Patent Publication Number: US-2021171262-A1

Title: Mail Assembly for Flats Transportation

Description:
BACKGROUND INFORMATION 
     The United States Postal Service (USPS), United Parcel Service (UPS), and Federal Express (FedEx), among other package delivery companies use the term “flats” to describe envelopes that can be used to transport a variety of items (e.g., advertising items, promotional items, product samples). The cost of mailing or shipping packages can be high, which is why numerous businesses have turned to flats for mailing materials. Flats are a cheaper alternative to mailing packages. Flats are less expensive to mail than non-flat materials (NFMs) because automated mailing procedures may be used with flats. Automated mailing procedures may include rollers, nips, sorting machines, conveyors, robotics, marking machines, channeling systems, and S-shaped pathways requiring significant deflection of envelopes and packages. 
     SUMMARY 
     Exemplary embodiments include a mail assembly. The mail assembly includes a mail tray that is sized and shaped to be inserted into a flat envelope and a plurality of protrusions extending distally out of the mail tray and forming at least one holding area on the mail tray for retaining at least one item, wherein each of the plurality protrusions is disconnected from the other protrusions. In some exemplary embodiments, the mail assembly is constructed from a fiber based material, a petroleum based plastic material, or a plant based plastic material. 
     The plurality of protrusions may be arranged in a predetermined pattern to form the at least one holding area. The predetermined pattern may be configured to form the at least one holding area to retain a single item or to retain multiple items. In other exemplary embodiments, the at least one holding area is formed in an interior of one of the protrusions. 
     In exemplary embodiments, each of the protrusions may extend an equal distance from the mail tray. In other exemplary embodiments, the mail assembly has a first set of protrusions extending a first distance from the mail tray and a second set of protrusions extending a second distance from the mail tray. In some exemplary embodiments, the first set of protrusions are arranged around a perimeter of the mail tray. 
     In exemplary embodiments, each of the protrusions may have the same shape. In other exemplary embodiments, the mail assembly has a first set of protrusions having a first shape and at least one second protrusion having a second shape, wherein the first shape is different from the second shape. In some exemplary embodiments, the protrusions have a conical frustum shape. In some exemplary embodiments, the protrusions taper from a proximal end on a top surface of the mail tray to a distal end. In some exemplary embodiments, the protrusions have a distal end that is flat. In some exemplary embodiments, the mail tray includes at least one hole that penetrates through the mail tray. 
     In some exemplary embodiments, the mail tray has a rectangular shape. In some exemplary embodiments, the mail tray has a shape that is designed to be inserted into a flat envelope such that the flat envelope has a substantially uniform thickness. 
     In still other exemplary embodiments, a method of packing an envelope with an item to be mailed is described. The method includes selecting a mail assembly comprising a mail tray and a plurality of protrusions extending distally out of the mail tray to forming at least one holding area on the mail tray, wherein the mail assembly is sized and shaped to correspond to the envelope, inserting the item into the holding area on the mail tray and inserting the mail assembly including the item into the envelope. 
    
    
     
       BRIEF DESCRIPTIONS OF DRAWINGS 
         FIG. 1  shows a perspective view of a mail assembly according to various exemplary embodiments. 
         FIG. 2  shows a side view of the mail assembly of  FIG. 1  according to various exemplary embodiments. 
         FIGS. 3A-D  show various side views of a protrusion of the mail assembly of  FIG. 1  according to various exemplary embodiments. 
         FIG. 4  shows a perspective view of a second mail assembly according to various exemplary embodiments. 
         FIGS. 5A-B  show a side views of protrusions of the mail assembly of  FIG. 4  according to various exemplary embodiments. 
         FIG. 6  shows a perspective view of a third mail assembly according to various exemplary embodiments. 
         FIG. 7  shows the mail assembly of  FIG. 4  inserted into a flat envelope according to various exemplary embodiments. 
         FIG. 8  shows a perspective view of a third mail assembly according to various exemplary embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The exemplary embodiments may be further understood with reference to the following description and the related appended drawings, wherein like elements are provided with the same reference numerals. The exemplary embodiments are related to a mail assembly including a mail tray and protrusions. The protrusions extend from the tray without having a connecting geometry. 
