Packaging system and method for opening a mailer

Abstract

A packaging system (100) includes an expander (104) which holds a packaging envelope (102) open, enabling a packer to easily insert an item to be packaged before closing the packaging envelope for shipment. The packaging system includes an envelope having a front sheet (108) and a back sheet (110), each of the front sheet and the back sheet including a bottom edge (112 / 114), a top edge (116 / 118), and opposing side edges (124 / 126). The front sheet and the back sheet are connected together along the bottom edge and along respective side edges. Interior faces of the front sheet and the back sheet define an interior pouch having a top side. An expander situated within the interior pouch is configured to engage with the interior face of the front sheet and the interior face of the back sheet such that the interior faces of the front sheet and the back sheet are spaced apart.

Description

[0001] PACKAGING SYSTEM AND METHOD FOR OPENING A MAILER

[0002] Field of the Invention

[0003] [1] The present invention relates generally to the field of postal packaging, and more particularly to a system and method for packing a packaging envelope for shipping an article.

[0004] Background

[0005] [2] Packaging envelopes are commonly referred to as mailers, and often have padding that provides cushioning properties that help to protect the items therein during shipment. Padded mailers, such as padded envelopes, are often used to ship items, particularly fragile items. Padded mailers are typically made with plastic airbubble material lining the inside of the mailer, however, alternatives such as foam, recycled fiber fluff, and paper-based cushioning material may be used. Padded mailers are provided to packers in a ready-to-use state. The packer typically retrieves a mailer from a supply, opens the mailer and inserts a product to be shipped without any assistance. The envelope is then closed before shipment.

[0006] Summary

[0007] [3] The present disclosure describes packaging systems and methods that make it easier for a packer to open a packaging envelope and then insert an item to be packaged before closing the packaging envelope for shipment. The system and method of the present disclosure provides a convenient system and method for more easily holding a packaging envelope open, which makes it easier to insert an object into the packaging envelope for shipping.

[0008] [4] More specifically, the present disclosure provides a packaging system which has an expander that can be used to open an envelope and make it easier to insert items into the envelope for shipment. The expander holds the envelope open, so that the packer can more easily insert items past the opening and into the envelope. The expander holding the envelope open is particularly useful for items that are uniquely shaped or otherwise shaped in a manner that does not reflect the shape of the envelope. The expansion functionality can be highly beneficial in environments in which the items to be shipped have unique geometries which can cause the items to be difficult to insert into conventional packaging envelopes. The packaging system can lay flat while the packaging system is in storage and readily and easily manually expanded by rotating the expander within the envelope. Rotation of the expander within the envelope pushes the side walls of the envelope apart. This makes it easier to insert an item into the packaging envelope. The expansion of the envelope can improve the packaging experience by holding the envelope open and / or by reducing the interference of the item against the opening of the envelope while the item is being inserted.

[0009] [5] An exemplary packaging system for packaging an item for shipment includes: an envelope having a front sheet and a back sheet, each of the front sheet and the back sheet including a bottom edge, a top edge, and opposing side edges; and the front sheet and the back sheet being connected together along the bottom edge and along respective side edges. An interior face of the front sheet and an interior face of the back sheet define an interior pouch having a top side; and an expander situated within the interior pouch. The expander is configured to engage with the interior face of the front sheet and the interior face of the back sheet such that the interior face of the front sheet and the interior face of the back sheet are spaced apart.

[0010] [6] In one or more embodiments, the expander is configured to be positioned in the interior pouch parallel to the interior faces of the front sheet and the back sheet to provide a flat envelope for storage.

[0011] [7] In one or more embodiments, the expander is configured to be positioned in the interior pouch perpendicular to the interior faces of the front sheet and the back sheet to provide an expanded envelope for packaging. [8] In one or more embodiments, the expander has a length dimension and a width dimension, and the length dimension is greater than the width dimension.

[0012] [9] In one or more embodiments, the envelope has an envelope width; and the length dimension of the expander is greater than the envelope width.

[0013]

[0010] In one or more embodiments, the expander has an oval shape or a vesica piscus shape.

