F IELD

[0001] The present disclosure relates to product packaging and, more particularly, to product containers that are made from recyclable materials and that include dunnage panels for securing product, methods for packaging product, and blanks and methods for making product containers.

B A C K GRO UND

[0002] 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.

[0003] 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.

[0004] Accordingly, those skilled in the art continue with research and development efforts in the field of product packaging.

S UMMARY

[0005] Disclosed are a product container, a packaging system, a blank for making a product container, a method for making a product container, and a method for packaging product. The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure. [0006] In an example, the disclosed 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 to secure an article therebetween.

[0007] In another examples, the disclosed 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 second dunnage panel includes a plurality of second discontinuous lines of weakness. The first dunnage panel and the second dunnage panel are substantially aligned and are laterally spaced apart to secure an article therebetween.

[0008] In an example, the disclosed packaging system includes a container including a container body that defines an internal volume of the container. The packaging system also includes a first dunnage panel located in the internal volume of the container. The first dunnage panel includes a plurality of discontinuous lines of weakness. The packaging system further includes a second dunnage panel located in the internal volume of the container. The first dunnage panel and the second dunnage panel are substantially aligned and are laterally spaced apart. The packaging system additionally includes an article located in the internal volume of the container and secured between the first dunnage panel and the second dunnage panel.

[0009] In an example, the disclosed blank includes a series of panels connected along a plurality of fold lines. A first one of the series of panels includes a plurality of discontinuous lines of weakness. 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. The first dunnage panel and the second dunnage panel are substantially aligned and are laterally spaced apart.

[0010] In an example, the disclosed method for forming a product container includes steps of: (1) 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 (2) 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. The first dunnage panel and the second dunnage panel are substantially aligned and are laterally spaced apart.

[0011] In an example, the disclosed method for packaging product includes 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 including a plurality of discontinuous lines of weakness, and 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 method also includes a step of securing an article between the first dunnage panel and the second dunnage panel.

[0012] Other examples of the disclosed product container, packaging system, blank, and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

B RIEF DE S C RIP T I ON OF THE DRAW ING S

[0013] Fig. l is a top plan view of a first example of a blank used to form a product container;

[0014] Fig. 2 is a perspective view of a first example of the product container;

[0015] Fig. 3 is a perspective view of a portion of the first example of the product container;

[0016] Fig. 4 is a perspective view of the first example of the product container; [0017] Fig. 5 is a perspective view of the first example of the product container, shown in a partially assembled condition;

[0018] Fig. 6 is a top plan view of a second example of the blank used to form the product container;

[0019] Fig. 7 is a perspective view of a second example of the product container;

[0020] Fig. 8 is a perspective view of the second example of the product container;

[0021] Fig. 9 is a perspective view of the second example of the product container, shown in a partially assembled condition;

[0022] Fig. 10 is a perspective view of the second example of the product container; and

[0023] Fig. 11 is a perspective view of an example of a dunnage panel of the product container.

D E TAILED DE S C RIP T ION

[0024] Referring generally to Figs. 1-11, by way of examples, the present disclosure is directed to a product container 110, a blank 300 for forming the product container 110, and a packaging system 100 that uses the product container 110 to securely contain product. The product container 110 is used to secure and protect product (e.g., articles of product) contained by the product container 110 without the need for or use of supplemental packaging materials, such as plastic molds, packaging peanuts, bubble wrap, air-filled bags, and the like.

[0025] Fig. 1 illustrates a first example of the blank 300 for forming a first example of the product container 110. Figs. 2-5 illustrate the first example of the product container 110 used for the packaging system 100. Fig. 6 illustrates a second example of the blank 300 for forming s second example of the product container 110. Figs. 7-10 illustrate the second example of the product container 110 used for the packaging system 100. Fig. 11 illustrates an example of a dunnage panel (e.g., first dunnage panel 210 and/or second dunnage panel 212) of the product container 110. [0026] As illustrated in Figs. 2-5 and 7-10, in one or more examples, the product container 110 includes a container body 114. The container body 114 defines an internal volume 112. The product container 110 also includes a first dunnage panel 210. The first dunnage panel 210 is located in the internal volume 112 of the container body 114. The product container 110 further includes a second dunnage panel 212. The second dunnage panel 212 is located in the internal volume 112 of the container body 114. The first dunnage panel 210 and the second dunnage panel 212 are substantially aligned with each other and are laterally spaced apart from each other to secure an article 102 therebetween (e.g., as shown in Figs. 3, 7 and 8). For example, the article 102 is sandwiched between the first dunnage panel 210 and the second dunnage panel 212.

[0027] In one or more examples, first dunnage panel 210 and the second dunnage panel 212 extend in generally (e.g., at least approximately) the same direction and run generally (e.g., at least approximately) alongside each other. In one or more examples, first dunnage panel 210 and the second dunnage panel 212 are arranged next to each other. In one or more examples, first dunnage panel 210 and the second dunnage panel 212 are generally parallel to and face each other.

[0028] Referring to Figs. 5, 7 and 9, in one or more examples, the first dunnage panel 210 includes a plurality of discontinuous lines of weakness 218. In one or more examples, the second dunnage panel 212 includes a plurality of second discontinuous lines of weakness 220. In one or more examples, the first dunnage panel 210 includes the plurality of discontinuous lines of weakness 218 and the second dunnage panel 212 includes the plurality of second discontinuous lines of weakness 220. In other words, both dunnage panels include a plurality of discontinuous lines of weakness. Alternatively, in other examples, the first dunnage panel 210 may lack (e.g., omit or not include) the plurality of discontinuous lines of weakness 218 or the second dunnage panel 212 may lack (e.g., omit or not include) the plurality of second discontinuous lines of weakness 220. In other words, at least one of the dunnage panels includes the plurality of discontinuous lines of weakness.

