Flat-sized flexible envelope with insert

Abstract

The flat oversize mail piece includes an envelope of expandable nature, a flexible insert within the pocket of the envelope and an item that may be rigid or non-rigid. In one embodiment, the insert is provided with a cutout that is asymmetrical to one side of the insert and envelope to matingly receive the item being shipped. In another embodiment, the insert is a thin plastic tray having a recess to receive the item being shipped and a plurality of cavities interconnected by thin webs that impart flexibility to the package.

Description

This application is a Continuation-In-Part of pending application No. 11/804,845, filed May 21, 2007.

This invention relates to a flat-sized flexible envelope with an insert. More particularly, this invention relates to a flat-sized flexible envelope having an insert for receiving an item to be mailed that conforms to USPS requirements for flexibility and uniform thickness of flat-size pieces.

As is known, various types of envelopes have been constructed for use in mailing items, such as digital video disks (DVDs) and compact disks (CDs). In some cases, the envelopes have been provided with padding, such as described in U.S. Pat. No. 5,662,420, wherein a macerated paper layer is sandwiched between two layers of paper.

In still other cases, as described in U.S. Pat. Nos. 5,544,473 and 7,108,650, it has been known to provide envelopes in which a packing material is inserted to receive an item for shipping.

Still other constructions have been known for use in shipping medical tests specimens wherein a receptacle is provided to receive a test specimen and the receptacle placed in an envelope, such as described in U.S. Pat. No. 5,620,097.

Recently promulgated United States Postal Service (USPS) regulations (see 39 CFR Part 111) provide standards for domestic mailing services that set forth minimum flexibility and uniform thickness criteria for flat-sized pieces.

Accordingly, it is an object of the invention to provide a package that satisfies the criteria for flat-sized pieces of the USPS.

It is another object of the invention to provide an envelope construction with a flexible insert for shipping items of rigid or non-rigid nature.

It is another object of the invention to provide a packaged DVD that qualifies for flat-sized piece postage in the United States.

It is another object of the invention to be able to mail an item, such as a DVD or a CD, in a manner that qualifies as a flat-sized piece postage in the United States.

Briefly, the invention provides a package that conforms to the requirements of a flat-sized piece for USPS requirements. The package is made to hold the item to be mailed and a flexible insert that occupies the inside of the package in a manner that allows the package to flex. The item to be received within the envelope may be of rigid nature or non-rigid nature.

In one embodiment, the insert has a cut-out of predetermined shape for receiving an item to be shipped in the package so that the item is prevented from shifting within the package. In another embodiment, the insert is in the form of a tray that has a recess for receiving the item in a manner to prevent the item from shifting within the package.

In each embodiment, the flexible insert and the item being packaged can be inserted into a pocket of a paper envelope of standard or an expandable construction, as described in U.S. Pat. No. 6,227,444, and a flap of the envelope can be folded over to close the pocket. In each embodiment, the flexible insert is of a height and width to substantially fill the pocket. Alternatively, the flexible insert and the item may be inserted in a sleeve, plastic bag, shrink-wrapped in plastic, or wrapped with a web of paper or plastic or the like to form the package for mailing purposes. Further, the envelope may be pre-lined with padding to protect fragile items.

The insert may be fixed within an envelope by a glue or adhesive or the insert may be slidably mounted within the envelope in an unsecured condition.

In the first embodiment, the insert is made of any suitable material, such a self-supporting plastic foam, corrugated paper board or the like. Typically, the cut-out in the insert is made asymmetrical and to one side of the insert. For example, the insert is made of L-shape. Where the envelope has a dimension of at least 10 inches on one side, the cut-out in the insert may be located symmetrically within the insert and still meet the criteria of the USPS for flat-sized pieces with a rigid insert.

When the insert is in place, the package may be flexed or bent in the area occupied by the flexible insert and particularly in a manner that allows the package to conform to the above noted regulations of the USPS.

In the second embodiment, the tray is made of a body of thin thickness of plastic that is shaped, as by molding, with a cut-out in the form of a recess that is sized to receive the item to be mailed. For example, the item may be a DVD holder, a CD holder, a pen, a cassette holder and the like. In any event, the recess is typically disposed asymmetrically within the tray and the tray is provided with a pattern of wells or cavities to impart a flexibility to the tray as well as rigidity.

