Abstract:
A package for mailing of a light-weight product includes a compressible body and a sheet that is less compressible than the body. A front face of the body has a cutout shaped to receive the product. The sheet has a planar first panel and a planar second panel. An inside face of the first panel is secured to a back face of the compressible body. The second panel is foldably connected to a first edge of the first panel and movable between a folded configuration in which the second panel covers the front face of the compressible body and an unfolded configuration in which the front face of the compressible body is uncovered and an inside face of the second panel is exposed. The sheet does not cover the top face and the bottom face of the compressible body.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to packaging for mailing of a small device, e.g., a small electronic device. 
       BACKGROUND 
       [0002]    A conventional technique for shipping of a light-weight breakable product is to cover the product in a protective wrapping, e.g., bubble wrap, and insert the wrapped product into an envelope or box. The envelope or box can then be mailed, e.g., as a first class parcel. 
       SUMMARY 
       [0003]    Although bubble wrap can protect a breakable product, the resulting package is relatively rigid. As such, the package typically needs to be mailed using parcel post. By making the package of compressible foam surrounded by paper cardstock, the packaging can be made more flexible so as to pass more easily through automated mailing equipment, while still protecting the product. In addition, the packaging can be mailed as a first class flat, which can have a postage rate significantly lower than a first class parcel. 
         [0004]    In one aspect, a package for mailing of a light-weight product includes a compressible body and a sheet that is less compressible than the body. The compressible body has a front face and a back face on a side of the body opposite the front face. The compressible body has a top face and a bottom face on a side of the body opposite the top face. The front face has a cutout shaped to receive the product. The sheet has a planar first panel and a planar second panel. An inside face of the first panel is secured to the back face of the compressible body. The second panel is foldably connected to a first edge of the first panel and movable between a folded configuration in which the second panel covers the front face of the compressible body and an unfolded configuration in which the front face of the compressible body is uncovered and an inside face of the second panel is exposed. The sheet does not cover the top face and the bottom face of the compressible body. 
         [0005]    In an uncompressed state the compressible body has a length, a height and a depth, the length may be greater than the height, the height may be greater than the depth. The length may be about 5 to 6 inches, e.g., 5.5 inches, the height may be about 2 to 4 inches, e.g., 3 inches, and the depth may be about 0.35 to 0.55 inches, e.g., 0.5 inches. The compressible body may be foam, e.g., an ether-like-ester (E.L.E.) foam with a density of 1.6 to 1.85 lb/ft 3 . The sheet may be cardstock. The sheet may have a planar third panel, and the third panel may be foldably connected to a second edge of the first panel, the second edge on an edge of the first panel opposite the first edge. The third panel may be movable between a folded configuration in which the third panel covers the front face of the compressible body and an unfolded configuration in which an inside face of the third panel is exposed. In the folded configuration the second panel may abuts the front face of the compressible body and the third panel may covers the second panel. The product may be a credit card reader, and an outside face of the second panel may have an image of a portable electronic device into which a jack of the credit card reader is to be inserted. The inside face of the second panel may have indicia of credit card networks. An inside face of the third panel may have instructions for use of the credit card reader. The sheet may include a first strip between the first panel and the second panel, and a second strip between the first panel and the third panel. The first strip and the second strip may have a length about equal to a depth of the compressible body. The sheet may include a tab projecting from the second panel. The sheet may have a slot to receive the tab, the slot positioned at an edge between the third panel and the second strip. The cutout may be an aperture extending through the compressible body to expose the first panel. The cutout may be no more than about 1.5 inches across. The compressible body may have a depth no greater than 0.5 inches. The cutout may be positioned in about a center of the front face of the compressible body. The cutout may be positioned about 2 inches from a side face of the compressible body. In the folded configuration a thickness of the package may not vary more than 0.25 inches across the package. In the folded configuration a distance between an outer face of the first panel and an outer face of the second panel may varies by no more than 0.25 inches across the package. 