[0014]

[0011] In one or more embodiments, the length dimension of the expander engaging with the respective interior faces causes tension in the expander

[0015]

[0012] In one or more embodiments, the expander is configured to bend along the length dimension while under tension.

[0016]

[0013] In one or more embodiments, the expander has a thickness dimension that is at least two times less than the width dimension.

[0017]

[0014] In one or more embodiments, the expander is planar.

[0018]

[0015] In one or more embodiments, the envelope is free of gussets.

[0019]

[0016] According to another aspect of the present disclosure, an exemplary expander for use in a packaging system is configured to be positioned in an interior pouch of an envelope parallel to interior faces of a front sheet and a back sheet of an envelope to provide a flat envelope for storage; and the expander is configured to be positioned in the interior pouch perpendicular to the interior faces of the front sheet and the back sheet to provide an expanded envelope for packaging.

[0020]

[0017] In one or more embodiments, the expander is planar.

[0021]

[0018] In one or more embodiments, the expander has an oval shape or a vesica piscus shape.

[0022]

[0019] In one or more embodiments, the expander is configured to bend while being pressed against the interior faces of the front sheet and the back sheet.

[0023]

[0020] In one or more embodiments, the expander has a length dimension and a thickness dimension, the thickness dimension being at least two times less than the length dimension.

[0021] In one or more embodiments, the expander is configured to be foldable along a fold line prior to engaging with the interior faces of the front sheet and the back sheet.

[0024]

[0022] According to another aspect of the present disclosure, a method of packaging an item for shipment includes: providing an envelope having a front sheet and a back sheet, each of the front sheet and the back sheet includes a bottom edge, a top edge, and opposing side edges; the front sheet and the back sheet being connected together along the bottom edge and along respective side edges to form a pouch; and arranging an expander within the pouch toward a bottom edge such that the expander engages the edges of the interior surfaces and presses the interior surfaces apart.

[0025]

[0023] In one or more embodiments, the method further includes pressing respective pointed ends of the expander into the opposing side edges of the front sheet and the back sheet.

[0026]

[0024] In one or more embodiments, the method further includes bending the expander within the pouch.

[0027]

[0025] The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail one or more illustrative embodiments of the invention. These embodiments, however, are but a few of the various ways in which the principles of the invention can be employed. Other objects, advantages and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.

[0028] Brief Description of the Drawings

[0029]

[0026] FIG. 1 is a front view of an exemplary packaging system in a flattened state during insertion of an expander into an envelope.

[0030]

[0027] FIG. 2 is the exemplary packaging system in the expanded state.

[0028] FIG. 3 is a front view of the exemplary packaging system in the flattened state.

[0031]

[0029] FIG. 4 is a top view of the exemplary packaging system in the flattened state.

[0032]

[0030] FIG. 5 is a bottom view of the exemplary packaging system.

[0033]

[0031] FIG. 6 is a side view of the exemplary packaging system.

[0034]

[0032] FIG. 7 is a top plan view of an exemplary expander.

[0035]

[0033] FIG. 8 is a side view of the expander.

[0036]

[0034] FIG. 9 is a cross-sectional view of the expander.

[0037]

[0035] FIG. 10 is a front view of the packaging system in the expanded state.

[0038]

[0036] FIG. 11 is a side view of the packaging system in the expanded state while the envelope is sealed.

[0039]

[0037] FIG. 12 is a top perspective view of the packaging system in the expanded state.

[0040]

[0038] FIG. 13 is a bottom perspective view of the packaging system in the expanded state.

[0041]

[0039] FIG. 14 is a front view of the bottom portion of the packaging system in the expanded state.

[0042]

[0040] FIG. 15 is a top plan view of an expander according to another embodiment.

[0043]

[0041] FIG. 16 is the expander of FIG. 15 in a folded state.