     As described above, mailing or shipping entities use automated mailing procedures for flats. In order to pass through the machines associated with automated mailing procedures, flats are typically required to be rectangular, flexible and of uniform thickness. There may also be additional requirements that are determined by each individual delivery company. However, an issue arises for shippers because many materials and/or products that the shipper wants to send using the less expensive flats mailing do not conform to the flats requirements. Thus, the exemplary embodiments provide a mail assembly that conforms to the flats requirements and may be used to ship multiple different types of materials and/or products. 
       FIG. 1  shows a perspective view of a mail assembly  100  according to various exemplary embodiments. The mail assembly  100  includes a mail tray  102  and multiple protrusions  120 , extending distally out of the mail tray  102 . In this example, the mail tray  102  is rectangular in shape, including a first side  104 , a second side  106 , a third side  108  and a fourth side  110 , forming a perimeter. The first side  104  and second side  106  are parallel to each other and shorter than the third side  108  and the fourth side  110 , which are parallel to one another. The dimensions of the mail tray  102  may be determined by dimensions of a flat into which the mail tray  102  is to be inserted. For example, in one exemplary embodiment, the mail tray  102  will be 12½″ by 9½″ to comply with equal measurements of a FedEx flat envelope. Those of skill in the art will understand that the dimensions of the mail tray  102  may be slightly smaller than the envelope itself, e.g., by ⅛ to ¼ inches, so that the mail tray  102  will fit into the flat envelope and allow the flat envelope to be sealed. In addition, it should be understood that the above dimensions are only exemplary and that the mail tray  102  may have any dimensions that correspond to a flat envelope size that is offered by a delivery company. 
     The protrusions  120  extend from the mail tray  102  without having any connecting geometry, meaning that each protrusion  120  is independent from any other protrusion  120 , e.g., a protrusion  120  is not connected to any other protrusion  120 . As will be explained in greater detail below, this lack of connecting geometry allows the mail assembly  100  to remain flexible when inserted into a flat envelope. The protrusions  120  may have a height (e.g., extend distally from the mail tray  102 ) consistent with the allowed thickness of the flat envelope. In one exemplary embodiment, a flat envelope has a thickness requirement of ¾″. Thus, in one example, the protrusions  120  may be ¾″. Those of skill in the art will understand that the height of the protrusions  120  may be slightly less than the flat envelope requirement to account for the thickness of the mail tray  102  and the thickness of the flat envelope itself. In addition, it should be understood that the above height is only exemplary and that the protrusions  120  may have any height that correspond to a flat envelope thickness requirement. 
     In the example of  FIG. 1 , the protrusions  120  are arranged in a pattern to form various holding areas for the items to be shipped, e.g., holding areas  130 ,  132  and  134 . These holding areas  130 ,  132  and  134  may each hold one or more items, or a single item may occupy one or more holding areas  130 ,  132  and  134 . It should be understood that when an item is placed on the mail tray  102  in one or more of the holding areas  130 ,  132  and  134 , the item should not extend beyond the distal end  124  of the protrusions  120 , e.g., the mail assembly  100  holding shipment items will have a generally uniform maximum thickness that comprises the thickness of the mail tray  102  plus the height of the protrusions  120 . As will be described in greater detail below, in some exemplary embodiments, one or more of the protrusions  120  may have varying heights. However, this will not change the maximum thickness of the mail assembly  100  because multiple protrusions  120  will have a same maximum height such that when the mail assembly  100  is placed into a flat envelope, the flat envelope will have a generally uniform thickness. 
     As described above,  FIG. 1  shows one exemplary pattern for arranging the protrusions  120 . However, it should be understood that the protrusions  120  may be organized into a variety of predetermined patterns, depending on the item being shipped. The predetermined pattern may allow the items to be oriented in specific direction so that they may be mailed using a flat envelope. For example, the protrusions  120  may be aligned in parallel rows creating parallel holding areas for mailing of pens. In another example, the protrusions  120  may be arranged such that a square or rectangular holding area is created in a middle of the mail tray  102  for mailing square or rectangular shaped items. Those skilled in the art will understand that predetermined patterns of protrusions  120  may be developed based on the items that are to be shipped and these patterns may create holding areas having regular shapes, irregular shapes, symmetrical shapes, asymmetrical shapes, etc. 
