US20230053426A1 - Packaging systems and associated containers, dunnage panels, blanks, and methods - Google Patents

Packaging systems and associated containers, dunnage panels, blanks, and methods Download PDF

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Publication number
US20230053426A1
US20230053426A1 US17/892,469 US202217892469A US2023053426A1 US 20230053426 A1 US20230053426 A1 US 20230053426A1 US 202217892469 A US202217892469 A US 202217892469A US 2023053426 A1 US2023053426 A1 US 2023053426A1
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United States
Prior art keywords
dunnage
container
panel
packaging system
internal volume
Prior art date
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Pending
Application number
US17/892,469
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English (en)
Inventor
Jonathan Lyon
Jeffrey S. James
Kenneth C. Smith
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WestRock Shared Services LLC
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WestRock Shared Services LLC
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Publication date
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Priority to US17/892,469 priority Critical patent/US20230053426A1/en
Assigned to WESTROCK SHARED SERVICES, LLC reassignment WESTROCK SHARED SERVICES, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JAMES, JEFFREY S., SMITH, KENNETH C., LYON, JONATHAN
Publication of US20230053426A1 publication Critical patent/US20230053426A1/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
    • B65D5/22—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form held erect by extensions of one or more sides being doubled-over to enclose extensions of adjacent sides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/4266—Folding lines, score lines, crease lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/64—Lids
    • B65D5/66—Hinged lids
    • B65D5/6626—Hinged lids formed by folding extensions of a side panel of a container body formed by erecting a "cross-like" blank
    • B65D5/665—Hinged lids formed by folding extensions of a side panel of a container body formed by erecting a "cross-like" blank the lid being held in closed position by self-locking integral flaps or tabs
    • B65D5/6661—Flaps provided over the total length of the lid edge opposite to the hinge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/64—Lids
    • B65D5/66—Hinged lids
    • B65D5/6626—Hinged lids formed by folding extensions of a side panel of a container body formed by erecting a "cross-like" blank
    • B65D5/665—Hinged lids formed by folding extensions of a side panel of a container body formed by erecting a "cross-like" blank the lid being held in closed position by self-locking integral flaps or tabs
    • B65D5/6661—Flaps provided over the total length of the lid edge opposite to the hinge
    • B65D5/6664—Flaps provided over the total length of the lid edge opposite to the hinge combined with flaps or tabs provided at the side edges of the lid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/127—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material

Definitions

  • the present disclosure relates to product packaging and, more particularly, to recyclable containers having a dunnage panel, methods for packaging a product, and associated blanks and methods for making packaging systems.
  • Retail products are commonly packaged and shipped in containers.
  • Many shipping containers include supplemental packaging materials, such as plastic molds, packaging peanuts, bubble wrap, air-filled bags, and the like, to hold the product in place, prevent it from being jostled around an interior of the shipping container, and otherwise protect the product from damage during shipping.
  • supplemental packaging materials are often not recyclable and/or product large amounts of material waste.
  • such shipping containers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Further considerations are the strength of the container and its suitability for holding and transporting the product.
  • the disclosed packaging system includes a container defining an internal volume.
  • the container includes a container body and a lid hingedly connected to the container body.
  • the packaging system further includes a dunnage panel received in the internal volume of the container.
  • the dunnage panel includes a plurality of discontinuous lines of weakness.
  • the disclosed packaging system includes a container having a container body defining an internal volume.
  • the container body includes a bottom wall, a plurality of container sidewalls connected to the bottom wall, a lid hingedly connected to the bottom wall, the lid configured to fold over an opening to the internal volume, and a container flap connected to the bottom wall, the container flap is hingedly foldable over an opening to the internal volume.
  • the packaging system further includes a dunnage panel received in the internal volume of the container, the dunnage panel having a plurality of discontinuous lines of weakness, the dunnage panel being removably insertable into the container.
  • the disclosed packaging system includes a container having a bottom wall, a plurality of container sidewalls connected to the bottom wall, and a lid hingedly connected to the bottom wall, the lid configured to fold over an opening to the internal volume.
