a bottom edge (14a, 16a), a top edge (14b, 16b), and an opposite side edge (14c, 16c), wherein the pieces are joined along each of their respective bottom edges (14a, 16a) and along each of their respective opposite side edges (14c, 16c) to define an interior space (22), wherein the direction from the bottom edge (14a, 16a) to the top edge (14b, 16b) is a bottom-to-top direction (20), and wherein the top edges (14b, 16b) of the pieces are not joined to form an opening (24) into the interior space (22); and A padding (18) is disposed in the interior space (22), the padding (18) comprising at least one expandable piece (19), the expandable piece (19) comprising a bottom edge (18a), a top edge (18b) and an opposite side edge (18c), wherein the bottom edge (18a) of the expandable piece (19) is attached to at least one of the front piece and the rear piece (14, 16) adjacent to the respective bottom edges (14a, 16a) of the front piece and the rear piece (14, 16), and the top edge (18b) and the opposite side edge (18c) of the expandable piece (19) are not attached to the front piece and the rear piece (14, 16), such that the expandable piece (19) can freely expand relative to the bag (12) in the bottom-to-top direction (20); Wherein, pulling the top edge (18b) of the expandable sheet (19) relative to the bag (12) in the bottom-to-top direction (20) causes the expandable sheet (19) to expand and increase the thickness of the pad (18).

2. The padded parcel (10) according to claim 1, wherein, The expandable sheet (19) includes an expandable slot sheet material (26) having a plurality of rows (30) formed by a plurality of slots (28), wherein each of the plurality of rows (30) extends laterally in the bottom-to-top direction (20); wherein the plurality of slots (28) forming the rows (30) extend laterally in the bottom-to-top direction (20).

3. The padded parcel (10) according to claim 2, wherein, The expandable sheet (19) has a relatively flat unexpanded state and an expanded state. In the unexpanded state, the expandable sheet (19) is flatly located in a plane, and in the expanded state, the slit (18) is opened to form an opening (29), and multiple portions of the slit sheet material (26) between the slits (28) are rotated away from the plane.

4. The padded parcel (10) according to any one of claims 1 to 3 further includes a divider disposed in the internal space (22), the divider comprising a top edge, a bottom edge, and opposite side edges, wherein, At least one of the bottom edge and the opposite side edge of the separator is fixed to at least one of the front piece and the rear piece (14, 16) adjacent to the respective edges of the front piece and the rear piece (14, 16).

5. The padded parcel (10) according to any one of claims 1 to 3 further includes a pull tab (46) extending from the top edge (18b) of the at least one expandable piece (19) and extending from the opening (24) to make it easier for a user to pull the top edge (18b) of the expandable piece (19) relative to the bag (12) in the bottom-to-top direction (20) to expand it.

6. The padded parcel (10) according to claim 5, wherein, The pull tab (46) includes a pull tab adhesive layer (48) covered by a pull tab removable release pad (50).

7. The padded parcel (10) according to any one of claims 1 to 3, wherein, The front sheet and the rear sheet (14, 16) are made of paper.

8. The padded parcel (10) according to any one of claims 1 to 3, wherein, The expandable sheet (19) is made of paper.

9. The padded parcel (10) according to claim 4, wherein, The separator is made of paper.

10. The padded parcel (10) according to any one of claims 1 to 3, wherein, The back piece (16) of the bag (12) has a greater length than the front piece (14) in the bottom-to-top direction (20) such that when the bottom edges (14a, 16a) of the front piece and the back piece (14, 16) are aligned, the top edge (16b) of the back piece (16) extends beyond the top edge (14b) of the front piece (14) in the bottom-to-top direction (20) to form a bag flap (34).

11. The padded parcel (10) according to claim 10, wherein, The rear panel (16) includes a fold line (36) adjacent to the top edge (14b) of the front panel (14) to facilitate folding the flap (34) over the top edge (14b) of the front panel (14) to close the opening (24).

12. The padded parcel (10) according to claim 10, wherein, The bag flap (34) includes a bag flap adhesive layer (38) adjacent to the top edge (16b) of the back piece (16) on the inner surface of the back piece (16), the inner surface of the back piece (16) facing the interior space (22) of the bag (12).

13. The padded parcel (10) according to claim 12, wherein, The cap adhesive layer (38) is covered by the cap removable release pad (40).

14. The padded parcel (10) according to any one of claims 1 to 3, wherein, The front sheet (14) includes a front sheet adhesive layer (42) adjacent to the top edge (14b) of the front sheet (14) on the outer surface of the front sheet (14), the outer surface of the front sheet (14) facing the outside of the bag (12).

15. The padded parcel (10) according to claim 14, wherein, The front adhesive layer (42) is covered by the front removable release pad (44).

16. The padded parcel (10) according to or any one of claims 1 to 3, wherein, The bag (12) includes mechanical fasteners adjacent to the top edges (14b, 16b) of the front and rear pieces (14, 16) for closing the opening (24) of the bag (12).

17. The padded parcel (10) according to any one of claims 1 to 3, wherein, The bag (12) includes sealant adjacent to the top edges (14b, 16b) of the front and rear pieces (14, 16) for sealing the opening (24) of the bag (12).

18. The padded parcel (10) according to any one of claims 1 to 3, wherein, The bag (12) includes at least one gusset plate at which the front piece (14) is connected to the rear piece (16) along each of the bottom edges (14a, 16a) of the front piece and the rear piece (14, 16) and each of the opposite side edges (14c, 16c) of the front piece and the rear piece (14, 16).

19. A method of packaging articles for shipment using the padded parcel (10) according to any one of claims 1 to 18, the method comprising the steps of: Provide the padded parcel (10); Insert the item into the internal space (22) of the bag (12); Pull the top edge (18b) of the expandable sheet (19) so that the expandable sheet (19) expands and increases the thickness of the pad (18); After the pulling step, the top edge (18b) of the expandable piece (19) is secured to the bag (12); and Seal the opening (24) of the bag (12).

20. A method for manufacturing a padded parcel (10) according to any one of claims 1 to 18, the method comprising the following steps: The front and rear pieces (14, 16) are provided in a face-to-face orientation, each piece including its own bottom edge (14a, 16a), its own top edge (14b, 16b), and its opposite side edges (14c, 16c). The front and rear pieces (14, 16) are joined along their respective bottom edges (14a, 16a) and along each of their respective opposite side edges (14c, 16c) to define the interior space (22), wherein the top edges (14b, 16b) of the pieces remain unjoined to form an opening (24) into the interior space (22). The pad (18) is placed in the interior space (22), the pad (18) including the at least one expandable piece (19), the at least one expandable piece (19) including the bottom edge (18a), the top edge (18b) and the opposite side edge (18c) of the at least one expandable piece (19). The bottom edge (18a) of the expandable piece (19) is fixed to the bag (12) by the bottom edges (14a, 14b) adjacent to the front and rear pieces (14, 16), wherein the top edge (18b) and the opposite side edge (18c) of the expandable piece (19) are free to move relative to the front and rear pieces (14, 16) of the bag (12); Wherein, pulling the top edge (18b) of the expandable sheet (19) relative to the bag (12) in the bottom-to-top direction (20) causes the expandable sheet (19) to expand and increase the thickness of the pad (18).

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