Product containers, packaging systems, packaging methods, and blanks and methods for making product containers

Abstract

A product container includes a container body that defines an internal volume. The product container also includes a first dunnage panel located in the internal volume of the container body. The first dunnage panel includes a plurality of discontinuous lines of weakness. The product container further includes a second dunnage panel located in the internal volume of the container body. The first dunnage panel and the second dunnage panel are substantially aligned and are laterally spaced apart. The first dunnage panel and the second dunnage panel are configured to secure an article therebetween.

What is claimed is: 
     
         1 . A product container comprising:
 a container body that defines an internal volume;   a first dunnage panel located in the internal volume of the container body and comprising a plurality of discontinuous lines of weakness; and   a second dunnage panel located in the internal volume of the container body,   wherein the first dunnage panel and the second dunnage panel are substantially aligned and laterally spaced apart to secure an article therebetween.   
     
     
         2 . The product container of  claim 1 , wherein:
 the first dunnage panel is coupled to the container body; and   the second dunnage panel is coupled to the container body.   
     
     
         3 . The product container of  claim 1 , further comprising a gap formed between the first dunnage panel and the second dunnage panel,
 wherein the gap has a width dimension that is less than or equal to a thickness dimension of the article.   
     
     
         4 . The product container of  claim 1 , wherein the plurality of discontinuous lines of weakness is configured to locally deform a portion of the first dunnage panel to a contour of a portion of the article. 
     
     
         5 . The product container of  claim 1 , wherein the second dunnage panel comprises a plurality of second discontinuous lines of weakness. 
     
     
         6 . The product container of  claim 5 , wherein the plurality of second discontinuous lines of weakness is configured to locally deform a portion of the second dunnage panel to a contour of a second portion of the article. 
     
     
         7 . The product container of  claim 1 , wherein:
 the container body comprises a plurality of sidewalls;   the first dunnage panel extends between an opposed pair of the plurality of sidewalls; and   the second dunnage panel extends between the opposed pair of the plurality of sidewalls.   
     
     
         8 . The product container of  claim 7 , wherein:
 the first dunnage panel is coupled to one of the opposed pair of the plurality of sidewalls; and   the second dunnage panel is coupled to one of the opposed pair of the plurality of sidewalls.   
     
     
         9 . The product container of  claim 7 , further comprising a first brace panel coupled to the first dunnage pane, wherein the first brace panel inhibits movement of the first dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         10 . The product container of  claim 9 , further comprising a second brace panel coupled to the second dunnage panel, wherein the second brace panel inhibits movement of the second dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         11 . The product container of  claim 9 , further comprising a second brace panel coupled to the first dunnage panel, wherein the second brace panel inhibits movement of the first dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         12 . The product container of  claim 1 , further comprising a lid hingedly connected to the container body,
 wherein the lid urges the second dunnage panel toward the first dunnage panel.   
     
     
         13 . The product container of  claim 1 , wherein the plurality of discontinuous lines of weakness comprises perforations. 
     
     
         14 . The product container of  claim 1 , wherein the plurality of discontinuous lines of weakness comprises cuts. 
     
     
         15 . The product container of  claim 1 , wherein the plurality of discontinuous lines of weakness comprises perforations and cuts. 
     
     
         16 . The product container of  claim 1 , wherein the plurality of discontinuous lines of weakness defines a repeating pattern. 
     
     
         17 . The product container of  claim 1 , wherein the container body comprises a cellulosic material. 
     
     
         18 . The product container of  claim 1 , wherein the first dunnage panel comprises a cellulosic material. 
     
     
         19 . The product container of  claim 1 , wherein the second dunnage panel comprises a cellulosic material. 
     
     
         20 . The product container of  claim 1 , wherein each one of the container body, the first dunnage panel, and the second dunnage panel is made of a recyclable material. 
     
     
         21 . The product container of  claim 1 , wherein the container body, the first dunnage panel, and the second dunnage panel are formed from a one-piece blank. 
     
     
         22 . A blank for forming the product container of  claim 1 . 
     
     
         23 . A product container comprising:
 a container body that defines an internal volume;   a first dunnage panel located in the internal volume of the container body and comprising a plurality of discontinuous lines of weakness; and   a second dunnage panel located in the internal volume of the container body and comprising a plurality of second discontinuous lines of weakness,   wherein the first dunnage panel and the second dunnage panel are substantially aligned and laterally spaced apart to secure an article therebetween.   
     
     
         24 . The product container of  claim 23 , further comprising a gap formed between the first dunnage panel and the second dunnage panel,
 wherein the gap has a width dimension that is less than or equal to a thickness dimension of the article.   
     
     
         25 . The product container of  claim 23 , wherein:
 the plurality of discontinuous lines of weakness is configured to locally deform a portion of the first dunnage panel to a contour of a portion of the article; and   the plurality of second discontinuous lines of weakness is configured to locally deform a portion of the second dunnage panel to a contour of a second portion of the article.   
     
     
         26 . The product container of  claim 25 , wherein the plurality of discontinuous lines of weakness and the plurality of second discontinuous lines of weakness comprise at least one of perforations and cuts. 
     
     
         27 . The product container of  claim 23 , wherein:
 the plurality of discontinuous lines of weakness defines a repeating pattern; and   the plurality of second discontinuous lines of weakness defines a repeating second pattern.   
     
     
         28 . The product container of  claim 23 , wherein:
 the container body comprises a plurality of sidewalls;   the first dunnage panel extends between an opposed pair of the plurality of sidewalls; and   the second dunnage panel extends between the opposed pair of the plurality of sidewalls.   
     