  • the packaging system further includes a dunnage panel received in the internal volume of the container, the dunnage panel having a plurality of discontinuous lines of weakness, the dunnage panel being integral with the container
  • the disclosed container blanks may be assembled into containers.
  • dunnage blanks may be assembled into dunnage panels.
  • the disclosed system blanks may be assembled into the disclosed packaging systems.
  • the disclosed method for forming a packaging system includes folding a plurality container panels about a plurality of container fold lines to form a container body that defines an internal volume from a plurality of container sidewalls.
  • the method further includes folding a plurality of dunnage panels about a plurality of dunnage fold lines to form a dunnage panel.
  • the method further includes positioning the dunnage panel in the internal volume of the container, wherein the dunnage panel includes a dunnage wall having a plurality of discontinuous lines of weakness.
  • the disclosed method for packaging an article includes partially assembling a container by folding a plurality of container panels about a plurality of container fold lines to form a container body that defines an internal volume from a plurality of container sidewalls.
  • the method further includes partially assembling a dunnage panel by folding a plurality of panels about a plurality of dunnage fold lines.
  • the method further includes positioning the article on a dunnage wall of the dunnage panel, wherein the dunnage wall includes a plurality of discontinuous lines of weakness.
  • FIG. 1 is a top plan view of a first example of a blank used to form a container
  • FIG. 2 is a top plan view of a first example of a blank used to form a dunnage panel
  • FIG. 3 perspective view of a first example of a packaging system
  • FIG. 4 a is a perspective view of the first example of a container formed from the blank of FIG. 1 ;
  • FIG. 4 b is a perspective view of the first example of a dunnage panel formed from the blank of FIG. 2 ;
  • FIG. 5 is a top plan view of a second example of a blank used to form a container
  • FIG. 6 is a top plan view of a second example of a blank to form a dunnage panel
  • FIG. 7 a is a perspective view of the second example of a container formed from the blank of FIG. 5 ;
  • FIG. 7 b is a perspective view of the second example of a dunnage panel formed by the blank of FIG. 6 ;
  • FIG. 8 is a perspective view of the second example of the packaging system of FIG. 7 ;
  • FIG. 9 is a top plan view of a third example of a blank to form a container.
  • FIG. 10 is a perspective view of a third example of a packaging system
  • FIG. 11 is a perspective view of the third example of a packaging system.
  • FIG. 12 is a perspective view of the third example of a packaging system.
  • the packaging system 100 includes a container 110 and a dunnage panel 210 .
  • the packaging system 100 is used to secure and protect product (e.g., articles of product) contained by the packaging system 100 without the need for or use of supplemental packaging materials, such as plastic molds, packaging peanuts, bubble wrap, air-filled bags, and the like.
  • container 110 may be formed from a container blank 110 ′ that is assemblable into a container 110 .
  • Container blank 110 ′ includes a plurality of container panels 118 ′ that are defined by a plurality of container fold lines 122 and form a plurality of container sidewalls 118 upon assembly into container 110 .
  • the container blank 110 ′ further includes a bottom panel 120 ′ that forms a bottom wall 120 upon assembly into container 110 .
  • the plurality of container panels 118 ′ may be of various shapes and sizes to form a desired shape for a container 110 .
  • the plurality of container panels 118 ′ may include various tabulated portions and flaps configured to fold along the plurality of container fold lines 122 and tuck into mating slots to hold the container 110 in a desired shape.
  • the container 110 defines an internal volume 112 having at least one opening.
  • the container 110 includes a container body 114 .
  • the container body 114 is defined by a bottom wall 120 and a plurality of container sidewalls 118 connected to the bottom wall.
  • the container 110 is generally rectangular in shape.
  • the container 110 further includes a lid 116 hingedly connected to the container body 114 .
  • the lid 116 is hingedly foldable over an opening to the internal volume 112 .
  • the plurality of container sidewalls 118 , the lid 116 , and the bottom wall 120 of the container 110 are defined by a plurality of container fold lines 122 .
  • the plurality of container fold lines 122 may include creases, perforations, partial cuts, full cuts, or any other suitable means of forming a line of weakness for folding the container blank 110 ′ into a container 110 .
