Flexible Insert Tray for Uniform Flat Mail Thickness
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Solution Overview
Problem
Existing envelope designs fail to meet United States Postal Service (USPS) criteria for flat-sized pieces, specifically in terms of flexibility, uniform thickness, and preventing item shifting during mailing, which are essential for qualifying as a flat-sized piece for postage.
Innovation Solution
A flexible insert tray made from self-supporting materials like corrugated board or paperboard, designed with foldable sections and recesses to accommodate items of various shapes and sizes, ensuring the package can flex and maintain uniform thickness while preventing shifting, thus meeting USPS requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid packing material is used to prevent item shifting, then item stability is improved, but package flexibility deteriorates
Solution Approach 1:
The patent uses a flexible insert made of corrugated fiberboard that can bend and flex while still providing structural support. The corrugated structure allows the material to be rigid enough to prevent item shifting yet flexible enough to allow the package to conform to postal service requirements for flat-sized pieces.
Solution Approach 2:
The insert is constructed from corrugated fiberboard, which is a composite material combining fluted corrugated sheet with flat linerboards. This composite structure provides both the rigidity needed for item stability and the flexibility required for package compliance with postal regulations.
2Stability of the object's composition
If padding material is added to maintain uniform thickness, then thickness uniformity is improved, but package complexity increases
Solution Approach 1:
The insert is constructed from a single blank of corrugated fiberboard that is folded and creased to create multiple segments and layers. This segmentation provides uniform thickness throughout the package while maintaining relative simplicity in the overall construction process.
Solution Approach 2:
The insert utilizes the third dimension by creating folded and creased structures that extend vertically from the flat blank. This dimensional transformation allows the insert to provide uniform thickness without requiring additional separate components or complex assembly procedures.
3Ease of manufacture
If a single blank material is used for the insert, then manufacturing simplicity is improved, but structural versatility deteriorates
Solution Approach 1:
The insert design incorporates multiple crease lines and foldable sections that allow a single blank of corrugated fiberboard to transform into various three-dimensional configurations. This dynamic structure enables the same basic blank to adapt to different item shapes and sizes while maintaining ease of manufacture through a standardized starting material.
Solution Approach 2:
The single blank of corrugated fiberboard serves multiple functions: it provides structural support, prevents item shifting, maintains uniform thickness, and allows package flexibility. The universal design can accommodate various item types and sizes, making it versatile despite using a single material type.
Data Source
AI summary
A blank is provided for making an insert that satisfies the USPS requirement that a flat-sized mail piece be uniformly thick so that any bumps, protrusions or other irregularities do not cause more than ¼″ variance in thickness.In one embodiment, when folded, the blank forms an insert with spacers about a quadrant that receives a good to be mailed.In other embodiments, when folded, the blank forms an insert with sleeves into which goods may be slid, or an insert with sleeves with closed ends and into which goods may be inserted into cutouts in the sleeves.