     The mail assembly  100  may be constructed from any material that allows the mail assembly to flex or bend as the mail assembly  100  (when in a flat envelope) moves through the automated machinery of the delivery company. Examples of materials may include fiber based materials, petroleum based plastic materials (e.g., polyethylene, polypropylene, polystyrene, polyester, nylon, acrylic, etc.), and plant based plastic materials (e.g., polylactic acid, cellulose acetate, etc.). 
       FIG. 2  shows a side view of the mail assembly  100  of  FIG. 1  according to various exemplary embodiments. It may be considered that  FIG. 2  shows a view of the first side  104  of the mail tray  102 . In this example, the protrusions  120  are of a uniform height and that height (including the thickness of the mail tray  102 ) complies with the requirements of the flat envelope into which the mail assembly  100  is to be inserted. The protrusions  120  may be formed into any three-dimensional shape (e.g., a cylinder, a cone, a prism, a frustum, etc.). In this exemplary embodiment, the protrusions  120  are shaped as conical frustums, wherein each protrusion  120  extends from a proximal end  122 , on a top surface of the tray  102 , to a distal end  124 , with a lateral side  126  therebetween. Thus, when the mail assembly  100  is inserted into a flat envelope, a bottom surface of the mail tray  102  may contact a first inside surface of the flat envelope and the distal ends  124  of the protrusions may contact a second inside surface of the flat envelope. In this arrangement, the conical frustum shape that has a flat distal end  124  (or any shape having a flat distal end) may have an advantage over protrusion  120  shapes that do not have a flat distal end  124  because the non-flat distal ends will have more pressure at a point where the shape contacts the flat envelope as opposed to the flat distal end  124  that will more evenly distribute the pressure on the flat envelope. 
     In the example of  FIG. 2 , each protrusion  120  tapers from the proximal end  122  to the distal end  124  (e.g., a diameter of the protrusion  120  at the proximal end  122  will be greater than a diameter of the protrusion  120  at the distal end  124 ). However, even though the exemplary embodiments are described as having conical frustum shaped protrusions  120 , this is not a requirement of the mail assembly  100 . Other shapes may also be used for the protrusions and satisfy the flexibility parameters for use in a flat envelope, including irregular shapes. Some examples of different shaped and/or sized protrusions will be provided below. 
       FIG. 3A  shows a side view of the protrusion  120  in a conical frustum shape. The protrusion  120  may cover varying amounts of area of the mail tray  102  (e.g., the diameter of the protrusion  120  at the proximal end  122  may be varied) either on the same mail tray  102  or between different types of mail trays  102 . These different sizes of protrusions  120  may be used to form particular shapes for holding areas (e.g., holding areas  130 ,  132 ,  134 ) or to result in a different level of flexibility for the mail assembly  100 . Similarly, the protrusions  120  may have varying amounts of taper between protrusions  120  on the same mail assembly  120  or between different types of mail assemblies  100 . Again, these variances may be made based on the type of item to be held by the mail assembly  100  or based on the flexibility characteristics of the mail assembly  100 . The protrusions  120  may be hollow, solid, or filled to any amount therebetween. Typically, hollow would be preferred because it will result in less material being used. However, there may be circumstances where partially completely filled protrusions  120  may be appropriate.  FIGS. 3B-3D  show transparent side views of the protrusion  120  according to different exemplary embodiments.  FIG. 3B  shows a protrusion  120  that is generally hollow, wherein a majority of the interior volume of the protrusion is empty space (e.g., 90% of the interior volume is empty).  FIG. 3C  shows a protrusion  120  that may be solid.  FIG. 3D  shows a protrusion  120  that is partially filled (e.g., approximately 50% of the volume is empty space). 