[0029] Referring now to Figs. 3 and 8, in one or more examples, the plurality of discontinuous lines of weakness 218 is configured to locally deform a portion of the first dunnage panel 210 to a contour of a portion of the article 102. Generally, the contour of the article 102 refers to a shape or profile of an exterior of the article 102. As such, the plurality of discontinuous lines of weakness 218 enables the first dunnage panel 210 to temporarily or resiliently bend or otherwise conform to the article 102 without creasing (e.g., propagating an elongated crease), damaging, or otherwise materially (e.g., permanently) altering the first dunnage panel 210. Additionally, the plurality of discontinuous lines of weakness 218 provides increased flexibility to the first dunnage panel 210 and controlled deformation of the first dunnage panel 210. As such, the first dunnage panel 210 is capable of flexing from a substantially planar configuration (e.g., as shown in Figs. 2, 4 and 7) to a curved configuration (e.g., as shown in Figs. 3 and 8) when loading (e.g., inserting) the article 102 between the first dunnage panel 210 and the second dunnage panel 212.

[0030] Similarly, in one or more examples, the plurality of second discontinuous lines of weakness 220 is configured to locally deform a portion of the second dunnage panel 212 to a contour of a second portion of the article 102. As such, the plurality of second discontinuous lines of weakness 220 enables the second dunnage panel 212 to temporarily or resiliently bend or otherwise conform to the article 102 without creasing (e.g., propagating an elongated crease), damaging, or otherwise materially (e.g., permanently) altering the second dunnage panel 212. Additionally, the plurality of second discontinuous lines of weakness 220 provides increased flexibility to the second dunnage panel 212 and controlled deformation of the second dunnage panel 212. As such, the second dunnage panel 212 is capable of flexing from a substantially planar configuration (e.g., as shown in Figs. 2, 4 and 7) to a curved configuration (e.g., as shown in Figs. 3 and 8) when loading (e.g., inserting) the article 102 between the first dunnage panel 210 and the second dunnage panel 212.

[0031] Referring still to Figs. 3 and 8, in one or more examples, the product container 110 includes a gap 124 formed between the first dunnage panel 210 and the second dunnage panel 212. The gap 124 has a width dimension 126. The width dimension 126 of the gap 124 refers to a substantially linear dimension measured between opposing surfaces (e.g., faces) of the first dunnage panel 210 and the second dunnage panel 212. The article 102 has a thickness dimension 104. The thickness dimension 104 of the article 102 refers to one dimension (e.g., the thickness or height) of the article 102. The width dimension 126 of the gap 124 is less than or equal to the thickness dimension 104 of the article 102. As such, the article 102 is held tightly between (e.g., clamped or compressed between) the first dunnage panel 210 and the second dunnage panel 212 such that the article 102 is prevented from moving relative to the product container 110.

[0032] In one or more examples, the width dimension 126 of the gap 124 between the first dunnage panel 210 and the second dunnage panel 212 varies (e.g., the width dimension 126 is not constant). For example, prior to loading or otherwise positioning the article 102 between the first dunnage panel 210 and the second dunnage panel 212, the width dimension 126 of the gap 124 is less than the thickness dimension 104 of the article 102. With the article 102 loaded or otherwise positioned between the first dunnage panel 210 and the second dunnage panel 212, the width dimension 126 of a portion of the gap 124, for example, proximate (e.g., at or near) the article 102, is substantially equal to the thickness dimension 104 of the article 102 and the width dimension 126 of another portion of the gap 124, for example, spaced away from the article 102, is less than the thickness dimension 104 of the article 102.

[0033] In one or more examples, the plurality of discontinuous lines of weakness 218 enables the first dunnage panel 210 to flex from the substantially planar configuration (e.g., as shown in Figs. 3, 5 and 9) to the curved configuration (e.g., as shown in Figs. 4 and 10) to increase the width dimension 126 of a portion of the gap 124. In one or more examples, the plurality of second discontinuous lines of weakness 220 (e.g., when present) enables the second dunnage panel 212 to flex from the substantially planar configuration (e.g., as shown in Figs. 3, 5 and 9) to the curved configuration (e.g., as shown in Figs. 4 and 10) to increase the width dimension 126 of a portion of the gap 124.

[0034] Referring now to Figs. 2-5 and 7-10, in one or more examples, the first dunnage panel 210 is coupled to the container body 114. In one or more examples, the second dunnage panel 212 is coupled to the container body 114. In one or more examples, the first dunnage panel 210 is integral to the container body 114. In one or more examples, the second dunnage panel 212 is integral to the container body 114.

[0035] In one or more examples, the container body 114 includes a plurality of sidewalls 118. For example, the container body 114 includes four sidewalls 118, identified individually as a first sidewall 128, a second sidewall 130, a third sidewall 132, and a fourth sidewall 134. The first sidewall 128 and the second sidewall 130 are opposite and generally parallel to each other. The third sidewall 132 and the fourth sidewall 134 are generally perpendicular to and extend between the first sidewall 128 and the second sidewall 130. The third sidewall 132 and the fourth sidewall 134 are opposite and generally parallel to each other.

[0036] Referring to Figs. 2-5, in one or more examples, the container body 114 also includes a first end wall 136 and a second end wall 138. The first end wall 136 and the second end wall 138 are shown positioned in an open condition or open state in Figs. 2-5.

[0037] In one or more examples, in a closed condition or closed state, the first end wall 136 is generally perpendicular to and extends between the plurality of sidewalls 118 (e.g., the first sidewall 128, the second sidewall 130, the third sidewall 132, and the fourth sidewall 134). In one or more examples, the first end wall 136 is coupled to one of the plurality of sidewalls 118 (e.g., the third sidewall 132). In one or more examples, the first end wall 136 is integral to (e.g., extends from) one of the plurality of sidewalls 118 (e.g., the third sidewall 132). The first end wall 136 is hingedly movable (e.g., foldable) relative to the one of the plurality of sidewalls 118 (e.g., the third sidewall 132) to which it is coupled to enclose a first end of the container body 114 (e.g., to open and close the product container 110).