The cavities are disposed in the tray in spaced apart relation and are connected to each adjacent cavity by a thin web of the tray body as well as to the recess that holds the item to be mailed. The thinness of the interconnecting web allows a cavity to pivot toward an adjacent cavity or the recess, if adjacent the recess, under a flexing or bending force imposed on the package. Where the cavities are disposed in parallel rows, the insert can be flexed or bent along a line that passes within a web in parallel between each two adjacent rows.

When the tray is in place, the package may be flexed or bent in the area occupied by the cavities and particularly in a manner that allows the package to conform to the above noted regulations of the USPS.

These and other objects and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:

FIG. 1 illustrates a perspective view of an envelope construction in accordance with the invention;

FIG. 2 illustrates a view taken on line 2-2 of FIG. 1;

FIG. 3 illustrates a view of a blank for making the envelope of FIG. 1 with an insert secured in place in accordance with the invention;

FIG. 4 illustrates an exploded view of a package for mailing a DVD or like cassette;

FIG. 5 illustrates a top view of a tray employed in the package of FIG. 4;

FIG. 6 illustrates a left side view of the tray of FIG. 5;

FIG. 7 illustrates a front side view of the tray of FIG. 5;

FIG. 8 illustrates an exploded view of a package employing a modified tray and an expandable envelope in accordance with the invention;

FIG. 9 illustrates a top view of the tray of FIG. 8;

FIG. 10 illustrates a left-side view of the tray of FIG. 9;

FIG. 11 illustrates a front view of the tray of FIG. 9;

FIG. 12 illustrates a perspective view of a modified tray in accordance with the invention;

FIG. 13 illustrates a top view of a modified tray similar to the tray of FIG. 12;

FIG. 14 illustrates a side view of the tray of FIG. 13;

FIG. 15 illustrates a front view of the tray of FIG. 13 and

FIG. 16 illustrates a cross-sectional view taken on line 16-16 of FIG. 13.

Referring to FIGS. 1 and 3, the envelope 10 is an expandable envelope constructed in a manner as described in U.S. Pat. No. 6,227,444 from a flat blank 11.

Referring to FIG. 3, the blank 11 includes a front panel 12 of rectangular shape and a back panel 13 that is secured to the front panel 12 along a horizontal fold line 14. In addition, the front panel 12 is provided with a rectangular array of score lines 15; each spaced inwardly from the respective edge of the panel 12 to define a rectangle within the panel 12 and diagonally disposed score lines 16 that connect the corners of the rectangle of score lines 15 with the corners of the panel 12.

The back panel 13 has a score line 17 spaced parallel to the fold line 14 to separate a trapezoidal section 18 located between the fold line 14 and score line 17 from a rectangular section 19.

The blank 11 also includes a pair of side flaps 20 each of which is separated from the front panel 12 by a fold line 21 and each of which includes a score line 22 at an intermediate point parallel to the front panel 12.

Each side flap 20 has a rounded end 23 at each end as well as a score line 24 that extends from the score line 22 on a side flap 20 to the corner of the front panel 12.

Each flap 20 is to be folded over the fold line 21 into folded over relation to the front panel 12. The back panel 13 is sized to be secured, as by an adhesive, to the folded over side flaps 20 to extend to and between the score lines 21 of the flaps 20.

The blank 11 also has a closure flap 25 that is secured to the front panel 12 along a horizontal fold line (as viewed) 26 and that includes a score line 27 spaced from the fold line 26 to separate a trapezoidal section 28 from a rectangular section 29.

Referring to FIGS. 1 and 3, the closure flap 25 includes a strip of adhesive or glue 30, such as a gummed or latex adhesive, for closing onto the back panel 13 as well as a removable strip 31 that covers over the adhesive 30 until the adhesive 30 is ready for use.

Referring to FIG. 3, each side flap 20 is provided with a line of adhesive (not shown) on the underside (as viewed) of the section between the score line 22 and the free edge of the flap 20 for securement to the underside of the back panel 13.

In order to form the envelope 10 of FIG. 1, the blank 11 of FIG. 3 is manipulated manually and/or mechanically in an automated manner in the following manner.