         [0006]    Implementations may optionally include one or more of the following advantages. The packaging may be sufficiently flexible to pass through automated mailing equipment, while still protecting the product from damage. The packaging may be mailed as a first class flat, which may result in significant cost savings if a large number of units of product are shipped. The inside covers of the packaging may provide space for instructions for use of the device, branding or advertising. The packaging may present an esthetically pleasing unboxing experience. 
         [0007]    The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0008]      FIG. 1  is a perspective illustration of an implementation of packaging in an unfolded configuration. 
           [0009]      FIG. 1A  is a perspective illustration of the sheet from the packaging in an unfolded configuration. 
           [0010]      FIG. 1B  is a perspective illustration of the compressible body from the packaging. 
           [0011]      FIG. 2A  is a top view illustration of the packaging in a folded configuration. 
           [0012]      FIG. 2B  is a perspective view illustration of the packaging in a folded configuration. 
           [0013]      FIG. 2C  is a front view illustration of the packaging in a folded configuration. 
           [0014]      FIG. 3  is a front view illustration of the packaging being inserted into an envelope. 
           [0015]      FIG. 4  is a front view illustration of the envelope. 
           [0016]      FIG. 5  is a perspective illustration of the packaging in an unfolded configuration. 
           [0017]      FIG. 6  is a side illustration of the packaging in an unfolded and flat configuration. 
       
    
    
       [0018]    Like reference symbols in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0019]      FIG. 1  is a perspective illustration of an implementation of a package  100  for mailing of a product  10 . The product  10  can be relatively light-weight, e.g., the total weight of the product  10  plus the package  100  can be thirteen ounces or less. The product  10  can be an electronic device. For example, the product  10  can be a credit-card reader that can be inserted into a port of a mobile electronic device, e.g., a smartphone, tablet computer, or the like. The port can be the audio port of the mobile electronic device. 
         [0020]    The package  100  includes two main components: a compressible body  110  with a front face  112  and a back face on a side of the body  110  opposite the front face  112 , and a sheet  120  that is foldable to cover the front face  112  and back face of the compressible body  110 . 
         [0021]    Referring to  FIG. 1B , the compressible body  110  can be a rectangular parallelepiped, and can have a depth D of about 0.35 to 0.55 inches, e.g., 0.5 inches, a height H of about 2 to 4 inches, e.g., 3 inches, and a length L of about 5 to 6 inches, e.g., 5.5 inches (see  FIGS. 2A and 2B ). Thus, the compressible body can have a main front face  112 , a back face on a side of the body  110  opposite the front face  112 , elongated top face  114  and a bottom face, and two side faces  115  (only one side face is visible in  FIGS. 1 and 1B ). 
         [0022]    The compressible body  110  can be a plastic foam material, e.g., an open-cell polyurethane foam. For example, the foam can be an ether-like-ester (E.L.E.) foam with a density from 1.6 to 1.85 lb/ft 3 . However, other materials with similar compressibility and flexibility could be used. The compressible body  110  is generally elastic, i.e., it will spring back to its original shape if subjected to the stresses typical in shipping, e.g., when passing through automated mailing equipment. 
         [0023]    Returning to  FIG. 1 , a cutout  116  is formed near the center of the front face  112  of the compressible body  110  in substantially the same shape as the product  10 . The cutout  116  can extend only partially into the compressible body  110 , i.e., be a recess, or the cutout  116  can extend entirely through the compressible body  110 , i.e., be an aperture, to expose the sheet  120  underneath. The cutout  116  has a length (along the same axis as length L) not more than 2 inches, e.g., not more than 1.5 inches. For example, the cutout can have a length of about 1 inch. In addition, the distance from an edge of the cutout to the side face  115  of the compressible body  110  should be at least one inch. For example, this distance can be about 2 inches. For shipping, the product  10  fits snugly into the cutout  116  and can be loosely held in place by friction. 
         [0024]    The sheet  120  is less compressible than the body  110 . The sheet  120  can also be somewhat less flexible than the body  110 . The sheet  120  can be paper. For example, the sheet  120  can be cardstock, e.g., 14 point cardstock paper. 