  • Blank 110 ′ is configured to fold along the plurality of container fold lines 122 to form the container 110 that may be configured to receive the dunnage panel 210 within the internal volume 112 of the container 110 .
  • the container blank 110 ′ may fold along the container fold lines 122 and be held together as a container 110 by any means of joining including an adhesive, tape, or by mechanical joining through tabs and slots of the container blank 110 ′.
  • the packaging system 100 includes a dunnage panel 210 formed by a dunnage blank 210 ′.
  • Dunnage panel 210 may be formed from dunnage blank 210 ′ that is assemblable into a dunnage panel 210 .
  • the dunnage blank 210 ′ includes a plurality of dunnage panels 214 ′ that are assemblable into a plurality of dunnage sidewalls 214 .
  • the dunnage blank 210 ′ further includes a central dunnage panel 212 ′ that is assemblable into a dunnage wall 212 .
  • the dunnage blank 210 ′ includes an envelope panel 220 ′ that is assemblable into an envelope wall 220 .
  • the envelope panel 220 ′ may include a tab panel 221 ′ that protrudes from the envelope panel 220 ′.
  • the dunnage blank 210 ′ includes a pocket panel 230 ′ hingedly connected to the central dunnage panel 212 ′.
  • the pocket panel 230 ′ is assemblable into a pocket wall 230 for further securing an article 700 on the dunnage panel 210 .
  • dunnage panel 210 is received (e.g., partially or fully) in the internal volume 112 of the container 110 .
  • the dunnage panel 210 may be positioned within the internal volume 112 of the container 110 such that it conforms to and holds an article 700 in place between the dunnage panel 210 and the container body 114 .
  • the lid 116 of the container 110 may abut the article 700 such that the article 700 is sandwiched between the lid 116 and the dunnage panel 210 , securing the article 700 in place.
  • the dunnage panel 210 includes a plurality of discontinuous lines of weakness 218 .
  • the plurality of discontinuous lines of weakness 218 include perforations.
  • the plurality of discontinuous lines of weakness 218 include cuts.
  • the plurality of discontinuous lines of weakness 218 include both perforations and cuts.
  • the plurality of discontinuous lines of weakness 218 are configured to partially fold, buckle, displace, bend, and otherwise change shape to match the shape and/or contour of and cradle around an article 700 placed on them.
  • the contour of the article 700 refers to a shape or profile of an exterior of the article 700 .
  • the plurality of discontinuous lines of weakness 218 enables the dunnage panel 210 to temporarily or resiliently bend or otherwise conform to the article 700 without creasing (e.g., propagating an elongated crease), damaging, or otherwise materially (e.g., permanently) altering the dunnage panel 210 . Additionally, the plurality of discontinuous lines of weakness 218 provides increased flexibility to the dunnage panel 210 and controlled deformation of the dunnage panel 210 . As such, the dunnage panel 210 is capable of flexing from a substantially planar configuration to a curved when loading (e.g., inserting) the article 700 between the dunnage panel 210 and the container 110 .
  • the plurality of discontinuous lines of weakness 218 may define a repeating pattern.
  • the plurality of discontinuous lines of weakness 218 may define a repeating honeycomb pattern or any other tessellated pattern for conforming locally to an article 700 .
  • the plurality of discontinuous lines of weakness 218 may define a non-uniform plurality that does not repeat.
  • the dunnage panel 210 includes a dunnage wall 212 and a plurality of dunnage sidewalls 214 .
  • the plurality of discontinuous lines of weakness 218 define a dunnage portion on the dunnage wall 212 .
  • the dunnage wall 212 is defined by a wall width W 1 , the dunnage portion defined by the plurality of discontinuous lines of weakness 218 , the dunnage portion having a dunnage width W 2 , and a perimeter portion having a perimeter width W 3 .
  • W 1 is greater than W 2 and W 3 .
  • the dunnage wall 212 is generally rectangular and includes a perimeter portion along all four sides with the dunnage portion being enclosed by and confined within the perimeter portion. The perimeter portion is continuous and thus free of any cuts, slits, or other lines of weakness.