[0038] In one or more examples, in the closed condition or closed state, the second end wall 138 is generally perpendicular to and extends between the plurality of sidewalls 118 (e.g., the first sidewall 128, the second sidewall 130, the third sidewall 132, and the fourth sidewall 134). The first end wall 136 and the second end wall 138 are opposite and generally parallel to each other. In one or more examples, the second end wall 138 is coupled to one of the plurality of sidewalls 118 (e.g., the fourth sidewall 134). In one or more examples, the second end wall 138 is integral to (e.g., extends from) one of the plurality of sidewalls 118 (e.g., the fourth sidewall 134). The second end wall 138 is hingedly movable (e.g., foldable) relative to the one of the plurality of sidewalls 118 (e.g., the fourth sidewall 134) to which it is coupled to enclose a second end of the container body 114 (e.g., to open and close the product container 110).

[0039] Referring to Figs. 7-10, in one or more examples, the container body 114 includes a bottom wall 140. In one or more examples, the bottom wall 140 is generally perpendicular to and extends between the plurality of sidewalls 118 (e.g., the first sidewall 128, the second sidewall 130, the third sidewall 132, and the fourth sidewall 134). In one or more examples, the bottom wall 140 is coupled to each of the plurality of sidewalls 118 (e.g., the first sidewall 128, the second sidewall 130, the third sidewall 132, and the fourth sidewall 134).

[0040] In one or more examples, the container body 114 also includes a lid 116. The lid 116 is shown in an open condition or open state in Figs. 7-9. The lid 116 is shown in a closed condition or closed state in Fig. 10.

[0041] In one or more examples, the lid 116 is coupled to one of the plurality of sidewalls 118 (e.g., the second sidewall 130). In one or more examples, the lid 116 is integral to (e.g., extends from) one of the plurality of sidewalls 118 (e.g., the second sidewall 130). The lid 116 is hingedly movable (e.g., foldable) relative to the one of the plurality of sidewalls 118 (e.g., the second sidewall 130) to which it is coupled to enclose the container body 114 (e.g., to open and close the product container 110). In the closed condition or closed state, the lid 116 forms a top wall 142 of the container body 114 (e.g., as shown in Fig. 10). The top wall 142 is generally perpendicular to and extends between the plurality of sidewalls 118 (e.g., the first sidewall 128, the second sidewall 130, the third sidewall 132, and the fourth sidewall 134). The bottom wall 140 and the top wall 142 are opposite and generally parallel to each other.

[0042] Referring again to Figs. 2-5 and 7-10, in one or more examples, the first dunnage panel 210 is generally perpendicular to and extends between an opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128 and the second sidewall 130). The second dunnage panel 212 is generally perpendicular to and extends between the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128 and the second sidewall 130). However, in other examples, the first dunnage panel 210 and/or the second dunnage panel 212 may be oriented at an oblique angle relative to the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128 and the second sidewall 130).

[0043] In one or more examples, the first dunnage panel 210 and the second dunnage panel 212 are adjacent (e.g., directly adjacent or arranged next) to each other and are in a face-to-face orientation. In one or more examples, the first dunnage panel 210 and the second dunnage panel 212 are proximate each other. For example, without the article 102 being located between the first dunnage panel 210 and the second dunnage panel 212, the width dimension 126 of the gap 124 between the first dunnage panel 210 and the second dunnage panel 212 is minimal (e.g., substantially less than the thickness dimension 104 of the article 102 to be secured between the first dunnage panel 210 and the second dunnage panel 212.

[0044] Referring to Figs. 2-5, in one or more examples, the first dunnage panel 210 is coupled to one of the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128). In one or more examples, the first dunnage panel 210 is integral to (e.g., extends from) one of the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128). In one or more examples, the first dunnage panel 210 is coupled to the other one of the opposed pair of the plurality of sidewalls 118 (e.g., the second sidewall 130).

[0045] In one or more examples, the second dunnage panel 212 is coupled to one of the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128). In one or more examples, the second dunnage panel 212 is integral to (e.g., extends from) one of the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128). In one or more examples, the second dunnage panel 212 is coupled to the other one of the opposed pair of the plurality of sidewalls 118 (e.g., the second sidewall 130).

[0046] In one or more examples, the first dunnage panel 210 and the second dunnage panel 212 are generally perpendicular to and extend between the first end wall 136 and the second end wall 138. In one or more examples, the first dunnage panel 210 is generally parallel to and is laterally spaced apart from the third sidewall 132. In one or more examples, the second dunnage panel 212 is generally parallel to and is laterally spaced apart from the fourth sidewall 134. However, in other examples, the first dunnage panel 210 may be oriented at an oblique angle relative to the third sidewall 132 and the second dunnage panel 212 may be oriented at an oblique angle relative to the fourth sidewall 134.

[0047] In one or more examples, the product container 110 includes a first brace panel 122. In one or more examples, the first brace panel 122 is coupled to the first dunnage panel 210. In one or more examples, the first brace panel 122 is integral to (e.g., extends from) the first dunnage panel 210. The first brace panel 122 inhibits movement of the first dunnage panel 210 relative to the container body 114, for example, relative to the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128 and the second sidewall 130) to which it is coupled. In other words, the first brace panel 122 impedes linear and/or rotational movement of the first dunnage panel 210 within the internal volume 112 of the container body 114 while permitting the first dunnage panel 210 to change its profile shape (e.g., develop a curvature) and conform to a portion of the article 102 secured between the first dunnage panel 210 and the second dunnage panel 212.

[0048] In one or more examples, the first brace panel 122 is substantially aligned with and is laterally spaced apart from the first dunnage panel 210. In one or more examples, the first brace panel 122 is located between, is generally parallel to, and is laterally spaced apart from the first dunnage panel 210 and the third sidewall 132. In one or more examples, the first brace panel 122 is generally perpendicular to and extends between the first sidewall 128 and the second sidewall 130. However, in other examples, the first brace panel 122 may be oriented at an oblique angle relative to the first sidewall 128 and the second sidewall 130. In one or more examples, the first brace panel 122 is coupled to the first sidewall 128 and the second sidewall 130. In one or more examples, the first brace panel 122 is generally perpendicular to and extends between the first end wall 136 and the second end wall 138. However, in other examples, the first brace panel 122 may be oriented at an oblique angle relative to the first end wall 136 and the second end wall 138. The first brace panel 122 also increases the strength and/or the structural rigidity of the product container 110.