         [0025]    Referring to  FIGS. 1 and 1A , in some implementations, the sheet  120  includes a center panel  122   a , a right panel  122   b  and a left panel  122   c . Each panel can be rectangular, and can have the same height H as the compressible body  110   a . In addition, each panel can have the same length as, or be slightly longer (e.g., by no more than 1 inch, e.g., by no more than 0.25 inches) than, the length L of the compressible body  110   a . The left panel  122   c  has an inner face  132   c  and the right panel  122   b  has an inner face  132   b , each inner face provided on the same side of the sheet  120 . Similarly, the right panel  122   b  has an outer face  130   b  (see  FIG. 3 ) and the left panel  122   c  has an outer face  130   c  (see  FIG. 2B ), each outer face provided by the opposite side of the sheet  120 . The sheet  120  can be a single unitary sheet of uniform composition, e.g., without seams. 
         [0026]    The left edge of the right panel  122   b  can be connected to the right edge of the center panel  122   a  by a strip  124   a , and the right edge of the left panel  122   b  can be connected to the left edge of the center panel  122   a  by a strip  124   b . The strips  124   a ,  124   b  are also rectangular, and can have the same height H as the compressible body  110   a . In addition, each strip  124   a ,  124   b  can have the same length as, or be slightly longer (e.g., by up to 0.25 inches) than, the depth D of the compressible body  110 . Each connecting edge between a panel and a strip can be creased so that the left and right panels  122   b  and  122   c  naturally tend to fold inwardly across the front face  112  of the compressible body  110 . 
         [0027]    A tab  126  can extend from the outer edge of the right or left panel  122   c  or  122   b . A slot  128  can be formed at the edge between the other panel and the adjacent strip, e.g., between the right panel  122   b  and the strip  124   a  if the tab extends from the left panel  122   c . The width of the slot  128  can be the same as the width of the tab  126 . 
         [0028]    The back face of the compressible body  110  is secured to the inner face  132   a  of the center panel  122   a  of the sheet  120 , e.g., by an adhesive. 
         [0029]    Referring to  FIGS. 2A and 2B , for shipping, the left and right panels  122   c  and  122   b  are folded inwardly to cover the front face  112  of the compressible body  110 . The tab  126 , if present, can be inserted into the slot  128  (see  FIG. 1 ) to hold the panels  122   b ,  122   c  in place. In some implementations, as shown in the top view of  FIG. 2A , the right panel  122   b  can abut the front face  112  of the compressible body  110 , and the left panel  122   c  can extend over the right panel  122   b . Thus, the right panel  122   b  is sandwiched between the body  110  and the left panel  122   c . Of course, for some implementations this could be reversed, with the left panel  122   c  abutting the compressible body  110 , and the right panel  122   b  extending over the right left  122   c.    
         [0030]    The strips  124   a  and  124   b  are positioned adjacent the sides faces  115  of the compressible body  110 . Due to slight bowing of the strips  124   a ,  124   b  they need not directly contact the compressible body  110 . 
         [0031]    With the panels  122   c  and  122   b  folded inwardly to cover the compressible body, the panels lay flat and the packaging  100  has a substantially uniform thickness. In particular, the depth of the packaging  100  does not vary by more than 0.25 inches across the package  100 . This is another requirement to qualify for the postal flat mailing rate. In addition, the total thickness of the package (i.e., the depth D of the compressible body  110  and the thickness of the panels  122   a ,  122   b  and  122   c ) is less than 0.75 inches, e.g., slightly more than 0.5 inches. 
         [0032]    As shown in  FIGS. 2A and 2B , the panel  122   a  and  124   b  cover the rear face and front face  112 , respectively, of the compressible body  110 . Similarly, the strips  124   a  and  124   b  cover the right and left side faces  115 , respectively, of the compressible body  110 . However, the thin top face  114  and bottom face (not labeled) of the compressible body  110  are not covered by the sheet, and are instead left exposed. Intruding a covering sheet on the top and bottom faces of the compressible body would increase the rigidity of the packaging  100 . Omitting the covering sheet  120  from the top and bottom faces improves the capacity of the packaging  100  to bend around an axis parallel to the height axis. This can help ensure that the packaging is sufficiently flexible to pass through automated mailing equipment. On the other hand, having the covering sheet  120  surround the front, rear and side faces provides increased rigidity against bending about other axes, thus helping protect the product from damage. 