  • the dunnage wall 212 and plurality of dunnage sidewalls 214 may be defined by a plurality of dunnage fold lines 224 .
  • the plurality of dunnage fold lines 224 may include creases, perforations, partial cuts, full cuts, or any other suitable means of forming a line of weakness for folding the dunnage blank 210 ′ into a dunnage panel 210 .
  • the plurality of dunnage sidewalls 214 may stay in the desired position by any means of joining including an adhesive, tape, or mechanical joining such as folds, tabs, and slots.
  • Dunnage panel 210 is configured to fold along the plurality of dunnage fold lines 224 to form the dunnage panel 210 that may be located within the internal volume 112 of the container 110 .
  • the plurality of dunnage sidewalls 214 may abut the plurality of container sidewalls 118 and rest on the container 110 bottom wall 120 when located in the container 110 such that the dunnage wall 212 is suspended within the internal volume 112 of the container 110 .
  • the position of the dunnage wall 212 within the internal volume 120 of the container 110 facilitates placement of the article 700 during transport.
  • the plurality of dunnage sidewalls 214 may be located around and connect to the dunnage wall 212 .
  • the plurality of dunnage sidewalls 214 may be of different sizes and configurations.
  • at least one of the plurality of dunnage sidewalls 214 is tapered.
  • at least two opposing sidewalls of the plurality of dunnage sidewalls 214 are tapered to suspend the dunnage wall 212 at an angle within the internal volume 120 of the container 110 .
  • the dunnage sidewalls 214 may act as risers for positioning the dunnage wall 212 at a desired location within the internal volume 120 .
  • the plurality of dunnage sidewalls 214 includes an envelope wall 220 hingedly foldable over the dunnage wall 212 .
  • the envelope wall 220 forms a pocket or envelope around an article 700 when the article 700 is located between the dunnage wall 212 and the envelope wall 220 .
  • the envelope wall 220 may include a tab 222 for opening and closing the envelope wall 220 .
  • the envelope wall 220 may be located between the article 700 and lid 116 of the container 110 when in an assembled configuration.
  • the plurality of dunnage sidewalls 214 includes a pocket wall 230 configured to form a pocket over the dunnage wall 212 .
  • the pocket wall 230 forms a pocket to confine an article 700 placed on the dunnage wall 212 .
  • the article 700 is nested between the dunnage wall 212 , the pocket wall 230 , and the envelope wall 220 for secure placement during shipping.
  • the dunnage panel 210 is integral with the container 110 such that it is a single, monolithic piece. Positioning of the dunnage panel 210 is achieved by folding the dunnage panel 210 into the internal volume 112 of the container 110 over one of the plurality of fold lines 122 .
  • the dunnage panel 210 is removably insertable into the container 110 such that they are two separate pieces that may be combined to form packaging system 100 . Positioning of the dunnage panel 210 is achieved by inserting the dunnage panel 210 into the internal volume 120 of the container 110 .
  • packaging system 300 includes a container 310 .
  • Container 310 FIG. 7 a
  • the container may be formed from a container blank 310 ′, FIG. 5 , that is assemblable into a container 310 .
  • the container may include a container body 314 defining an internal volume 312 .
  • the container body 314 includes a bottom wall 320 , a plurality of container sidewalls 318 connected to the bottom wall 320 , a lid 316 hingedly connected to the bottom wall 320 , the lid 316 configured to fold over an opening to the internal volume 312 and a container flap 322 .
  • the container blank 310 ′ may include a plurality of container panels 318 ′ that are defined by a plurality of container fold lines 324 and form a plurality of container sidewalls 318 upon assembly into container 310 .
  • the container blank 310 ′ further includes a bottom panel 320 ′ that forms a bottom wall 320 upon assembly into container 310 .
  • the plurality of container panels 318 ′ may be of various shapes and sizes to form a desired shape for a container 310 .
  • the plurality of container panels 318 ′ may include various tabulated portions and flaps configured to fold along the plurality of container fold lines 324 and tuck into mating slots to hold the container 310 in a desired shape.