[0049] In one or more examples, the product container 110 includes a second brace panel 144. In one or more examples, the second brace panel 144 is coupled to the second dunnage panel 212. The second brace panel 144 inhibits movement of the second dunnage panel 212 relative to the container body 114, for example, relative to the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128 and the second sidewall 130) to which it is coupled. In other words, the second brace panel 144 impedes linear and/or rotational movement of the second dunnage panel 212 within the internal volume 112 of the container body 114 while permitting the second dunnage panel 212 to change its profile shape (e.g., develop a curvature) and conform to a portion of the article 102 secured between the first dunnage panel 210 and the second dunnage panel 212.

[0050] In one or more examples, the second brace panel 144 is substantially aligned with and is laterally spaced apart from the second dunnage panel 212. In one or more examples, the second brace panel 144 is located between, is generally parallel to, and is laterally spaced apart from the second dunnage panel 212 and the fourth sidewall 134. In one or more examples, the second brace panel 144 is generally perpendicular to and extends between the first sidewall 128 and the second sidewall 130. However, in other examples, the second brace panel 144 may be oriented at an oblique angle relative to the first sidewall 128 and the second sidewall 130. In one or more examples, the second brace panel 144 is coupled to the first sidewall 128 and the second sidewall 130. In one or more examples, the second brace panel 144 is generally perpendicular to and extends between the first end wall 136 and the second end wall 138. However, in other examples, the second brace panel 144 may be oriented at an oblique angle relative to the first end wall 136 and the second end wall 138. The second brace panel 144 also increases the strength and/or the structural rigidity of the product container 110.

[0051] Referring to Figs. 7-10, in one or more examples, the first dunnage panel 210 is coupled to one of the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128). In one or more examples, the first dunnage panel 210 is integral to (e.g., extends from) one of the opposed pair of the plurality of sidewalls 118 (e.g., the first sidewall 128).

[0052] In one or more examples, the second dunnage panel 212 is coupled to first dunnage panel 210. In one or more examples, the second dunnage panel 212 is integral to (e.g., extends from) the first dunnage panel 210.

[0053] In one or more examples, the first dunnage panel 210 and the second dunnage panel 212 are generally perpendicular to and extend between the third sidewall 132 and the fourth sidewall 134. However, in other examples, the first dunnage panel 210 and the second dunnage panel 212 may be oriented at an oblique angle relative to the third sidewall 132 and the fourth sidewall 134.

[0054] In one or more examples, the first dunnage panel 210 is generally parallel to and is spaced away from the bottom wall 140. However, in other examples, the first dunnage panel 210 may be oriented at an oblique angle relative to the bottom wall 140.

[0055] In one or more examples, the second dunnage panel 212 is generally parallel to and is spaced away from the top wall 142 (e.g., the lid 116 in the closed condition or state). However, in other examples, the second dunnage panel 212 may be oriented at an oblique angle relative to the top wall 142. [0056] In one or more examples, the product container 110 includes the first brace panel 122 and the second brace panel 144, which are coupled to the first dunnage panel 210. In one or more example, the first brace panel 122 and the second brace panel 144 are opposite each other. In one or more examples, the first brace panel 122 and the second brace panel 144 are integral to (e.g., extend from) the first dunnage panel 210. In one or more examples, the first brace panel 122 extends between the first dunnage panel 210 and the bottom wall 140 proximate to or adjacent to (e.g., at or near) the third sidewall 132. In one or more examples, the second brace panel 144 extends between the first dunnage panel 210 and the bottom wall 140 proximate to or adjacent to the fourth sidewall 134. The first brace panel 122 and the second brace panel 144 inhibit, or at least resist, movement of the first dunnage panel 210 relative to the container body 114, for example, relative to the bottom wall 140. In other words, the first brace panel 122 and the second brace panel 144 impede linear and/or rotational movement of the first dunnage panel 210 within the internal volume 112 of the container body 114 while permitting the first dunnage panel 210 to change its profile shape (e.g., develop a curvature) and conform to a portion of the article 102 secured between the first dunnage panel 210 and the second dunnage panel 212.

[0057] In one or more examples, each one of the first brace panel 122 and the second brace panel 144 serves as a strut or a spring that biases the first dunnage panel 210 away from the bottom wall 140. For example, the each one of the first brace panel 122 and the second brace panel 144 has an accordion shape, for example, including a plurality of rigid panel-portions 150 interspersed with and connected by flexural hinges 152.

[0058] In one or more examples, with the lid 116 in the closed state and forming the top wall 142 of the container body 114, the top wall 142 (e.g., the lid 116) urges the second dunnage panel 212 toward the first dunnage panel 210 and maintains the second dunnage panel 212 in position relative to the first dunnage panel 210.

[0059] In one or more examples, the product container 110 includes a third brace panel 146 and a fourth brace panel 148, which are coupled to the second dunnage panel 212. In one or more example, the third brace panel 146 and the fourth brace panel 148 are opposite each other. In one or more examples, the third brace panel 146 and the fourth brace panel 148 are integral to (e.g., extend from) the second dunnage panel 212. In one or more examples, the third brace panel 146 extends between the second dunnage panel 212 and the top wall 142 (e.g., the lid 116 in the closed state) proximate to or adjacent to the third sidewall 132. In one or more examples, the fourth brace panel 148 extends between the second dunnage panel 212 and the top wall 142 (e.g., the lid 116 in the closed state) proximate to or adjacent to the fourth sidewall 134. The third brace panel 146 and the fourth brace panel 148 inhibit, or at least resist, movement of the second dunnage panel 212 relative to the container body 114, for example, relative to the top wall 142. In other words, the third brace panel 146 and the fourth brace panel 148 impede linear and/or rotational movement of the second dunnage panel 212 within the internal volume 112 of the container body 114 while permitting the second dunnage panel 212 to change its profile shape (e.g., develop a curvature) and conform to a portion of the article 102 secured between the first dunnage panel 210 and the second dunnage panel 212.