         [0033]    As shown in  FIG. 3 , in the folded configuration, the packaging  100  can be inserted into an envelope  150 , e.g., an envelope formed of 100 lb. paper. The envelope can have a height of about 5¼ inches, and a length of about 8 inches. 
         [0034]    As shown in  FIG. 4 , the flap  152  of the envelope  150  is closed, and a large sticker  160 , e.g., a 4″ by 4″ mailing label, can be placed over the flap to secure the flap of the envelope to the body. Thus, the product cannot be removed from the envelope without damaging the envelope or the mailing label. Damage to the envelope or mailing label can therefore provide evidence of tampering with the product  10 . The mailing label  160  includes the address information  162  for shipping of the envelope. 
         [0035]    Once the package  100  is in the sealed envelope  150 , the entire assembly should not have any bumps, protrusions or other irregularities, and the main thickness of the envelope  150  does not vary by more than 0.25 inches. Thus, the envelope should qualify for the postal flat mailing rate. 
         [0036]    Upon receipt by a customer, the envelope  150  can be opened and the package  100  (still in the folded configuration) can be removed. Returning to  FIGS. 2B-2C , in the folded configuration, the outer face  130   c  of the left panel  122   c  becomes the exposed front face of the packaging  100 . The outer face  130   c  can include indicia of the manufacturer or supplier of the product  10 . For example, the outer face  130   c  can include the name  136   a  of the manufacturer or supplier, and a company logo  136   b  of the manufacturer or supplier. 
         [0037]    Referring to  FIG. 5 , to unbox the product, the tab  126  is removed from the slot  128 , and the left panel  122   c  is folded outwardly. This exposes the outer face  130   b  of the right panel  122   b , which still covers the compressible body  110 . The outer face  130   c  can include imagery  138 , e.g., printed on the sheet  120  or applied with a sticker. The imagery  136  can illustrate the product  10  and the method of using the product  10 . For example, if the product  10  is a credit card reader, the imagery can include a picture  10 ′ of the credit card reader and a picture  20 ′ of a smartphone, and can show the position for the credit card reader to be inserted into the smartphone, e.g., the alignment of the connector for the credit card reader to the audio input of the smartphone. 
         [0038]    The outward folding of the left panel  122   c  also exposes the inner face  132   c  of the left panel  122   c . The inner face  132  of the left panel  122   c  can include indicia  140  with instructions for use of the product. Again, the instructions can be printed on the sheet  120  or applied with a sticker. 
         [0039]    Referring to  FIG. 6 , the right panel  122   b  is folded outwardly, exposing the front surface  112  of the compressible body  110  and the cutout  116  holding the product  10 . The product  10  can now be removed manually from the cutout  116 . 
         [0040]    The outward folding of the right panel  122   b  also exposes the inner face  132   b  of the right panel  122   b . The inner face  132  of the left panel  122   c  can include indicia  142  with branding, trademark or similar information. For example, if the product is a credit card reader, the indicia  142  can include the logos of the various credit cards networks, e.g., VISA, MASTERCARD, AMEX, and the like, through which the card reader can accept payment. Again, the indicia  142  can be printed on the sheet  120  or applied with a sticker. 
         [0041]    A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the subject matter described. For example, the sheet  120  could only include two panels, e.g., the center panel  122   a  and either the right or left panel  122   b  or  122   c . As another example, the right and left panel  122   b  and  122   c  could extend across less than all of the length of the front face  112  of the compressible body  110 , e.g., the right and left panel  122   a  and  122   c  could each extend about half-way across the compressible body  110 . In this case, the slot  128  could be located near the outer edge of the panel rather than adjacent the strip  124   a . Accordingly, other implementations are within the scope of the following claims.