"as long as I don't outright copy their envelope design, which I am not, we should be OK.".
As someone who worked also in a Patent application bureau I can tell you that this supposition could prove itself to be completely wrong. Many patents are worded in such a way that even using the idea that underlines the patent application in a changed way is not possible without infringing the original patent. In fact, not to allow it is one of the main goals of a patent application.
You'd better to consult a professional patent consultant who will read in between the lines of existing patents and inform you about the possibilities of your "changes" in a professional way. Unless you know the rules of patents applications you can not be sure on your own. Good luck.
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