[0060] Referring now to Fig. 11, which illustrates an example of the first dunnage panel 210 including the plurality of discontinuous lines of weakness 218. As illustrated, in one or more examples, the second dunnage panel 212 is substantially the same as the first dunnage panel 210 and the plurality of second discontinuous lines of weakness 220 is substantially the same as the plurality of discontinuous lines of weakness 218 (e.g., shown in Fig. 11). In other words, Fig. 11 is also representative of one or more examples of the second dunnage panel 212 in which the second dunnage panel 212 includes the plurality of second discontinuous lines of weakness 220.

[0061] The first dunnage panel 210 or the second dunnage panel 212 includes an articlesupport surface 228. The article-support surface 228 is configured to support (e.g., contact) the article 102 when the article 102 is secured between the first dunnage panel 210 or the second dunnage panel 212.

[0062] In one or more examples, the plurality of discontinuous lines of weakness 218 are disposed or located on a portion of the article-support surface 228 of the first dunnage panel 210. For example, the plurality of discontinuous lines of weakness 218 are disposed or located about a central portion or region of the article-support surface 228 of the first dunnage panel 210. As such, the first dunnage panel 210 includes a margin 222 that surrounds the article-support surface 228 and that extends along a perimeter of the first dunnage panel 210. The margin 222 lacks any of the plurality of discontinuous lines of weakness 218. The margin 222 provides increased strength and rigidity to the first dunnage panel 210, particularly, along edges of the first dunnage panel 210. The geometry and/or area defined by the margin 222 and the plurality of discontinuous lines of weakness 218 may depend on the size of the product container 110, the size, shape, and/or weight of the article 102 to be secured between the first dunnage panel 210 and the second dunnage panel 212, and other factors. Further, the configuration of the margin 222 and the plurality of discontinuous lines of weakness 218 facilitate controlled deformation of the first dunnage panel 210 to a generally central region of the first dunnage panel 210.

[0063] Similarly, in one or more examples, the plurality of second discontinuous lines of weakness 220 are disposed or located on a portion of the article-support surface 228 of the second dunnage panel 212. For example, the plurality of second discontinuous lines of weakness 220 are disposed or located about a central portion or region of the article-support surface 228 of the second dunnage panel 212. As such, the second dunnage panel 212 includes the margin 222 that surrounds the article-support surface 228 and that extends along a perimeter of the second dunnage panel 212. The margin 222 lacks any of the plurality of second discontinuous lines of weakness 220. The margin 222 provides increased strength and rigidity to the second dunnage panel 212, particularly, along edges of the second dunnage panel 212. The geometry and/or area defined by the margin 222 and the plurality of second discontinuous lines of weakness 220 may depend on the size of the product container 110, the size, shape, and/or weight of the article 102 to be secured between the first dunnage panel 210 and the second dunnage panel 212, and other factors. Further, the configuration of the margin 222 and the plurality of discontinuous lines of weakness 218 facilitate controlled deformation of the second dunnage panel 212 to a generally central region of the second dunnage panel 212.

[0064] In one or more examples, the plurality of discontinuous lines of weakness 218 define a dunnage portion 226 of the first dunnage panel 210. The first dunnage panel 210 has a panel width Wl. The dunnage portion 226 of the first dunnage panel 210, defined by the plurality of discontinuous lines of weakness 218, has a dunnage width W2. The margin 222 (e.g., a perimeter portion of the article-support surface 228) has a margin width W3. In one or more examples, In one or more examples, the panel width Wl is greater than the dunnage width W2 and the margin width W3. In one or more examples, the first dunnage panel 210 is generally rectangular and includes the margin 222 along all four sides with the dunnage portion 226 being enclosed by and confined within the margin 222. The margin 222 is continuous and thus free of any cuts, slits, or other lines of weakness.

[0065] In one or more examples, the plurality of second discontinuous lines of weakness 220 define the dunnage portion 226 of the second dunnage panel 212. The second dunnage panel 212 has a panel width Wl. The dunnage portion 226 of the second dunnage panel 212, defined by the plurality of second discontinuous lines of weakness 220, has the dunnage width W2. The margin 222 (e.g., a perimeter portion of the article-support surface 228) has the margin width W3. In one or more examples, the panel width Wl is greater than the dunnage width W2 and the margin width W3. In one or more examples, the second dunnage panel 212 is generally rectangular and includes the margin 222 along all four sides with the dunnage portion 226 being enclosed by and confined within the margin 222. The margin 222 is continuous and thus free of any cuts, slits, or other lines of weakness.

[0066] In one or more examples, the panel width Wl, the dunnage width W, and the margin width W3 of the first dunnage panel 210 and the second dunnage panel 212 are the same. In one or more examples, one or more of the panel width Wl, the dunnage width W, and the margin width W3 of the first dunnage panel 210 is different than one or more of the panel width Wl, the dunnage width W, and the margin width W3 of the second dunnage panel 212.

[0067] The plurality of discontinuous lines of weakness 218 are configured to partially fold, displace (e.g., to an out of plane orientation relative to a remaining portion of the first dunnage panel 210), buckle, bend, or otherwise change shape such that a shape of a portion of the first dunnage panel 210 changes to match the shape of or cradle around the article 102 supported by the article-support surface 228 of the first dunnage panel 210 and secured between the first dunnage panel 210 and the second dunnage panel 212.

[0068] Similarly, the plurality of second discontinuous lines of weakness 220 are configured to partially fold, displace (e.g., to an out of plane orientation relative to a remaining portion of the second dunnage panel 212), buckle, bend, or otherwise change shape such that a shape of a portion of the second dunnage panel 212 changes to match the shape of or cradle around the article 102 supported by the article-support surface 228 of the second dunnage panel 212 and secured between the first dunnage panel 210 and the second dunnage panel 212. [0069] In one or more examples, the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 include, or are formed by, cuts (e.g., as shown in Fig. 11). In one or more examples, the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 include, or are formed by, perforations. In one or more examples, the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 include, or are formed by, cuts and perforations. For example, a first portion (e.g., an interior portion) of the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 may include, or be formed by, cuts and a second portion (e.g., a peripheral portion) of the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 may include, or be formed by, perforations.