First, the side flaps 20 are folded along the fold lines 21 over the front panel 12. Next, the back panel 13 is folded about the fold line 14 onto the exposed adhesive on the side flaps 20. In this respect, the back panel 13 is of a width to extend to and between the score lines 22 of the side flaps 20, as indicated in FIG. 1. At this time, the trapezoidal section 18 of the back panel 13 covers over the lower ends 23 of the side flaps 20 in an overlapping manner and completely seals the two lower corners of the envelope 10. Also, the two upper corners of the back panel 13 lie over the rounded ends 23 of the side flaps 20 to leave the uppermost rounded ends 23 of the side flaps 20 exposed.

Once the back panel 13 is secured in place as shown in FIG. 1, a pocket is formed within the envelope 10.

Referring to FIG. 3, a flexible insert 32 is secured to the front panel 12, for example by a suitable adhesive. As illustrated, the insert 32 is of L-shape and defines a cut-out located asymmetrically to one side of the insert 32 for receiving an item 33 (see FIG. 1) to be shipped in the completed envelope 10.

The insert 32 is made of any suitable material, such as a self supporting plastic foam, cardboard or the like. Preferably, a lightweight plastic foam is used.

As indicated in FIG. 3, the insert 32 extends width-wise to and between the vertical score lines 15 of the front panel 12 and extends height-wise to and between the horizontal score lines 15 of the front panel 12 in order to substantially fill the pocket of the envelope 10.

Referring to FIG. 2, the insert 32 has a thickness of from 1/16 inches to 1¼ inches and preferably a thickness of ½ inch. The thickness of the insert 32 may be up to ¾ of an inch.

Alternatively, the insert 32 need not be secured to either the front panel 13 or the back panel 13. In this case, the insert 32 may be slid into the pocket of the envelope 10 after the envelope has been fabricated. For example, the insert 32 may be inserted into the envelope by a user when the item 33 is being inserted.

Further, the insert 32 may be dropped onto a die cut flat sheet and then the sheet closed around the insert 32 and rigid inserted item 33 creating an envelope.

When the insert 32 is in place, the pocket of the envelope 10 is expanded into the condition as indicated in FIG. 2. As viewed, the insert 32 extends to and between the vertical score lines 15 of the front panel 12 and to and between the score lines 22 of the side flaps 20. Also, the edges of the front panel 12 beyond the vertical score lines 15 bend downwardly, as viewed, and the sections of each side flap 20 between the respective fold line 21 and score line 22 bend upwardly, as viewed, to define V-shaped side edges to the envelope 10. A similar V-shaped bottom edge to the envelope 10 is also formed. As a result, the insert 32 being of a thickness equal to the largest width of the V-shaped side and bottom edges of the envelope 10 is restrained from shifting sideways or vertically, and particularly, no more than 1 inch in an envelope 10 of a 9 inch×12 inch size with score lines 15 on the front panel 12 being spaced ¼ inch from the edges of the front panel 12 and the insert 32 being ½ inch in thickness.

Insertion of the insert 32 may be accomplished manually or automatically through suitable mechanical equipment.

Referring to FIG. 1, the item 33 may be rigid, such as a DVD holder or a CD holder, or the item may be non-rigid, i.e. flexible. In either case, the item 33 is matingly disposed within the cut-out of the insert 32. In this respect, the item 33 has a shape corresponding to the shape of the cut-out and a thickness corresponding to the thickness of the insert 32.

The item 33 may be inserted into the cut-out of the insert 32 within the pocket of the envelope 10 manually or automatically. Further, the item 33 and insert 32 may be inserted in the same operation by any suitable means. After the item 33 has been inserted into the cut-out of the insert 32, the removable cover strip 31 is removed and the closure flap 25 folded via the fold line 26 over the back panel 13 in order to close the pocket and seal the item 33 therein.

Upon closing over of the closure flap 25, the trapezoidal section 28 of the closure flap 25 over lies the rounded ends 23 of the side flaps 20 to seal the two upper corners of the envelope 10. At the same time, the remainder of the closure flap 25 is of a width equal to the width of the back panel 13 to form a neat closure herewith.

The envelope 10 may be of any suitable size. For example, for shipping a DVD holder, the envelope, when closed, has a width of 12-½″ and a height of 10″. In addition, the insert 32 is of ½″ thickness and the DVD holder 33 has a corresponding ½″ thickness, a width of 7.5″ and a height of 5.25″.