[0044] Detailed Description

[0045]

[0042] Turning now to the drawings, a packaging system includes an expander which holds a packaging envelope open, enabling a packer to easily insert an item to be packaged before closing the packaging envelope for shipment. The packaging system includes an envelope having a front sheet and a back sheet, each of the front sheet and the back sheet including a bottom edge, a top edge, and opposing side edges. The front sheet and the back sheet are connected together along the bottom edge and along respective side edges. Interior faces of the front sheet and the back sheet define an interior pouch having an open top side. An expander situated within the interior pouch is configured to engage with the interior face (or “interior surface”) of the front sheet and the interior face (or “interior surface”) of the back sheet such that the interior faces of the front sheet and the back sheet are spaced apart.

[0046]

[0043] The expander can hold the envelope open, so that the packer can more easily insert items through and past the opening and into the envelope. The expander is flat and relatively thin, so that when the expander is in the pouch and parallel to the interior faces there is no appreciable change in the thickness of the mailer. The expander has a greater maximum width dimension, however, such that rotation of the expander within the envelope, to an orientation with the width dimension perpendicular to the interior faces, pushes the side walls of the envelope apart, and holding the envelope open. The expander holding the envelope open is particularly useful for items that are uniquely shaped or otherwise shaped in a manner that does not reflect the shape of the envelope. Thus, the envelope can lay flat while the packaging system is in storage and is readily and easily manually expanded by rotating the expander within the envelope to push the side walls apart and hold the envelope open for packing.

[0047]

[0044] An exemplary packaging system 100 is shown in FIG. 1 and includes an envelope (or mailer) 102 and an expander 104. The envelope 102 includes a pouch 106 (See FIG. 2) formed by at least a front sheet 108 and a back sheet 1 10. To facilitate description, references to the front sheet 108 or the back sheet 110 are used to mean a single sheet, a multi-sheet, or a multi-layer construction with one or more layers of cushioning materials. Each of the front sheet 108 and the back sheet 110 includes a bottom edge 112 and 1 14, respectively, a top edge 1 16 and 1 18, respectively, and opposing side edges 124 and 126, respectively. A direction from the bottom edges 112, 114 to the top edges 116, 118, is referred to herein as a bottom-to-top direction 120 relative to the pouch 106 and a direction from a face of the front sheet 108 to a face of the back sheet 110 is referred to herein as a thickness direction 122 (See FIGS. 4-6). The envelope 102 has a pouch width 133 and a pouch length 135 (See FIG. 3), each of which is perpendicular to the thickness direction 122 and each other. The pouch width 133 extends between the side edges 124, 126 in a direction perpendicular to the bottom-to-top direction 120. The pouch length 135 extends between the top edge of the front sheet 108 (or the back sheet 110, whichever is shorter in the bottom-to-top direction 120) and the bottom edges 112, 114 in the bottom-to-top direction 120.

[0048]

[0045] The front sheet bottom edge 1 12 is affixed to the back sheet bottom edge 114 and the opposing front sheet side edges 146 are affixed to the opposing back sheet side edges 166, respectively. The edges 1 12, 1 14, 1 16 ,118, when affixed in this manner, form an interior space 128 of the assembled pouch 106 (See FIG. 2). The bottom edges 1 12, 1 14 and opposing side edges 124, 126 may be affixed to each other with, for example, an adhesive, a mechanical fastener, or a fold line. The front sheet top edge 116 and the back sheet top edge 118 remain unconnected from each other to form an opening 130 into the interior space 128 of the pouch 106 for inserting an article to be packaged therein.

[0049]

[0046] As shown in FIG. 2, the back sheet 1 10 of the pouch 106 may have a greater length in the bottom-to-top direction 120 than does the front sheet 108. As a result, when the bottom edges 1 12, 1 14 of the front sheet 108 and back sheet 1 10 are aligned with each other and affixed, the back sheet top edge 118 extends beyond the front sheet top edge 1 16 in the bottom-to-top direction 120. The extension of the back sheet top edge 1 18 beyond the front sheet top edge 116 in the bottom-to-top direction 120 forms a pouch flap (or “flap”) 132. The pouch flap 132 may be folded over the top edge 116 of the front sheet 108 to close the opening 130 of the pouch

[0050] 106. The pouch flap 132 may be secured to the front sheet 108 to seal the mailer 102 for shipment. The back sheet 110 may include a fold line adjacent the top edge 124 of the front sheet 108, on the pouch flap 132, to facilitate folding the pouch flap 132 over the top edge 124 of the front sheet 108. Folding the pouch flap 132 over the top edge 124 and securing the pouch flap 132 to the front sheet 108 closes the opening 130, and secures the item to be shipped within the pouch 106.