[0070] Generally, the cuts refer to slit or linear incision formed (e.g., pierced) through the material forming the dunnage panel (e.g., the first dunnage panel 210 or the second dunnage panel 212). Generally, the perforations refer to row or linear segment of small holes formed (e.g., punched) through the material forming the dunnage panel (e.g., the first dunnage panel 210 or the second dunnage panel 212).

[0071] In one or more examples, the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 define or form a pattern 214. In one or more examples, the pattern 214 is uniform and is repeated along the article-support surface 228 (e.g., is a repeating pattern on the article-support surface 228). In other examples, the plurality of discontinuous lines of weakness 218 and/or the plurality of second discontinuous lines of weakness 220 may be non-uniform and non-repeated along the article-support surface 228. In one or more examples, the pattern 214 is symmetric. In one or more examples, the pattern 214 is asymmetric.

[0072] In one or more examples, the pattern 214 includes columns and/or rows of lines (e.g., line segments) of weakness 224. In one or more examples, each one of the lines of weakness 224 is formed by a cut segment or a perforation segment. In one or more examples, one or more of the lines of weakness 224 is linear (e.g., straight). In one or more examples, one or more of the lines of weakness 224 is curved. [0073] The pattern 214 of the lines of weakness 224 may have any one of various two- dimensional geometries. In one or more examples, the pattern 214 (e.g., located on an interior region of the article-support surface 228) includes a plurality of lines weakness 224 (e.g., three lines of weakness 224 as shown in Fig. 11) radiating outward from a central point. In one or more examples, each one of the plurality of lines of weakness 224 of the pattern 214 is equally angularly oriented (e.g., clocked) relative to a directly adjacent one of the plurality of lines of weakness 224 of the pattern 214. In one or more examples, the pattern 214 (e.g., located about a peripheral region of the article-support surface 228) includes a plurality of lines of weakness 224 (e.g., two lines of weakness 224 as shown in Fig. 11) oriented at an oblique angle relative to each other.

[0074] In one or more examples, the pattern 214 of the plurality of discontinuous lines of weakness 218 and the pattern 214 of the plurality of second discontinuous lines of weakness 220 are the same. In one or more examples, the pattern 214 of the plurality of discontinuous lines of weakness 218 and the pattern 214 of the plurality of second discontinuous lines of weakness 220 are different.

[0075] The example configurations of the pattern 214 and/or of any one of the lines of weakness 224 of the plurality of discontinuous lines of weakness 218 and/or the plurality of second lines of weakness 220 described and illustrated herein are provided as examples and other configurations of the pattern 214 and/or of any one of the lines of weakness 224 may be implemented without departing from the intended structure of the first dunnage panel 210 and/or the second dunnage panel 212 and without departing from the principles of the present disclosure and purpose of the product container 110. As other examples, the pattern 214 of the lines of weakness 224 (e.g., of the plurality of discontinuous lines of weakness 218 and/or the plurality of second lines of weakness 220) may define or form a honeycomb pattern, a polygonal pattern, a star-shaped pattern, or other tessellated pattern configured to enable the first dunnage panel 210 and/or the second dunnage panel 212 to locally conform to the shape of the article 102 secured between the first dunnage panel 210 and the second dunnage panel 212.

[0076] Examples of the product container 110 are used to form the packaging system 100. In other words, the packaging system 100 includes the product container 110 and the article 102 secured between the first dunnage panel 210 and the second dunnage panel 212 (e.g., as shown in Figs. 4, 9 and 10). The product container 110 includes the container body 114 that defines the internal volume 112 of the product container 110. The packaging system 100 also includes the first dunnage panel 210 located in the internal volume 112 of the product container 110. The first dunnage panel 210 includes the plurality of discontinuous lines of weakness 218. The packaging system 100 further includes the second dunnage panel 212 located in the internal volume 112 of the product container 110. The first dunnage panel 210 and the second dunnage panel 212 are substantially aligned with each other and are laterally spaced apart from each other. The article 102 is located in the internal volume 112 of the product container 110 and secured between the first dunnage panel 210 and the second dunnage panel 212.

[0077] Referring now to Figs. 1 and 6, examples of the product container 110 are formed from the blank 300. In other words, in one or more examples, the container body 114, the first dunnage panel 210, and the second dunnage panel 212 are formed from the blank 300. In one or more examples, the blank 300 is a one-piece blank (e.g., a blank of sheet material). In one or more examples, the blank 300 includes a series of panels 302 connected along a plurality of fold lines 304. Generally, each one of the series of panels 302 defines or forms a structural portion of the product container 110. In one or more examples, a first one of the series of panels 302 includes the plurality of discontinuous lines of weakness 218. The series of panels 302 is foldable about the plurality of fold lines 304 to form the container body 114 from a plurality of the series of panels 302, the first dunnage panel 210 from the first one of the series of panels 302, and the second dunnage panel 212 from a second one of the series of panels 302. In one or more examples, the second one of the series of panels 302 includes the plurality of second discontinuous lines of weakness 220.

[0078] Generally, the blank 300 has an exterior surface and an interior surface, which is opposite the exterior surface. The exterior surface of the blank 300 generally defines at least a portion of an exterior surface of the product container 110. The interior surface of the blank 300 generally defines at least a portion of an interior surface of the product container 110. In one or more examples, portions of the exterior surface and/or the interior surface of the blank 300 may include printed graphics, such as advertising and/or promotional materials. [0079] Generally, the blank 300 is a single, unitary sheet of suitable substrate. The blank 300 provides the packaging structure of the product container 110. The blank 300 includes the plurality of panels 302. The panels 302 are aligned and are connected together, for example, in series, by the plurality of preformed fold lines 304. Generally, the panels 302 included in the blank 300 correspond to and are used to form the sidewalls, end walls, bottom wall, and top wall (e.g., lid), dunnage panels, brace panels, and other structural components (e.g., flaps, tabs, etc.) of the product container 110. The panels 302 of the blank 300 are folded along the fold lines 304 to form, assemble, or construct the product container 110. The panels 302 may be secured or otherwise held together in an assembled condition by any suitable means of panel joining, such as, but not limited to, adhesives, tape, staples, or by mechanically joining fastening features (e.g., tabs and slots) formed by the blank 300.

