Flexible Mailer Blank With Expandable Pockets for USPS Flats

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing envelopes require inserts to hold goods in place and do not conform to USPS regulations for flat-sized pieces, limiting their flexibility and expansion capabilities.

Innovation Solution

A one-piece paperboard blank is designed with score lines and flaps to create expandable pockets, allowing the envelope to expand while maintaining a flat appearance, and includes a closure flap for secure sealing without the need for additional inserts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional envelopes are constructed with internal gussets and glued by hand, then they can expand to increase capacity, but they require additional inserts to hold goods in place and do not conform to USPS flat-sized regulations

Engineering Contradiction:

ImproveexpandabilityVSAvoidinsert requirement

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention merges the functions of the envelope body and the goods-holding structure into a single integrated blank. The side flaps with extensions are designed to form pockets that both expand the envelope capacity and simultaneously hold goods in place, eliminating the need for separate inserts while maintaining USPS flat-sized compliance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The blank is segmented into functional zones: front panel, back panel, side flaps with extensions forming pockets, and closure flap. Each segment serves a specific purpose, with the side flaps and extensions creating expandable pocket structures that integrate goods holding into the envelope's basic construction.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If envelopes are designed to expand for increased capacity, then they can hold more goods, but they cannot be shipped flat and conform to USPS flat-sized piece regulations

Engineering Contradiction:

ImprovecapacityVSAvoidflat appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The envelope is designed with dynamic characteristics through score lines that allow the blank to transition between a flat shipped state and an expanded used state. The side flaps and extensions can be folded along predetermined lines to create pockets, enabling the envelope to adapt its shape from flat to three-dimensional as needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention utilizes dimensional transformation by designing the blank to fold from a two-dimensional flat configuration into a three-dimensional expanded structure with pockets. The side flaps and extensions create vertical and horizontal dimensions when folded, allowing capacity expansion while maintaining flat shipping capability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If envelopes use internal gusset construction, then they can expand, but the gussets restrict the insertion of papers and goods

Engineering Contradiction:

ImproveexpandabilityVSAvoidinsertion ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

Instead of using internal gussets that protrude into the envelope cavity and obstruct insertion, the invention inverts the approach by forming pockets through side flaps and extensions that fold outward and downward. This creates a clear insertion path from the top opening, allowing easy paper and goods insertion while maintaining expandability.

Inventive Principle:

Principle #13The other way round (Inversion)

4Productivity

If envelopes are made to conform to USPS flat-sized regulations, then they can be shipped without additional fees, but they cannot provide expandable pockets for goods

Engineering Contradiction:

Improveshipping efficiencyVSAvoidpocket formation

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The blank is pre-designed with score lines and fold lines that guide the formation of pockets during the stuffing process. The side flaps and extensions are positioned and dimensioned in advance to automatically form pockets when folded, enabling pocket creation as part of the normal envelope assembly process rather than requiring additional steps or components.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20260028157A1Flexible Mailer and Blank for Making Same

Publication Date: 2026.01.29 CONFORMER PRODS

AI summary

A one-piece blank is provided to fold into an envelope with self-contained pockets to receive goods for mailing. In one embodiment, each side flap of the blank is provided with an extension that is foldable into a pocket for disposition over the back panel of the blank. In a second embodiment, each side flap is provided with a pair of interconnected extensions that are foldable into pockets along with a part of the side flap for disposition over the back panel.The envelope formed by a blank is expandable to receive goods and when stuffed conforms to the United States Postal Service regulations for flat-sized pieces.