[0051]

[0047] The front sheet 108 may include an adhesive layer adjacent the top edge 116 of the front sheet 108 on an outer surface of the front sheet 108 (the outer surface of the front sheet 108 facing an exterior of the pouch 106) for sealing the mailer 102 for shipment. Thus, when the pouch flap 132 is folded over the top edge

[0052] 116 of the front sheet 108, the exterior of the front sheet 108 can adhere to the pouch flap 132, thereby closing the opening 130 and sealing the padded mailer 102. Alternatively or additionally, the pouch flap 132 may include an adhesive layer on an inner surface of the back sheet top edge 1 18. The adhesive layer or layers may be covered by one or more removable release liners to prevent adherence of the pouch flap 132 or front sheet 108 to anything prior to removal of the release liner. Upon removal of the release liner, exposing the adhesive layer, the pouch flap 132 may be folded over and adhered to the front sheet 108.

[0053]

[0048] The front sheet 108 and the back sheet 1 10 are made of mailer material, which preferably is recyclable, and more preferably the entire mailer is made of recyclable material, preferably curbside-recyclable such that no disassembly and separation of materials is necessary for recycling. Paper is an exemplary mailer material. The mailer material may be any type and grade of paper, such as kraft paper, depending on the particular application or environment in which the mailer 102 is to be used. The mailer material may have any of various basis weights and may be made of zero to 100% recycled material. In some embodiments, the mailer material may be laminated or may include any other suitable material such as another paper, plastic sheets, metal foil, or any other combination thereof. Wax or other coatings and chemical treatments may be added to the mailer material to add or improve desired properties such as moisture resistance or thermal resistance for cold chain applications. The mailer or envelope 102 used in the systems and methods discussed herein is not limited to a mailer having a particular material, the described mailer 102 is just one example of a mailer that could be used in the following systems and methods.

[0054]

[0049] Referring briefly to FIGS. 7-9, an exemplary expander 104 is shown. The expander 104 can include flat expander faces (or “flat faces”) 134, expander edges 140, and pointed ends 142. The expander 104 has an end-to-end length dimension 143 extending between the pointed ends 142. The expander 104 can be flat or planar in shape, but made of a material strong and flexible enough to expand the pouch 106 (FIG. 2) while slightly bending end-to-end along the length dimension 143 under tension. In being planar, the expander 104 can have a thickness of its edges 140 which is an order of magnitude (such as two times) less than the length and width of its faces 134. This thickness of the edges 140 can also generally be consistent across the length and width of the faces 134. Alternatively or additionally, the thickness of the edges 140 can vary along the length or the width of the faces 134.

[0055]

[0050] The expander 104 may have an end-to-end length dimension 143 that is longer than the pouch width 133. A benefit of the end-to-end length dimension 143 being longer than the pouch width 133 is that the tension in the expander 104 will create a snug fit within the pouch 106 (FIG. 2). The snug fit along the end-to-end length dimension 143 will prevent the expander 104 from moving within the pouch 106 so that the envelope 102 does not need to be held open, manually, or otherwise.

[0056]

[0051] The flat faces 134 can have an oval shape, a vesica piscus (pointed oval) shape, or any other suitable shape to allow for at least a portion of the edges of the expander 104 to press into the interior surfaces 136, 138 of the pouches 106 (FIG. 2). The vesica piscus shape, having faces narrower on the ends than in the middle, allows the expander 104 to press the center of the interior surfaces 136, 138 outwardly without overstretching, tearing, or otherwise damaging the portion of the front and back sheets 108, 1 10 near the side edges 124, 126. The pointed ends 142 of the vesica piscus shape also can fit between the interior surfaces 136, 138 near the side edges 124, 126 without stressing the side edges 124, 126 enough to cause the side edges 124, 126 to separate from each other. Further, the vesica piscus shape maximizes the contact area of the expander edges 140 with the interior surfaces 136, 138, providing a more stable opening of the pouch 106 than would be achieved with a lower contact area between the edges 140 and the interior surfaces 136, 138.

