Patent Application
20230053426
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. However, such supplemental packaging materials are often not recyclable and/or product large amounts of material waste.
Moreover, for cost and environmental considerations, 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.
Accordingly, those skilled in the art continue with research and development efforts in the field of product packaging.
Disclosed are various packaging systems.
In one example, 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.
In another example, 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.
In another example, 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
Also disclosed are various container blanks. The disclosed container blanks may be assembled into containers.
Also disclosed are various dunnage blanks. The dunnage blanks may be assembled into dunnage panels.
Also disclosed are various system blanks. The disclosed system blanks may be assembled into the disclosed packaging systems.
Also disclosed are methods for forming a packaging system from a container blank and a dunnage blank.
In one example, 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.
Also disclosed are methods for packaging an article.
In one example, 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.
Other examples of the disclosed packaging systems and associated containers, dunnage panels, blanks, and methods will become apparent from the following detailed description, the accompanying drawings and the appended claims
Referring generally to
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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′.
Referring to
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In one example, 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.
Referring to
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. For example, 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. In another example, 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 W1, the dunnage portion defined by the plurality of discontinuous lines of weakness 218, the dunnage portion having a dunnage width W2, and a perimeter portion having a perimeter width W3. In one example, W1 is greater than W2 and W3. In another example, 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. Upon folding along the dunnage fold lines 224, 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. In one example, at least one of the plurality of dunnage sidewalls 214 is tapered. In another example, 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. Further, the dunnage sidewalls 214 may act as risers for positioning the dunnage wall 212 at a desired location within the internal volume 120.
In one example, referring to
Still referring to
In one example, 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.
In another example, 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.
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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. In one example, the container flap 322 is hingedly foldable over an opening to the internal volume 312. In one example, 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.
Referring to
The packaging system 300 further includes a dunnage panel 410,
In one example, 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. For example, 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. In another example, the plurality of discontinuous lines of weakness 418 may define a non-uniform plurality that does not repeat.
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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. In one example, the dunnage panel 610 is integral with the container 510. Such that they are a single monolithic piece. In another example, 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.
In one example, 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. For example, 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. In another example, 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. Specifically, the container 110 may be made from any suitable packaging material, such as a cellulosic material. Examples of 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. Examples of 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 dunnage panel 210 may be formed from virgin fibers, recycled fibers, or combinations thereof. The dunnage panels 210, 410 and 610 may be recyclable.
Also disclosed is a method 800 for forming a packaging system 100 from a container blank 110′ and a dunnage blank 210′, as shown and described herein. 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. In one example, the positioning 830 includes inserting the dunnage panel 210 into the internal volume 112 of the container. In another example, when the dunnage panel 210 is integral with the container 110, 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.
Also disclosed is a method 900 for packaging an article 700. 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.
Unless otherwise indicated, the terms “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.
As used herein, 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. For example, “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. In other examples, “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.
For the purpose of this disclosure, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated with one another. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, 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.
As used herein, the term “substantially” refers to a condition that is essentially the stated condition that performs the desired function or achieves the desired result. As used herein, 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.
Those skilled in the art will appreciate that not all elements described and illustrated in
Further, 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.
The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. One skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, although various examples of the disclosed packaging system, including the container, the container blank, the dunnage panel, and the dunnage blank, have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.
The present application is a nonprovisional patent application which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/235-983, filed 23 Aug. 2021, the entire contents of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63235983 | Aug 2021 | US |