  • the container blank 310 ′ may further include a flap panel 322 ′ that is assemblable into a container flap 322 connected to a bottom wall 320 of a container body 314 .
  • the container flap 322 is hingedly foldable over an opening to the internal volume 312 .
  • the container flap 322 is positioned between the lid 316 and the dunnage panel 410 when the container flap 322 is folded over an opening to the internal volume 312 of the container 310 .
  • the container flap 322 may be positioned at an angle within the container 310 such that it is positioned at the upper end of the container 310 at the back side of the container 310 , 322 a, near the lid 316 . Further, the container flap 322 is positioned at a lower depth of the container 310 on the front side, 322 b, to facilitate positioning at an angle in the interior volume 312 . The container flap 322 being positioned at an angle assists in maintaining the article 700 from touching the lid 316 or bottom wall 320 of the container 310 . Additionally, the positioning of container flap 322 at an angle limits or prevents the dunnage panel 410 from moving within the internal volume 312 and applies a downward force on the article 700 against the dunnage panel 410 .
  • the packaging system 300 further includes a dunnage panel 410 , FIG. 7 b , received in the internal volume 312 of the container 310 , the dunnage panel 410 having a plurality of discontinuous lines of weakness 418 .
  • the dunnage panel 410 is removably insertable into the container 310 .
  • the dunnage panel 410 is integral with the container 310 such that they are a single, monolithic piece.
  • the plurality of discontinuous lines of weakness 418 include perforations. In another example, the plurality of discontinuous lines of weakness 418 include cuts. In yet another example, the plurality of discontinuous lines of weakness 418 include both perforations and cuts.
  • the plurality of discontinuous lines of weakness 418 are configured to partially fold, buckle, displace, bend, and otherwise change shape to match the shape and/or contour of and cradle around an article 700 placed on them. Generally, the contour of the article 700 refers to a shape or profile of an exterior of the article 700 .
  • the plurality of discontinuous lines of weakness 418 enables the dunnage panel 410 to temporarily or resiliently bend or otherwise conform to the article 700 without creasing (e.g., propagating an elongated crease), damaging, or otherwise materially (e.g., permanently) altering the dunnage panel 410 . Additionally, the plurality of discontinuous lines of weakness 418 provides increased flexibility to the dunnage panel 410 and controlled deformation of the dunnage panel 410 . As such, the dunnage panel 410 is capable of flexing from a substantially planar configuration to a curved when loading (e.g., inserting) the article 700 between the dunnage panel 410 and the container 310 .
  • the plurality of discontinuous lines of weakness 418 may define a repeating pattern.
  • the plurality of discontinuous lines of weakness 418 may define a repeating honeycomb pattern or any other tessellated pattern for conforming locally to an article 700 .
  • the plurality of discontinuous lines of weakness 418 may define a non-uniform plurality that does not repeat.
  • the dunnage panel 410 may be formed from a dunnage blank 410 ′.
  • the dunnage blank 410 ′ includes a plurality of dunnage panels 414 ′ that are assembly into a plurality of dunnage sidewalls 414 .
  • the plurality of dunnage panels 414 ′ are connected to a central dunnage panel 412 ′ that is assemblable into a dunnage wall 412 .
  • the dunnage blank 410 ′ includes a plurality of dunnage panels 414 ′ including two opposing tapered sidewalls having a length approximately equal to Wi and two different opposing sidewalls of different widths to yield a dunnage panel 410 having a dunnage wall 412 that sits at an angle within the internal volume 312 of the container 310 , see FIG. 8 .
  • packaging system 500 includes a container 510 .
  • Container 510 may be formed from a container blank 510 ′, see FIG. 9 , that is assemblable into container 510 .
  • the container 510 includes a bottom wall 520 , a plurality of container sidewalls 518 connected to the bottom wall 520 , and a lid 516 hingedly connected to the bottom wall 520 .
  • the lid 516 is configured to fold over an opening to the internal volume 512 .
  • the container blank 510 ′ may include a plurality of container panels 518 ′ that are defined by a plurality of container fold lines 522 and form a plurality of container sidewalls 518 upon assembly into container 510 .