[0080] In one or more examples, the container body 114 includes, or is made of, a cellulosic material. In one or more examples, the first dunnage panel 210 includes, or is made of, a cellulosic material. In one or more examples, the second dunnage panel 212 includes, or is made of, a cellulosic material.

[0081] In one or more examples, each one of the container body 114, the first dunnage panel 210, and the second dunnage panel 212 is made of a recyclable material. In one or more examples, an entirety of the product container 110 is made of a recyclable material.

[0082] Referring to Figs. 1 and 6, in one or more examples, the blank 300 includes a longitudinal axis 306, a first edge 308, and a second edge 310 that is opposite the first edge 308 along the longitudinal axis 306. The panels 302 are generally connected to and extend from each other, in series, along the longitudinal axis 306 from the first edge 308 to the second edge 310 of the blank 300.

[0083] Referring now to Fig. 1, which illustrates a first example configuration or layout of the blank 300 for forming the first example of the product container 110, as shown in Figs. 2-5.

[0084] In one or more examples, panel 312 extends from the first edge 308 to fold line 314, which is generally parallel to the first edge 308. Panel 312 forms the first brace panel 122 of the product container 110. [0085] In one or more examples, panel 316 extends from and is foldably (e.g., hingedly) connected to panel 312 along fold line 314. Panel 316 forms a first connector panel 154 (e.g., as shown in Fig. 3) of the product container 110 that extends between and interconnects the first dunnage panel 210 and the first brace panel 122.

[0086] In one or more examples, panel 320 extends from and is foldably (e.g., hingedly) connected to panel 316 along fold line 318, which is generally parallel to fold line 314. Panel 320 forms the first dunnage panel 210. In one or more examples, panel 320 includes the plurality of discontinuous lines of weakness 218. However, in other examples, panel 320 may omit the plurality of discontinuous lines of weakness 218 and forms a solid dunnage panel.

[0087] In one or more examples, panel 322 extends from and is foldably (e.g., hingedly) connected to panel 320 along fold line 324, which is generally parallel to fold line 318. Panel 322 forms a portion (e.g., a first sidewall-portion 128a) of the first sidewall 128 of the container body 114 (e.g., as shown in Fig. 4).

[0088] In one or more examples, panel 326 extends from and is foldably (e.g., hingedly) connected to panel 322 along fold line 328, which is generally parallel to fold line 324. Panel 326 forms the third sidewall 132 of the container body 114.

[0089] In one or more examples, panel 330 extends from and is foldably (e.g., hingedly) connected to panel 326 along fold line 332, which is generally parallel to fold line 328. Panel 330 forms the second sidewall 130 of the container body 114.

[0090] In one or more examples, panel 334 extends from and is foldably (e.g., hingedly) connected to panel 330 along fold line 336, which is generally parallel to fold line 332. Panel 334 forms the fourth sidewall 134 of the container body 114.

[0091] In one or more examples, panel 338 extends from and is foldably (e.g., hingedly) connected to panel 334 along fold line 340, which is generally parallel to fold line 336. Panel 338 forms another portion (e.g., a second sidewall-portion 128b) of the first sidewall 128 of the container body 114 (e.g., as shown in Fig. 4). [0092] In one or more examples, panel 342 extends from and is foldably (e.g., hingedly) connected to panel 338 along fold line 344, which is generally parallel to fold line 340. Panel 342 forms the second dunnage panel 212. In one or more examples, panel 342 includes the plurality of second discontinuous lines of weakness 220. However, in other examples, panel 342 may omit the plurality of second discontinuous lines of weakness 220 and forms a solid dunnage panel.

[0093] In one or more examples, panel 338 extends from and is foldably (e.g., hingedly) connected to panel 334 along fold line 340, which is generally parallel to fold line 336. Panel 338 forms another portion (e.g., a second sidewall-portion 128b) of the first sidewall 128 of the container body 114 (e.g., as shown in Fig. 4).

[0094] In one or more examples, panel 346 extends from and is foldably (e.g., hingedly) connected to panel 342 along fold line 348, which is generally parallel to fold line 344. Panel 346 forms a second connector panel 156 (e.g., as shown in Fig. 3) of the product container 110 that extends between and interconnects the second dunnage panel 212 and the second brace panel 144.

[0095] In one or more examples, panel 350 extends from and is foldably (e.g., hingedly) connected to panel 346 along fold line 352, which is generally parallel to fold line 348. Panel 350 forms the second brace panel 144 of the product container 110.

[0096] In one or more examples, panel 354 extends from and is foldably (e.g., hingedly) connected to panel 326 along fold line 356, which is generally parallel to and extends between fold line 328 and fold line 332. Panel 354 forms the first end wall 136 of the product container 110.

[0097] In one or more examples, panel 358 extends from and is foldably (e.g., hingedly) connected to panel 334 along fold line 360, which is generally parallel to and extends between fold line 336 and fold line 340. Panel 358 forms the second end wall 138 of the product container 110.

[0098] In one or more examples, the blank 300 also includes one or more closure flaps 362.

Each one of the closure flaps 362 extends from and is foldably (e.g., hingedly) connected to a corresponding one of the panels 302 (e.g., panels 322, 330, 338, 354, 358) along a corresponding one of the fold lines 304. In one or more examples, one or more of the closure flaps 362 is a lip flap or end flap that is configured to be folded into a face-to-face and generally parallel position with and optionally, mechanically joined to, a corresponding one of the panels 302 to provide strength and/or rigidity to the product container 110 and/or to secure the product container 110 in the assembled state. In one or more examples, one or more of the closure flaps 362 is a glue flap that is configured to be folded into a face-to-face and generally parallel position with and connected (e.g., adhered) to a face of a corresponding one of the panels 302 to secure the product container 110 in the assembled state.