The envelope 10 with the insert 32 therein conforms to the recently promulgated United States Postal Service (USPS) requirements for minimum flexibility criteria for flat-size pieces. As of Jul. 15, 2007, USPS regulation 301 (Physical Standards) found at http://pe.usps.gov/text/dmm300/301.htm provides:

1.0 Physical Standards for Flats

1.1 General Definition of Flat Size Mail

Flat-size mail other than that in 3.0, Physical Standards for Automation Flats, is:

• • a. More than 11-½ inches long, or more than 6-⅛ inches high, or more than ¼ inch thick.
  • b. Not more than 15 inches long, or more than 12 inches high, or more than ¾ inch thick, except for Periodicals mail under 707.26.0.
  • c. Rectangular with four square corners or with finished corners that do not exceed a radius of 0.125 inch (⅛ inch).

1.3 Minimum Flexibility for Flat-Size Pieces provides a test as follows:

• • 1. Place the piece with the length parallel to the edge of the flat surface and extend piece half way off the surface;
  • 2. Press down on the piece at a point 1 inch from the outer edge, in the center of the piece's length, exerting steady pressure;
  • 3. The piece is not flexible if it cannot bend at least 1 inch vertically without being damaged;
  • 4. The piece is flexible if it can bend at least 1 inch vertically without being damaged and it does not contain a rigid insert.

If the piece is a flat 10 inches or longer and contains a rigid insert, the following tests are to be conducted:

• • 1. Place the piece with the length perpendicular to the edge of a flat surface and extend the piece 5 inches off the surface;
  • 2. Press down on the piece at a point 1 inch from the outer edge, in the center of the piece's length, exerting steady pressure;
  • 3. Turn the piece around and repeat steps 1 and 2. The piece is flexible if both ends can bend at least 2 inches vertically without being damaged.

The following test is for flats less than 10″ and that contains a rigid insert:

• • 1. Place the piece with the length perpendicular to the edge of a flat surface and extend the piece one-half of its length off the surface;
  • 2. Press down on the piece at a point one inch from the outer edge, in the center of the piece's width, exerting steady pressure;
  • 3. Turn the piece around and repeat steps 1 and 2; the piece is flexible if both ends can bend at least 1 inch vertically without being damaged.

The USPS requirements (1.4) for uniform thickness are:

Flat-size mailpieces must be uniformly thick so that any bumps, protrusions, or other irregularities do not cause more than ¼-inch variance in thickness. When determining variance in thickness, exclude the outside edges of a mailpiece (1 inch from each edge) when the contents do not extend into those edges. Also, exclude the selvage of any polywrap covering (see 3.3) from this determination. Mailers must secure nonpaper contents to prevent shifting of more than 2 inches within the mailpiece if shifting would cause the piece to be nonuniform in thickness or would result in the contents bursting out of the mailpiece.

The envelope 10 as shown in FIG. 1 that is stuffed with a DVD holder 33 as described above and being of a size of 12½″ wide and 10″ high passes the minimum flexibility criteria for flat-sized pieces of the USPS for flats 10 inches or longer that contain a rigid insert.

An envelope having dimensions of 9⅞ inches wide and 8 inches high with a CD holder 5⅞ inches wide×4⅞ inches high asymmetrically to one side of the cut-out in the insert 32 also passes the USPS minimum flexibility criteria for flats less than 10 inches long and that contain a rigid insert.

The combination of envelope, flexible insert and packaged item may have different relative sizes in order to pass the flexibility tests of the USPS. For example, the envelope may have a maximum size of 12 inches high and 15 inches wide.

Further, the insert 32 may have one or more cutouts for receiving rigid items other than rectangular items, such as DVD holders and CD holders. For example, for a large size envelope, the insert may have a cut-out that is symmetrically placed. Further, such a cut-out may be of any suitable shape such as rectangular, circular, or otherwise, to receive a circular item or otherwise. Further, the insert 32 may be provided with a slit in order to receive a slender item, such as a pencil.

As noted above, the envelope may be pre-lined with padding. In such an embodiment, the insert 32 may be fixed or not in place.

Referring to FIG. 4, a package 33 is formed of an insert 34 in the form of a rectangular tray and a wrapper or sleeve 35 that envelopes the tray 34.

As illustrated, the tray 34 is made of a thin thickness of plastic that is shaped, as by molding, with a cut-out in the form of a recess 36 that is sized to receive an item 37 to be mailed. For example, in the illustrated embodiment, the item may be a DVD holder or the like. The recess 36 is disposed within the tray 34 asymmetrically of the X and Y axes of the tray 34 as viewed.