       FIG. 4  shows a perspective view of a second mail assembly  200  according to various exemplary embodiments. The mail assembly  200  is substantially similar to the mail assembly  100  and comprises a mail tray  202  capable of retaining a variety of items. However, in this exemplary embodiment, there are first protrusions  220  and second protrusions  230  that extend distally out of the mail tray  202 . The first protrusions  220  and second protrusions  230  are substantially similar to the protrusions  120  in terms of shape. However, in this example the height of the first protrusions  220  is less than the height of the second protrusions  230 . In  FIG. 4 , the height difference is exaggerated to illustrate that there is a difference in height. In an actual embodiment, the height difference will be slight, e.g., ⅛ to ¼ inches. As shown in  FIG. 4 , the first protrusions  220  (that extend less than the second protrusions  230 ) line a perimeter of the mail tray  202 . The reason for this slight lessening of the height of the perimeter protrusions  220  is that this may allow the mail assembly  200  to be placed into a flat envelope more easily. For example, as described above, the flat envelope may have a maximum thickness and the thickness of the combined mail tray  202  and the second protrusions  230  may correspond to this maximum thickness. However, because the thickness of the combined mail tray  202  and the first protrusions  230  is slightly less and because this is on the perimeter of the mail assembly  200  that will be inserted first into the flat envelope, this may be inserted more easily into the opened flat envelope and then be used to guide the slightly thicker portion of the mail assembly  200  including the second protrusions  230  into the flat envelope. As described above, while the thickness of the loaded flat envelope is supposed to be uniform, a minor variance between the perimeter and the center should not be enough to disqualify the mail assembly  200  from meeting the flat requirements of most delivery services and will aid the shipper in packaging the products within the flat envelope. 
       FIGS. 5A-B  show a side views of protrusions  220  and  230  of the mail assembly  200  of  FIG. 4 , respectively, according to various exemplary embodiments.  FIG. 5A  shows the first protrusion  220  extending from a proximal end  222 , on a top surface of the tray  202 , to a distal end  224 , which may contact an inside surface of the flat, with a lateral side  226  therebetween.  FIG. 5B  shows the second protrusion  230  extending from a proximal end  232 , on a top surface of the tray  202 , to a distal end  234 , which may contact an inside surface of the flat, with a lateral side  236  therebetween. In this example, the height of the protrusion  220  is less than a height of the second protrusion  230 . Also, in this example, a tapering angle of the first protrusion  220  is greater than a tapering angle of the second protrusion  230 . However, this differing tapering angle is only exemplary, and the same tapering angle may be used. Additionally, although in this exemplary embodiment the first protrusion  220  and the second protrusion  230  are conical frustums, the first protrusions  220  may have a different shape when compared to a shape of the second protrusions  230 . 
       FIG. 6  shows a perspective view of a third mail assembly  300  according to various exemplary embodiments. The third mail assembly  300  of  FIG. 6  is substantially similar to the second mail assembly  200  of  FIG. 4  in that it includes a mail tray  302 , first protrusions  320  of a first height and second protrusions  330  of a second height. The tray  302  further comprises holes  340 . The holes  340  may include additional advantages for the mail assembly  300 . For example, by including the holes  340 , less material may be used to manufacture the mail assembly  300 . The holes  340  may also be used to more easily handle the mail assembly  300 . In addition, the holes  340  may provide more clearance for the items to be retained in the mail tray  302 , e.g., the items to be retained in the mail tray  302  may have a portion that extends into one or more of the holes  340  such that the item will not extend beyond the distal end of the protrusions  320  or  330 . Although the exemplary embodiment shows two holes  340 , any number of holes  340  may be used and may be placed in various locations within the perimeter of the mail tray  302  to accommodate the particular items being shipped. Additionally, although the holes  340  in the exemplary embodiment are circular, the holes  340  may be of a different shape. 
       FIG. 7  shows the mail assembly  200  of  FIG. 4  inserted into a flat envelope  10  according to various exemplary embodiments. Although any of the previously described mail assemblies ( 100 ,  200  and  300 ) may be inserted into the flat envelope  10 ,  FIG. 7  shows a perspective view of the example mail assembly  200  being inserted into the envelope  10 . The envelope  10  includes a perimeter  12 , a top portion  14 , a bottom portion  16  and an opening  18 . The perimeter  12  includes a first longitudinal edge  22 , a second longitudinal edge  24  and a lateral edge  26 . The lateral edge  26  is parallel to the opening  18  and opposite of the opening  18 . The first longitudinal edge  22  and second longitudinal edge  24  connect the lateral side  26  to the opening  18 . The top portion  14  and bottom portion  16  are connected to one another such that a minimum thickness occurs along the perimeter  12 . According to the USPS, the envelope  10  must have at least one dimension that is greater than eleven and a half inches in length, six and one eighth inches in height, or one-quarter of an inch in thickness. Maximum dimensions of the envelope  10  are fifteen inches in length, twelve inches in height, and three-quarters of an inch in thickness, wherein the length is the dimension parallel to the address as read, and the height is the dimension perpendicular to the length. These dimensions are only provided to provide context for the mail assembly  200  and different delivery companies may have different requirements for their flat envelopes. The mail assembly  200  may be sized and shaped to conform to a variety of the dimensions of the envelope  10 . 
