I mailed out 6 1/2" squares with instructions of what kind of pen to write with and included a self addressed stamped envelope. One of my old co-workers rounded up Sue's friends at the department which was like herding kittens with all the shifts.
When I got the patches back, I put individual backs on them. Then I appliqued fabric envelopes around the border of the back of the quilt and was able to fit two patches in each envelope.
A larger yellow envelope was used for a label. The straggler blocks can fit in there too. I mailed it to my friend Judy who delivered it to Sue last week. She just loved it :). Some of the pictures were taken at her house. You can see she had all the patches out and was reading them. :).