Referring to FIG. 5, the recess 36 is located in an upper left-hand corner of the tray 34. In addition, the recess 36 is of rectangular shape and is defined by a flat floor 38 and four flat side walls 39 that extend upwardly from the floor 38. One or more projections 40 extend centrally from each side wall 39 into the recess 36 in order to hold the DVD holder (not shown) between the floor 38 and the underside of each projection 40.

In addition, each side wall 39 has an enlarged section 41 at each end outside the plane of the side wall 39 to form an enlarged corner 42 of the recess 36 for forming and protection.

The floor 38 of the recess 36 may be smooth and flat or may be formed with a depressed design such as described below to impart rigidity and to receive the DVD holder (not shown) in a manner in which the DVD holder can be more easily removed.

The tray 34 is provided with a pattern of cavities or wells 43 to impart a thickness to the tray 34 as well as rigidity. These cavities 43 are spaced apart and are arranged in rows. As shown, there are two rows of cavities 43 along the front of the tray 34 and three rows of cavities 43 along the right-hand side of the tray 34 as viewed.

Each cavity 43 is of rectangular shape with a flat floor 46 and four upstanding walls 47, each of which walls 47 is formed with vertical flutes or ribs 48, as viewed, in order to impart rigidity to the cavity 45. As illustrated, the cavities may be of different sizes.

Referring to FIGS. 6 and 7, the underside of the flat floor 46 of each cavity 43 is co-planar with the underside of the floor 38 of the recess 36 and the walls 47 of each cavity 43 is of the same height as the walls 39 of the recess 36.

A thin web 49 connects each cavity 43 with an adjacent cavity 43 and the recess 36 and each row of cavities with an adjacent row of cavities 43. The connecting webs 49 allow the tray 34 to flex between adjacent rows of cavities 43, between the recess 36 and the adjacent row of cavities 43 and between each pair of cavities 43 in a row. In this regard, the thin web 49 allows the bottoms of two adjacent cavities 43 to pivot toward each other.

A small flat flange 50 extends about the entire periphery of the tray 34

The tray 34 can be of any suitable size. For example, the tray 34 may have outside dimensions of 8.375 inches by 11.0 inches and a thickness of 0.671 inches. The webs 49 may have a length of 0.30 inches between the flutes or ribs 48 of adjacent cavities 43.

Referring to FIG. 4, once the item 37 (e.g. a DVD holder) has been placed in the recess 36, either manually or automatically by suitable equipment, the tray 34 may be slipped into the sleeve 35 with the side having the front rows of cavities 43 being inserted first and the ends of the sleeve closed in conventional manner to form a package suitable for mailing as a flat-sized piece in conformance with United States Postal Service (USPS) regulations (see 39 CFR Part 111).

When packaged, a flexing or bending force imposed on the side of the package occupied by the rows of cavities 43 causes the tray 34 to flex between the rows of cavities 43 as well as between the recess 36 and the adjacent row of cavities 43 and, particularly, in a manner to conform with the above described United States Postal Service requirements for flat-sized packages.

Referring to FIG. 8, wherein like reference characters indicate like parts as above, the package 51 may be made with a tray 34′ of a smaller size than the tray described above and an envelope 10 as described above in the embodiment of FIG. 1.

The tray 34′ being of a smaller size, for example, having a recess 36 for receiving a jewel case and with overall dimensions of 7 inches by 8.875 inches, a lesser number of rows of cavities 43 is required. In addition, the overall thickness of the tray 34′ may be made smaller such as with a height of 0.548 inches. Likewise, the size of the cavities 43 may be different and the spacing between cavities 43 may be greater or less, e.g. with the webs 49 having a length of 0.25 inches between the flutes 48 of the cavities 43.

As illustrated, two rows of cavities 43 are disposed to each of two sides of the recess 36. In addition, the cavity 36 is formed with a depression 52 in the floor of the recess that has a pattern as shown in FIG. 9 with a circle 53 with four radiating channels 54.

Referring to FIG. 12 wherein like reference characters indicate like parts as above, the tray 55 may be modified to have a recess 56 for shipping items other than CDs and DVDs. For example, the item might be an elongated pen (not shown) or any other suitably shaped structure.