     The mail assembly  200  may have a predetermined pattern of the second protrusions  230  for mailing items that must be held in specific orientations to be mailed in the envelope  10 . The mail assembly  200 , along with the items (not shown) on the tray  202 , may be inserted through the opening  18  until the mail assembly  200  abuts the lateral edge  26 . As one of ordinary skill in the art will understand, the first height of the first protrusions  220  is less than the second height of the second protrusions  230  to better enable the mail assembly  200  insertion into the envelope  10 . The first height conforms to a lower thickness of the envelope  10  along the perimeter  12 . The second height conforms to a maximum thickness of the envelope  10 , giving a greater clearance for the items on the tray  202 . Once the mail assembly  200  is completely inserted into the envelope  10 , the opening  18  may be sealed to be ready for pickup by the delivery company. 
     As described above, the mail assembly  200  (and the mail assemblies  100  and  300 ) not only conform to the size requirements of the flat envelope  10 , but also conform to the flexibility requirements for using automated machinery to sort and otherwise process the loaded flat envelope  10 . For example, after the delivery company picks up the loaded flat envelope  10 , the delivery company may place the loaded flat envelope  10  into an automated system for sorting and processing (e.g., weighing, placing in trays, applying barcodes, etc.). This automated system may have various machines and conveyors through which the loaded flat envelope  10  travels. These machines and conveyors may bend, twist, and flex the loaded flat envelope  10  as it traverses the automated system. Since the mail assembly  200  does not have connecting geometry between the different protrusions  220  and/or  230 , the mail assembly  200  within the loaded flat envelope  10  may also be bent, twisted, and flexed without causing the mail assembly  200  to break, crack or otherwise damage the flat envelope  10 . Thus, the mail assemblies according to the exemplary embodiments, allow for the flats requirements of delivery companies to be satisfied, allowing a shipper to use the lower cost flats delivery. 
       FIG. 8  shows a perspective view of a third mail assembly  800  according to various exemplary embodiments. The mail assembly  800  is substantially similar to the mail assemblies  100  and  400  and comprises a mail tray  802  capable of retaining a variety of items. However, in this exemplary embodiment, there are first protrusions  820  and a second protrusion  830  that extend distally out of the mail tray  802 . The first protrusions  820  are substantially similar to the protrusions  120  in terms of shape. The second protrusion  830  is a different shape. Specifically, the protrusion  830  has a rectangular shape, e.g., the  4  walls of the rectangle are a single protrusion. However, like the other protrusions described herein, the protrusion  830  is also disconnected from any other protrusion. 
     In this example, an interior of the rectangular protrusion  830  may be considered a holding area  835  that is configured to hold the product(s) for mailing. Thus, in this example, multiple protrusions do not form a holding area as in the example of  FIG. 1 , but rather a single protrusion may form a holding area. In another example, a single mail assembly may comprise holding areas that are formed from a single protrusion and other holding areas that may be formed from multiple protrusions depending on the product or products that are being mailed. 
     This example also shows that the protrusions may take the form of any shape. For example, the rectangular protrusion  830  with the rectangular holding area  835  may be used for products that have a rectangular shape, e.g., a SIM card for a mobile device. In another example, the product that is being shipped may be a set of adhesive glow-in-the-dark plastic stars that are designed to attach to the ceiling of a child&#39;s room. In this type of example, the protrusions may take the form of a star-shape where the interior holding area is star-shaped and one or more plastic stars may be placed in the star-shaped protrusions for mailing. From these examples, it will be clear to those skilled in the art that the protrusions may be any shape. 
     Although this application described various embodiments each having different features in various combinations, those skilled in the art will understand that any of the features of one embodiment may be combined with the features of the other embodiments in any manner not specifically disclaimed or which is not functionally or logically inconsistent with the operation of the device or the stated functions of the disclosed embodiments. 
     It will be apparent to those skilled in the art that various modifications may be made in the present disclosure, without departing from the spirit or the scope of the disclosure. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalent.