FOLDABLE MAILER

Abstract

A foldable mailer suitable for mailing a vial comprising a single substrate formed of a base, a top panel, a right panel, a left panel, and a flap; wherein the top panel and the base are joined by a middle spacer, the left panel and the base are joined by a left spacer, the right panel and the base are joined by a right spacer, and the flap and the top panel are adjoined by a top spacer; and a vial holder adhered to the substrate, the vial holder comprising a foam block having a slot suitable for encasing a vial.

Claims

1. A foldable mailer suitable for mailing a vial comprising a single substrate formed of a base, a top panel, a right panel, a left panel, and a flap; wherein the top panel and the base are joined by a middle spacer, the left panel and the base are joined by a left spacer, the right panel and the base are joined by a right spacer, and the flap and the top panel are adjoined by a top spacer; and a vial holder adhered to the substrate, the vial holder comprising a foam block comprising a slot suitable for encasing a vial.

2. The foldable mailer of claim 1 wherein an insert is formed on an outer edge of the left panel and a mating slot is cut near an edge of the right panel.

3. The foldable mailer of claim 1 wherein the vial holder is adhered to the top panel of the substrate.

4. The foldable mailer of claim 1 wherein the vial holder is adhered to the base of the substrate.

5. A method of assembling a mailer from a single substrate formed of a base, a top panel, a right panel, a left panel, and a flap, wherein the top panel and the base are joined by a middle spacer, the left panel and the base are joined by a left spacer, the right panel and the base are joined by a right spacer, and the flap and the top panel are adjoined by a top spacer, the left panel comprising an insert at an outer edge thereof and the right panel comprising a mating slot at an outer edge thereof; and a vial holder adhered to the substrate, the vial holder comprising a foam block comprising a slot suitable for encasing a vial, the method comprising the steps of: folding the top panel towards the base along two edges of the middle spacer so that a gap is formed between the top panel and the base, wherein the foam block is located in the gap; folding each of the left panel and the right panel towards each other, along the two edges of the left spacer and the right spacer, respectively, placing the insert within the mating slot, and folding the flap along the edges of the top spacer so it overlaps the bottom portion of the base.

6. A foldable mailer suitable for mailing an item comprising a single substrate formed of a base, a top panel, a right panel, a left panel, and a flap; wherein the top panel and the base are joined by a middle spacer, the left panel and the base are joined by a left spacer, the right panel and the base are joined by a right spacer, and the flap and the top panel are adjoined by a top spacer.

7. The mailer of claim 6 further comprising means for holding a vial.

8. The mailer of claim 7 wherein the means for holding a vial comprises a foam block adhered to the substrate, the foam block comprising a slot suitable for encasing a vial.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0006] FIG. 1 illustrates a plan view of a mailer for fragile items of the present invention, in unassembled form.

[0007] FIG. 2 illustrates the mailer of FIG. 1 in partially assembled form.

[0008] FIG. 3 illustrates the mailer of FIG. 1 in fully assembled form.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0009] FIG. 1 illustrates a plan, unfolded view of the mailer 2. The mailer 2 is preferably formed from a single substrate such as cardboard that is stiff enough to maintain its shape, bendable to form the finished mailer as will be described, yet light enough to be mailed cheaply. In addition, the substrate should be suitable for printing such as for advertising, mailing addresses and the like.

[0010] When unfolded as in FIG. 1, the mailer 2 is defined by several regions as follows. A top panel 4 abuts a middle spacer 12, which in turn abuts a base 6. A left panel 8 abuts a left spacer 14, which in turn abuts the base 6. A right panel 10 abuts a right spacer 16, which in turn abuts the base 6. Also abutting the top panel 4 is a top spacer 18, which in turn abuts a flap 28. An insert 20 is formed on the outer edge of the left panel 8, and a mating slot 22 is cut near the edge of the right panel 10 as shown.

[0011] A foam vial holder 24, which is rectangular in plan is affixed (such as with adhesive) to the top panel 4. The foam vial holder 24 acts as a means for holding the vial, and it has a slot 26 cut along its length, suitable for allowing a glass vial to be inserted within and held by the foam 24 as shown by the dotted vial in FIG. 2. The biasing pressure of the foam will hold the vial in place without the need for any adhesive, but a small amount of adhesive (or tape) may be applied if desired to ensure the vial does not fall out easily during transit.

[0012] Assembly of the mailer 2 may proceed as shown in FIG. 2 by folding along the lines of abutment as follows. The top panel 4 is folded downwards towards the base along the two edges of the middle spacer 12 so that a gap is formed between the top panel 4 and the base 6, the thickness of which is defined by the width if the middle spacer 12. That thickness should be approximately equal to the thickness of the foam vial holder 24, which will be a slightly larger than the diameter of the glass vial being shipped. This will ensure a good fit of the vial and protect it during shipment. The top panel 4 is folded towards the base 6 as shown by the arrow 1 in FIG.2.

[0013] Next, the left panel 8 and the right panel 10 are then each folded over towards each other, along the two edges of the left spacer 14 and the right spacer 16, respectively, as shown by the arrows 2 and 3, in the same manner as the top panel 4 described above. The insert 20 may then be inserted within the mating slot 22, an as such the foam vial holder 26 will be covered and protected by this assembly. Adhesive may be used to secure the closure at this point.

[0014] The flap 28 may then be folded along the edges of the top spacer 18 so it overlaps the bottom portion of the base 6, and a small amount of adhesive (or tape, etc.) may be used to secure the assembled package to provide the completed assembly in FIG. 3. The name of the addressee and postage may be imprinted on either side of the mailer as desired (or shipping labels may be used).

[0015] The dotted lines that define each of the spacers 12, 14, 16 and 18 may be perforated, scored, or otherwise marked so as to make it easy for the user to fold and assemble the mailer as described. Optionally, the recipient of the mailer may tear the top panel off from the rest of the mailer at the middle spacer 12 and keep just the top panel 4 as a holder for the vial while discarding the rest of the mailer. This is useful in particular if decorative advertising is placed on the top panel 4.

[0016] In an alternative embodiment, the vial holder 26 may be located on the base 6 instead of the top panel 4.

[0017] The foam block is described in the preferred embodiment as a means for holding the vial, but other means may be used instead of the foam block if desired as long as it is secured within the assembled mailer as described. In a further alternative, the vial or another object may be placed within the assembled mailer without using the means for holding the vial as described, but such implementation may not be as secure.

[0018] In the non-limiting preferred embodiment, the size of the mailer is as follows: [0019] Width of left panel: 2.43 inches [0020] Width of right panel: 2.64 inches [0021] Width of all spacers: 31/64 inch [0022] Width of base (and top panel): 4.75 inches [0023] Height of base (and left and right panels): 6.75 inches [0024] Height of top panel: 6.75 inches [0025] Height of flap: inch

[0026] These dimensions may of course be varied as desired.

[0027] Although the preferred embodiments have been described above by way of example only, it will be understood by those skilled in the art that modifications may be made to the disclosed embodiments without departing from the scope herein.