In addition, the tray 55 is molded of a one-piece body to have a plurality of elongated cavities or wells 57 in a pattern wherein two rows of spaced apart cavities 57 extend from one side of the recess 56. Where the recess 56 is disposed angularly, as shown, to one side of the tray 55, one row of cavities has one more cavity than the other row to lie closer to the recess 56. In addition, a single cavity 57 is disposed on the opposite side of the recess 56 in line with the row having the lesser number of cavities. That is to say, the recess 56 is disposed angularly across the two rows of cavities 57 rather than being in parallel with a cavity 57.

Each cavity 57 has a rounded bottom 58 and an upstanding peripheral wall defining a pair of opposed side walls 60 and a pair of semi-circular end walls 61 connecting the two side walls 60. In addition, a plurality of flutes 62, i.e. semi-circular grooves) extend across the bottom 58 of each cavity 57 and into each of the two opposed side walls 60.

The flutes 62 may be angularly disposed across each side wall 60 as shown in FIG. 12 or may be vertically disposed across side wall 60 as shown in FIG. 13.

The recess 56 has a flat bottom 63 coplanar with the bottom 58 of each cavity 57 and a peripheral wall 64 upstanding from the bottom 63. As illustrated, the peripheral wall 64 is of an ovate shape having a pair of parallel side walls 65 and a pair of semi-circular end walls 66 connecting the side walls 65. In addition, one or more projections 67 are provided on each of the side walls 65 for retaining an item within the recess 56.

In this embodiment, the recess 56 has a width of 0.701 inches between the side walls 65 to receive a pen or the like. The tray 55 may have outside dimensions of 6.0 inches by 8.50 inches and an overall thickness of 0.580 inches.

As illustrated, the recess 56 is asymmetrically disposed within the tray 55, i.e. to one side of the tray 55. In addition, at least one cavity 57 is disposed to one side of the recess 56 and two rows of cavities 57 are provided on the opposite side of the recess 56.

As above, a thin web 68 extends between adjacent cavities 57 and between the recess 56 and the adjacent cavities 57 to impart flexibility to the tray 55. In addition, a thin flange 69 extends about the periphery of the tray 52.

Referring to FIGS. 13 to 16, wherein like reference characters indicate like parts as above, the recess 56 may have a rounded bottom 70 that is coplanar with the bottoms of the cavities 57 and that is shaped to accommodate the item, e.g. a pen, to be inserted into the recess 57. Likewise, each projection 67 is formed out of a side wall 65 of the recess 57 and is shaped to retain the item within the recess 53.

When the tray 55 is placed in an envelope, sleeve or wrapper, the section of the tray 57 containing the multiple rows of cavities 57 is able to flex under a bending force in a manner to conform to the above described United States Postal Service requirements for flat-sized packages. In addition, the left-hand section of the tray with the single cavity 57 is able to flex relative to the recess 56 along a line parallel to the axis of the recess 56.

The trays in each of the above described embodiments is made of a plastic material that may be clear, translucent or opaque. Also, each tray may be placed in an envelope of conventional structure, an expandable envelope as described in U.S. Pat. No. 6,227,444 or a wrapper or sleeve.

The invention thus provides an insert or tray that is able to receive and retain rigid or non-rigid items within an envelope or wrapper to form a package that can be mailed as a flat-sized piece as defined by the USPS.

The envelope and insert 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.

Excluding the outside edges of a mail piece, i.e., one inch from the edge, when determining variance in thickness, the insert secures the item within the cutout of the insert 32 so as to prevent shifting of more than 2 inches within the envelope.

Claims

1. A flat-sized package comprising

an item to be mailed disposed within the package; and

a flexible insert disposed within the package to prevent said item from shifting within the package, said insert being flexible within the area occupied by said insert under a bending force imposed on at least one side of the package.

2. A flat-sized package as set forth in claim 1 wherein said insert has a cut-out of predetermined shape for receiving said item.

3. A flat-sized package as set forth in claim 2 wherein said insert is made of foam plastic.

4. A flat-sized package as set forth in claim 1 wherein said insert is a tray having a recess receiving said item.

5. A flat-sized package as set forth in claim 4 wherein said tray includes a pattern of cavities disposed in spaced apart relation and a plurality of thin webs interconnecting said cavities to allow each said cavity to pivot toward an adjacent cavity.