[0057]

[0052] Alternatively or additionally, the expander 104 may be shaped in a manner that is configured to accommodate a specific item in a package. For example, the flat faces 134 of the expander 104 may be symmetrical or asymmetrical depending on the physical features of the item to be shipped within the packaging system 100. For example, the expander 104 can be thinner mid-length than near the pointed ends 142. Alternatively or additionally, the expander 104 can be thicker near the pointed ends 142 than it is in the middle. The expander 104 can be made of cardboard, plastic, composite, cardstock, or any other suitable material having sufficient stiffness to hold the pouch open. The expander 104 can be made of a single layer or multiple layers of materials and can also be a made of a single piece of material or multiple pieces of material.

[0058]

[0053] Turning back to FIG. 1 , an expander 104 is shown being inserted into the pouch 106 of the envelope 102 through the envelope opening 130. The pouch 106 has a pouch width 133 extending between the side edges 124, 126 of the envelope 102. The expander 104 can have a length dimension 143 (see FIG. 8) extending from end to end that may be slightly longer than the pouch width 133. Therefore, the expander 104 may need to be rotated to be able to slide through the opening 130 or otherwise be placed into the pouch 106 of the envelope 102. Insertion of the expander 104 into the envelope 102 can generally be accomplished by placing the expander faces 134 (FIG. 7) parallel to the interior surfaces 136, 138 of the envelope 102. The expander 104 may also be inserted while the expander faces 134 are not parallel to the interior surfaces 136, 138 of the envelope 102. For example, the expander 104 may be inserted into the pouch 106 while the faces 134 of the expander 104 are at a slight acute angle in relation to the interior surfaces 136, 138 of the envelope 102. Alternatively or additionally, the expander 104 may be integrated into the envelope 102, itself.

[0059]

[0054] Referring next to FIG. 2, the packaging system 100 is shown in an expanded state. In the expanded state, the expander 104 is rotated such that the expander faces 134 are perpendicular to the interior surfaces 136, 138 of the front and back sheets 108, 1 10 of the envelope 102. This positioning allows the edges 140 of the expander 104 to press into the sheets 108, 110 of the envelope 102, pushing the front and back sheets 108, 1 10 away from each other and opening the pouch 106 for easier insertion of an item to be shipped into the envelope 102. The expander 104 holds the pouch 106 and the opening 130 in an open state, which advantageously allows an item to be placed within the packaging system 100 with only one hand, one automated arm, or one of any suitable placement mechanism. This eliminates the need for another hand or device to assist in holding open the pouch 106 and opening 130 while the item is being packaged.

[0060]

[0055] Turning next to FIGS 3-6, the packaging system 100 in a flattened state is shown. As shown, in the flattened state, the pouch 106 and / or opening 130 (FIG. 2) of the envelope 102 may remain substantially closed so that the packaging system

[0061] 100 remains flat for storage. This allows for a large volume of packaging systems 100 to be partially assembled and stored, for example, prior to packaging a large volume of items for shipping. Assembly of the packaging system 100 including insertion of the expander 104 can take place either immediately before expanding the packaging system 100 or at any other time prior to expanding the packaging system 100.

[0062]

[0056] FIGS. 10 and 1 1 further show positioning of the expander 104 in an expanded state. FIG. 10 shows the pointed ends 142 (FIGS. 12-13) of the expander 104 engaging with the side edges 124, 126 of the front and back sheets 108, 110 so that the length of the expander 104 downwardly curves in a direction opposite to the bottom-to-top direction 120. When the pointed ends 142 of the expander 104 push into the side edges 124, 126, the expander 104 bends along its length. This bending of the expander 104 causes the bottom portions 144, 146 to be pulled upwardly into a bottom face 134 of the expander 104. The bottom portions 144, 146 being upwardly pulled can create on the front and back sheets 108, 1 10 a downward curve (concave) shape corresponding to the curve along the length of the expander 104.