  • the container blank 510 ′ further includes a bottom panel 520 ′ that forms a bottom wall 520 upon assembly into container 510 .
  • the plurality of container panels 318 ′ may be of various shapes and sizes to form a desired shape for a container 510 .
  • the plurality of container panels 518 ′ may include various tabulated portions and flaps configured to fold along the plurality of container fold lines 522 and tuck into mating slots to hold the container 510 in a desired shape.
  • the plurality of container sidewalls 518 includes at least one container tab 518 a.
  • Container tap 518 a is hingedly connected to the container lid 516 and may fold either inward toward the internal volume 512 , see FIG. 10 , or up away from the internal volume 512 , see FIGS. 11 and 12 .
  • the container tab 518 a facilitates maintaining the container 510 in a closed configuration for shipping.
  • the packaging system 500 further includes a dunnage panel 610 received in the internal volume 512 of the container 510 .
  • the dunnage panel 610 is formed by a dunnage blank 610 ′ that is assemblable into the dunnage panel 610 .
  • the dunnage blank 612 includes a plurality of dunnage panels 614 ′ that are assemblable into a plurality of dunnage sidewalls 614 .
  • the dunnage blank 610 ′ further includes a central dunnage panel 612 ′ that is assemblable into a dunnage wall 612 .
  • the dunnage panel 610 has a plurality of discontinuous lines of weakness 618 .
  • the dunnage panel 610 is integral with the container 510 . Such that they are a single monolithic piece.
  • the dunnage panel 610 is a separate piece that it removably insertable into the internal volume 512 of the container 510 .
  • the dunnage panel 610 is configured to receive an article 700 such that the article 700 is sandwiched between the lid 516 and the dunnage panel 610 .
  • the plurality of discontinuous lines of weakness 618 include perforations. In another example, the plurality of discontinuous lines of weakness 618 include cuts. In yet another example, the plurality of discontinuous lines of weakness 618 include both perforations and cuts.
  • the plurality of discontinuous lines of weakness 618 are configured to partially fold, buckle, displace, bend, and otherwise change shape to match the shape and/or contour of and cradle around an article 700 placed on them. Generally, the contour of the article 700 refers to a shape or profile of an exterior of the article 700 .
  • the plurality of discontinuous lines of weakness 618 enables the dunnage panel 610 to temporarily or resiliently bend or otherwise conform to the article 700 without creasing (e.g., propagating an elongated crease), damaging, or otherwise materially (e.g., permanently) altering the dunnage panel 610 . Additionally, the plurality of discontinuous lines of weakness 618 provides increased flexibility to the dunnage panel 610 and controlled deformation of the dunnage panel 610 . As such, the dunnage panel 610 is capable of flexing from a substantially planar configuration to a curved when loading (e.g., inserting) the article 700 between the dunnage panel 610 and the container 510 .
  • the plurality of discontinuous lines of weakness 618 may define a repeating pattern.
  • the plurality of discontinuous lines of weakness 618 may define a repeating honeycomb pattern or any other tessellated pattern for conforming locally to an article 700 .
  • the plurality of discontinuous lines of weakness 618 may define a non-uniform plurality that does not repeat.
  • each component of the disclosed packaging systems 100 , 300 , and 500 may be of a cellulosic material.
  • the container 110 may be made from any suitable packaging material, such as a cellulosic material.
  • suitable packaging material include paperboard, corrugated board, cardboard, plastic, combinations thereof and any other suitable material known to those skilled in the art and guided by the teachings provided herein.
  • Suitable paperboard materials may be, for example, a solid bleached sulfate (SBS) substrate, an uncoated natural kraft (UNC) substrate, or a coated natural kraft (CNK) substrate.
  • the container 110 may be formed from virgin fibers, recycled fibers, or combinations thereof.
  • the containers 110 , 310 and 510 may be recyclable.
  • the dunnage panels 210 , 410 , and 610 may be made from any suitable packaging material, such as a cellulosic material.