6. A flat-sized package as set forth in claim 1 further comprising an an envelope receiving said item and said insert and wherein said package has a uniform thickness of not more than ¾ inch.

7. A tray for a mailer comprising

a thin plastic body;

a recess disposed in asymmetric relation within said body for receiving an item to be mailed;

a plurality of cavities disposed in said body on at least two sides of said recess, at least some of said cavities being disposed in spaced apart relation to each other to define a thin web therebetween in said body.

8. A tray as set forth in claim 7 wherein said recess is of rectangular shape having a floor, a plurality of walls upstanding from said floor, and at least one projection on at least one of said walls projection into said recess for retaining an item therein.

9. A tray as set forth in claim 8 wherein each said cavity has a floor coplanar with said floor of said recess, a plurality of upstanding walls, and a plurality of ribs on each said wall for rigidifying said wall.

10. A tray as set forth in claim 7 wherein each said cavity has a floor, a peripheral wall upstanding from said floor with a pair of parallel side walls therein and a plurality of ribs extending within and between said pair of parallel side walls and said floor for rigidifying said cavity.

11. A tray as set forth in claim 7 wherein said cavities are disposed in a pair of rows on each of two sides of said recess.

12. In combination

a tray comprising a thin plastic body; a recess disposed in asymmetric relation within said body for receiving an item to be mailed; a plurality of cavities disposed in said body on at least two sides of said recess, at least some of said cavities being disposed in spaced apart relation to each other; and a plurality of thin webs in said body interconnecting said cavities;

an item in said recess of said tray; and

an envelope receiving said tray and said item.

13. The combination as set forth in claim 12 wherein said envelope has a pocket for receiving said tray and a closure flap for closing over said pocket.

14. The combination as set forth in claim 12 where said envelope is prescored with an expandable pocket for receiving said tray.

15. The combination as set forth in claim 11 wherein said envelope is a sleeve receiving said tray in slide fit relation.

16. The combination as set forth in claim 11 wherein said envelope is a wrapper enveloping said tray and said item.

17. In combination

an envelope having a pocket;

an item to be mailed in said pocket; and

a flexible insert within said pocket having a cut-out of predetermined shape receiving said item and being of a height and width to substantially fill the remainder of said pocket and to be shipped in said envelope.

18. The combination as set forth in claim 17 wherein said insert is secured to said envelope.

19. The combination as set forth in claim 17 wherein said insert is made of self-supporting plastic foam.

20. The combination as set forth in claim 17 wherein said insert is of L-shape and said cut-out is disposed asymmetrically to one side of said insert.

21. The combination as set forth in claim 17 wherein said envelope has a closure flap for closing over said pocket.

22. The combination as set forth in claim 17 wherein said envelope is a sleeve receiving said insert and said item in slide fit relation.

23. The combination as set forth in claim 17 wherein said envelope is a wrapper enveloping said insert and said item.

24. The combination as set forth in claim 17 wherein said envelope has a dimension of at least ten inches on one side thereof.

25. The combination as set forth in claim 17 wherein said insert has a thickness of from 1/16 inches to 1¼ inches.

26. The combination as set forth in claim 17 wherein, with an uppermost half of said envelope supported on a horizontal plane, a lowermost half of said envelope is bendable relative to said horizontal plane about a longitudinal axis located at mid-height thereof to deflect a lowermost edge thereof for a vertical distance of at least one inch from said horizontal plane.

27. The combination as set forth in claim 26 wherein said item is rigid.

28. The combination as set forth in claim 27 wherein, with an uppermost half of said envelope supported on a horizontal plane, a lowermost half of said envelope is bendable relative to said horizontal plane about a longitudinal axis located at mid-height thereof to deflect a lowermost edge thereof for a vertical distance of at least one inch from said horizontal plane.

29. The combination as set forth in claim 28 wherein, with one side of said envelope supported on said horizontal plane and five inches of the opposite side of said envelope projecting in an unsupported manner, said opposite side of said envelope is bendable relative to said horizontal plane to deflect an edge thereof for a vertical distance of at least two inches from said horizontal plane.

30. The combination as set forth in claim 29 wherein, with said opposite side of said envelope supported on said horizontal plane and five inches of said one side of said envelope projecting in an unsupported manner, said one side of said envelope is bendable relative to said horizontal plane to deflect an edge thereof for a vertical distance of at least two inches from said horizontal plane.