[0063]

[0057] As shown in FIG. 11 , the packaging system 100 can be sealed in the expanded state using any suitable method. One method of sealing the packaging system 100, for example, may be by folding the flap 132 over a portion of the outside of the front sheet 108 and adhering the flap 132 to the front sheet 108 with an adhesive. The packaging system 100 can also be sealed using any other suitable method that may or may not include a flap 132, such as wrapping the packaging system 100 with another wrapping material, stapling or otherwise fastening the sheets 108, 1 10 together, folding the top edges of the envelope 102 together, or any other suitable method. The expander 104 can remain in the same location while the packaging system 100 is sealed and, therefore, an item can be placed comfortably within the expanded pouch 106.

[0064]

[0058] Turning next to FIGS 12-14, the packaging system 100 in the expanded state is shown. FIG. 12 shows the expander 104 positioned so that the width direction of the expander is perpendicular to the interior surfaces 134 of the envelope 102, and therefore the expander edges 140 are pressing against the interior surfaces 136, 138 of the front and back sheets 108, 110. The pressing of the expander edges 140 into the interior surfaces 136, 138 of the envelope 102 expands the pouch 106 and the opening 130 for easier insertion of an item into the envelope 102.

[0065]

[0059] FIG. 13 shows a bottom perspective view of the packaging system 100 in the expanded state. In the expanded state, portions of the front and back sheets 108, 110 near the bottom edges 1 12, 1 14 are located beneath the expander 104 in the bottom-to-top direction 120 (FIG. 1 ). The bottom edges 112, 1 14 of the front and back sheets 108, 1 10, run along the length of the expander 104.

[0066]

[0060] FIG. 14 shows a front view of the bottom portion of the packaging system 100 in the expanded state. As shown, in the expanded state, the pressing of the expander 104 into the interior surfaces 136, 138 of the front and back sheets 108, 110, can result in the bottom portions of the faces being pulled upwardly in the bottom-to-top direction 120 (FIG. 1 ) into the face 134 on the bottom of the expander 104. Further, the expander 104 can have a length longer than the pouch width 133. The combination of the pressing of the bottom portion of the front and back sheets 108, 110 into the expander face 134 and the pressing of the pointed ends 142 of the expander 104 into the side edges 124, 126 of the sheets 108, 1 10 results in the bowing or concave effect shown in FIG. 10.

[0067]

[0061] Turning next to FIGS. 15 and 16, another embodiment of an expander 204 is shown. This expander 204 is similar to the previously-described expander 104 shown in FIG. 7, except that this expander 204 is foldable, such as along a fold line 250. The foldability of the expander 204 allows the expander to be inserted, stored, or integrated into the envelope 102 (FIG. 1 ) in a folded state and then unfolded while the expander 204 is being positioned to push the front and back sheets 108, 1 10 of the envelope 102 apart. The fold line 250 can be along the center of the expander face 234 or at any other suitable location that still allows the expander 204 to adequately expand the pouch 106 (FIG. 2). The fold line can be along a length dimension or along a width dimension of the expander 204. There can be more than one fold line 250 at multiple locations on the expander 204 depending on the requirements of the application. The fold line 250 can be attached to, integrated with, or otherwise arranged along the bottom of the pouch 106 so that the expander 204 can be easily unfolded for expansion of the envelope 102.

[0068]

[0062] In summary, an exemplary packaging system 100 includes an expander 104 which holds a packaging envelope 102 open, enabling a packer to easily insert an item to be packaged before closing the packaging envelope 102 for shipment. The packaging system 100 includes an envelope 102 having a front sheet 108 and a back sheet 1 10, each of the front sheet 108 and the back sheet 1 10 including a bottom edge 1 14, a top edge 1 18, and opposing side edges 126. The front sheet 108 and the back sheet 110 are connected together along the bottom edges 112, 114 and along respective side edges 124, 126. An interior face of the front sheet 136 and an interior face of the back sheet 138 define an interior pouch 106 having an opening (or “top side) top side 130. An expander 104 situated within the interior pouch 106 is configured to engage with the interior surface 136 of the front sheet 108 and the interior surface 138 of the back sheet 110 such that the interior surface of the front sheet 136 and the interior surface of the back sheet 138 are spaced apart.