  • suitable packaging material include paperboard, corrugated board, cardboard, plastic, combinations thereof and any other suitable material known to those skilled in the art and guided by the teachings provided herein.
  • Suitable paperboard materials may be, for example, a solid bleached sulfate (SBS) substrate, an uncoated natural kraft (UNC) substrate, or a coated natural kraft (CNK) substrate.
  • SBS solid bleached sulfate
  • UNC uncoated natural kraft
  • CNK coated natural kraft
  • the dunnage panel 210 may be formed from virgin fibers, recycled fibers, or combinations thereof.
  • the dunnage panels 210 , 410 and 610 may be recyclable.
  • the method 800 includes folding 810 a plurality container panels 118 ′ about a plurality of container fold lines 122 to form a container body 114 .
  • the container body 114 defines an internal volume 112 from a plurality of container sidewalls 118 .
  • the method 800 further includes folding 820 a plurality of dunnage panels 214 ′ about a plurality of dunnage fold lines 224 to form a dunnage panel 210 .
  • the dunnage panel 210 comprises a dunnage wall 212 having a plurality of discontinuous lines of weakness 218 .
  • the method 800 further includes positioning 830 the dunnage panel 210 in the internal volume 112 of the container 110 .
  • the positioning 830 includes inserting the dunnage panel 210 into the internal volume 112 of the container.
  • the positioning 830 includes folding the dunnage panel 210 about one of the plurality of container fold lines 122 such that most of the dunnage wall 212 is suspended in the internal volume 112 of the container 110 .
  • the method 900 includes partially assembling a container 110 by folding a plurality of container panels 118 ′ of a container blank 110 ′ about a plurality of container fold lines 122 to form a container body 114 that defines an internal volume 112 from a plurality of container sidewalls 118 .
  • the method 900 further includes partially assembling 920 a dunnage panel 210 by folding a plurality of panels 214 ′ of a dunnage blank 210 ′ about a plurality of dunnage fold lines 224 .
  • the method 900 further includes positioning 930 the article 700 on a dunnage wall 212 of the dunnage panel 210 , wherein the dunnage wall 212 comprises a plurality of discontinuous lines of weakness 218 .
  • first,” “second,” “third,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
  • the phrase “at least one of,” when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed.
  • “at least one of item A, item B, and item C” may include, without limitation, item A or item A and item B. This example also may include item A, item B, and item C, or item B and item C.
  • “at least one of” may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; and other suitable combinations.
  • Coupled refers to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated with one another.
  • the elements may be associated directly or indirectly.
  • element A may be directly associated with element B.
  • element A may be indirectly associated with element B, for example, via another element C. It will be understood that not all associations among the various disclosed elements are necessarily represented. Accordingly, couplings other than those depicted in the figures may also exist.
  • the term “substantially” refers to a condition that is essentially the stated condition that performs the desired function or achieves the desired result.
  • the term “approximately” refers to a condition that is close to the stated condition, but not exactly, the stated condition that still performs the desired function or achieves the desired result. However, use of the terms “substantially” and “approximately” do not exclude a condition that is exactly the stated condition.
  • FIGS. 1 - 12 need be included in every example and not all elements described herein are necessarily depicted in each illustrative example. Unless otherwise explicitly stated, the schematic illustrations of the examples depicted in FIGS. 1 - 12 are not meant to imply structural limitations with respect to the illustrative example. Rather, although one illustrative structure is indicated, it is to be understood that the structure may be modified when appropriate. Additionally, modifications, additions and/or omissions may be made to the illustrated structure.
  • references throughout the present specification to features, advantages, or similar language used herein do not imply that all of the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar language used throughout the present disclosure may, but do not necessarily, refer to the same example.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cartons (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Closures For Containers (AREA)
US17/892,469 2021-08-23 2022-08-22 Packaging systems and associated containers, dunnage panels, blanks, and methods Pending US20230053426A1 (en)

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US202163235983P 2021-08-23 2021-08-23
US17/892,469 US20230053426A1 (en) 2021-08-23 2022-08-22 Packaging systems and associated containers, dunnage panels, blanks, and methods

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