     
         29 . The product container of  claim 28 , further comprising a first brace panel coupled to the first dunnage panel, wherein the first brace panel inhibits movement of the first dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         30 . The product container of  claim 29 , further comprising a second brace panel coupled to the second dunnage panel, wherein the second brace panel inhibits movement of the second dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         31 . The product container of  claim 29 , further comprising a second brace panel coupled to the first dunnage panel, wherein the second brace panel inhibits movement of the first dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         32 . The product container of  claim 23 , wherein the container body, the first dunnage panel, and the second dunnage panel are formed from a one-piece blank 
     
     
         33 . A blank for forming the product container of  claim 23 . 
     
     
         34 . A packaging system comprising:
 a product container comprising a container body that defines an internal volume of the product container;   a first dunnage panel located in the internal volume of the product container and comprising a plurality of discontinuous lines of weakness;   a second dunnage panel located in the internal volume of the product container,   wherein the first dunnage panel and the second dunnage panel are substantially aligned and laterally spaced apart; and   an article located in the internal volume of the product container and secured between the first dunnage panel and the second dunnage panel.   
     
     
         35 . The packaging system of  claim 34 , wherein:
 the product container further comprises a gap formed between the first dunnage panel and the second dunnage panel;   the article has a thickness dimension; and   the gap has a width dimension that is less than or equal to the thickness dimension of the article.   
     
     
         36 . The packaging system of  claim 34 , wherein the plurality of discontinuous lines of weakness is configured to locally deform a portion of the first dunnage panel to a contour of a portion of the article. 
     
     
         37 . The packaging system of  claim 34 , wherein the plurality of discontinuous lines of weakness defines a repeating pattern. 
     
     
         38 . The packaging system of  claim 34 , wherein the second dunnage panel comprises a plurality of second discontinuous lines of weakness. 
     
     
         39 . The packaging system of  claim 38 , wherein the plurality of second discontinuous lines of weakness is configured to locally deform a portion of the second dunnage panel to a contour of a second portion of the article. 
     
     
         40 . The packaging system of  claim 38 , wherein the plurality of second discontinuous lines of weakness defines a repeating second pattern. 
     
     
         41 . The packaging system of  claim 38 , wherein the plurality of discontinuous lines of weakness and the plurality of second discontinuous lines of weakness comprise at least one of perforations and cuts. 
     
     
         42 . The packaging system of  claim 34 , wherein:
 the container body comprises a plurality of sidewalls;   the first dunnage panel extends between an opposed pair of the plurality of sidewalls; and   the second dunnage panel extends between the opposed pair of the plurality of sidewalls.   
     
     
         43 . The packaging system of  claim 42 , further comprising a first brace panel coupled to the first dunnage panel, wherein the first brace panel inhibits movement of the first dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         44 . The packaging system of  claim 43 , further comprising a second brace panel coupled to the second dunnage panel, wherein the second brace panel inhibits movement of the second dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         45 . The packaging system of  claim 43 , further comprising a second brace panel coupled to the first dunnage panel, wherein the second brace panel inhibits movement of the first dunnage panel relative to the opposed pair of the plurality of sidewalls. 
     
     
         46 . The packaging system of  claim 34 , wherein the container body, the first dunnage panel, and the second dunnage panel are formed from a one-piece blank. 
     
     
         47 . A blank for forming the container body, the first dunnage panel, and the second dunnage 
     
     
         34 . claim  34 . 
     
     
         48 . A blank for forming a product container, the blank comprising:
 a series of panels connected along a plurality of fold lines,   wherein:
 a first one of the series of panels comprises a plurality of discontinuous lines of weakness; and 
 the series of panels is foldable about the plurality of fold lines to form:
 a container body that defines an internal volume from a plurality of the series of panels; 
 a first dunnage panel located in the internal volume of the container body from the first one of the series of panels; and 
 a second dunnage panel located in the internal volume of the container body from a second one of the series of panels, 
 wherein the first dunnage panel and the second dunnage panel are substantially aligned and laterally spaced apart. 
 
   
     
     
         49 . The blank of  claim 48 , wherein the second one of the series of panels comprises a plurality of second discontinuous lines of weakness. 
     
     
         50 . A method for forming a product container from a blank, the method comprising steps of:
 forming a plurality of discontinuous lines of weakness in a first one of a series of panels connected along a plurality of fold lines; and   folding the series of panels about the plurality of fold lines to form:
 a container body that defines an internal volume from a plurality of the series of panels; 
 a first dunnage panel located in the internal volume of the container body from the first one of the series of panels; and 
 a second dunnage panel located in the internal volume of the container body from a second one of the series of panels, 
 wherein the first dunnage panel and the second dunnage panel are substantially aligned and laterally spaced apart. 
   
     
     
         51 . The method of  claim 50 , further comprising forming a plurality of second discontinuous lines of weakness in the second one of the series of panels. 
     
     
         52 . A method for packaging an article, the method comprising steps of:
 partially assembling a product container by folding a series of panels of a blank along a plurality of fold lines provided therein to form:
 a container body that defines an internal volume; 
 a first dunnage panel located in the internal volume of the container body and comprising a plurality of discontinuous lines of weakness; and 
 a second dunnage panel located in the internal volume of the container body, 
 wherein the first dunnage panel and the second dunnage panel are substantially aligned and laterally spaced apart; and 
   securing the article between the first dunnage panel and the second dunnage panel.