[0069]

[0063] Although the invention has been shown and described with respect to certain embodiments, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment of the invention.

Claims

ClaimsWe claim:1 . A packaging system for packaging an item for shipment comprising: an envelope having a front sheet and a back sheet, each of the front sheet and the back sheet including a bottom edge, a top edge, and opposing side edges; and the front sheet and the back sheet being connected together along the bottom edge and along respective side edges, an interior face of the front sheet and an interior face of the back sheet defining an interior pouch having a top side; and an expander situated within the interior pouch; wherein the expander is configured to engage with the interior face of the front sheet and the interior face of the back sheet such that the interior face of the front sheet and the interior face of the back sheet are spaced apart.

2. The packaging system according to claim 1 , wherein the expander is configured to be positioned within the interior pouch parallel to the interior face of the front sheet and the interior face of the back sheet to provide a flat envelope for storage.

3. The packaging system according to claim 1 or any of claims 1 or 2 wherein the expander is configured to be positioned in the interior pouch perpendicular to the interior face of the front sheet and the interior face of the back sheet to provide an expanded envelope for packaging.

4. The packaging system according to claim 1 or any of claims 1-3, wherein: the expander has a length dimension and a width dimension, and wherein the length dimension is greater than the width dimension.

5. The packaging system according claim 4, wherein: the envelope has an envelope width; and wherein the length dimension of the expander is greater than the envelope width.

6. The packaging system according to claim 1 or any of claims 1-5, wherein the expander has an oval shape or a vesica piscus shape.

7. The packaging system according to claim 4, wherein the length dimension of the expander engaging with the respective interior faces causes tension in the expander.

8. The packaging system according to claim 7, wherein the expander is configured to bend along the length dimension while under tension.

9. The packaging system according to claim 1 or any of claims 1-8, wherein the expander has a thickness dimension that is at least two times less than the width dimension.

10. The packaging system according to claim 1 or any of claims 1-9, wherein the expander is planar.11 . The packaging system according to claim 1 or any of claims 1-10, wherein the envelope is free of gussets.

12. An expander for use in the system of claim 1 , wherein: the expander is configured to be positioned in an interior pouch of an envelope parallel to an interior face of a front sheet and an interior face of a back sheet of an envelope to provide a flat envelope for storage; andwherein the expander is configured to be positioned in the interior pouch perpendicular to the interior face of the front sheet and the interior face of the back sheet to provide an expanded envelope for packaging.

13. The expander according to claim 12, wherein the expander is planar.

14. The expander according to claim 12 or any of claims 12 or 13, wherein the expander has an oval shape or a vesica piscus shape.

15. The expander according to claim 12 or any of claims 12-14, wherein the expander is configured to bend while being pressed against the interior face of the front sheet and the interior face of the back sheet.

16. The expander according to claim 12 or any of claims 12-15, wherein the expander has a length dimension and a thickness dimension, the thickness dimension being at least two times less than the length dimension.

17. The expander according to claim 12 or any of claims 12-16, wherein the expander is configured to be foldable along a fold line prior to engaging with the interior face of the front sheet and the interior face of the back sheet.

18. A method of packaging an item for shipment comprising: providing an envelope having a front sheet and a back sheet, each of the front sheet and the back sheet including a bottom edge, a top edge, and opposing side edges; the front sheet and the back sheet being connected together along the bottom edge and along respective side edges to form a pouch; and arranging an expander within the pouch toward a bottom edge such that the expander engages the edges of the interior surfaces and presses the interior surfaces apart.

19. The method according to claim 18, further comprising: pressing respective pointed ends of the expander into the opposing side edges of the front sheet and the back sheet.

20. The method according to claim 18 or any of claims 18 or 19, further comprising: bending the expander within the pouch.

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