[0099] In one or more examples, the blank 300 include one or more closure tabs 364a and one or more closure apertures 364b to mechanically joint one of the panels 302 or one of the closure flaps 362 to a corresponding one of the panels 302 or one of the closure flaps 362. At least a portion of the closure tab 364a is configured to be received by and to fit within the closure aperture 364b to secure the blank 300 in the assembled state after construction of the product container 110. In one or more examples, the closure tab 364a extends from an edge of at least one of the panels 302 (e.g., panel 322) or from a corresponding one of the fold lines 304 (e.g., fold line 324) and the closure aperture 364b, corresponding to the closure tab 364a, is formed through the blank 300 along at least one of the fold lines 304 (e.g., fold line 344) or along an edge of a corresponding one of the panels 302 (e.g., panel 338). In one or more examples, the closure tab 364a extends from an edge of at least one of the closure flaps 362 (e.g., the closure flaps 362 connected to panel 354 and panel 358) and the closure aperture 364b, corresponding to the closure tab 364a, is formed through a corresponding one of the panels 302 (e.g., panel 326 and panel 334).

[00100] Turning now to construction of the product container 110 from the blank 300 and generally referring to Figs. 1-5, each one of the panels 302 and the closure flaps 362 is folded about a corresponding fold line 304 relative to another one of the panels 302 or closure flaps 362 to construct the product container 110. Generally, the panels 302 and the closure flaps 362 are folded into a generally perpendicular orientation relative to a corresponding panel 302 to which it is connected. [00101] As best illustrated in Figs. 3 and 4, in one or more examples, in the assembled condition of the product container 110, panel 316 (e.g., forming the first connector panel 154) is folded to be generally parallel to and in face-to-face relationship with and is secured (e.g., glued) to an interior surface of panel 330 (e.g., forming the second sidewall 130). In one or more examples, in the assembled condition of the product container 110, panel 346 (e.g., forming the second connector panel 156) is folded to be generally parallel to and in face-to-face relationship with and is secured (e.g., glued) to the interior surface of panel 330 (e.g., forming the second sidewall 130).

[00102] As best illustrated in Figs. 2 and 3, in one or more examples, in the assembled condition of the product container 110, the closure flap 362 connected to panel 312 (e.g., forming the first brace panel 122) is folded to be generally parallel to and in face-to-face relationship with and is secured (e.g., glued) to an interior surface of panel 322 (e.g., forming the first sidewall-portion 128a of the first sidewall 128). in one or more examples, in the assembled condition of the product container 110, the closure flap 362 connected to panel 350 (e.g., forming the second brace panel 144) is folded to be generally parallel to and in face-to-face relationship with and is secured (e.g., glued) to an interior surface of panel 338 (e.g., forming the second sidewall-portion 128b of the first sidewall 128).

[00103] As best illustrated in Fig. 4, in one or more examples, in the assembled condition of the product container 110, panel 322 (e.g., forming the first sidewall-portion 128a of the first sidewall 128) and panel 338 (e.g., forming the second sidewall-portion 128b of the first sidewall 128) are folded to be coplanar. As such the first sidewall-portion 128a and the second sidewallportion 128b form a composite or discontinuous first sidewall 128 of the product container 110.

[00104] As best illustrated in Fig. 4, in one or more examples, the closure tab 364a, extending from an edge of panel 322, is coupled to the closure aperture 364b, disposed along an edge of panel 338, to secure the first sidewall-portion 128a and the second sidewall-portion 128b together to form the first sidewall 128 of the product container 110.

[00105] The example configurations of the blank 300 for forming the product container 110 described and illustrated herein are provided as examples and other configurations of the blank 300 may be implemented without departing from the intended structure and purpose of the product container 110 and without departing from the principles of the present disclosure. As other examples, the blank 300 may include other configurations and/or layouts of the panels 302 and fold lines 304. Alternatively, the product container 110 may be formed or constructed using a plurality of blanks, for example, in which each one of the plurality of blanks forms one or more structure components of the product container 110.

[00106] Referring now to Fig. 6, which illustrates a second example configuration or layout of the blank 300 for forming the second example of the product container 110, as shown in Figs. 7-10.

[00107] In one or more examples, panel 366 extends from the first edge 308 to fold line 368, which is generally parallel to the first edge 308. Panel 366 forms at least a portion of the lid 116 and, thus, the top wall 142 of the product container 110.

[00108] In one or more examples, panel 370 extends from and is foldably (e.g., hingedly) connected to panel 366 along fold line 368. Panel 370 forms the second sidewall 130 of the product container 110.

[00109] In one or more examples, panel 374 extends from and is foldably (e.g., hingedly) connected to panel 370 along fold line 372, which is generally parallel to fold line 368. Panel 374 forms the bottom wall 140 of the product container 110.

[00110] In one or more examples, panel 378 extends from and is foldably (e.g., hingedly) connected to panel 374 along fold line 376, which is generally parallel to fold line 372. Panel 378 forms the first sidewall 128 of the product container 110.

[00111] In one or more examples, panel 380 extends from and is foldably (e.g., hingedly) connected to panel 378 along fold line 382, which is generally parallel to fold line 376. Panel 380 forms the first dunnage panel 210. In one or more examples, panel 380 includes the plurality of discontinuous lines of weakness 218. However, in other examples, panel 380 may omit the plurality of discontinuous lines of weakness 218 and forms a solid dunnage panel.

[00112] In one or more examples, panel 384 extends from and is foldably (e.g., hingedly) connected to panel 380 along fold line 386, which is generally parallel to fold line 382. Panel 384 forms the second dunnage panel 212. In one or more examples, panel 384 includes the plurality of second discontinuous lines of weakness 220. However, in other examples, panel 384 may omit the plurality of second discontinuous lines of weakness 220 and forms a solid dunnage panel.

[00113] In one or more examples, panel 388 extends from and is foldably (e.g., hingedly) connected to panel 374 along fold line 390, which is generally perpendicular to and extends between fold line 372 and fold line 376. Panel 388 forms the third sidewall 132 of the product container 110.

[00114] In one or more examples, panel 392 extends from and is foldably (e.g., hingedly) connected to panel 374 along fold line 394, which is generally perpendicular to and extends between fold line 372 and fold line 376. Panel 392 forms the fourth sidewall 134 of the product container 110.

[00115] In one or more examples, two or more panels 396 extend from and are foldably (e.g., hingedly) connected to panel 380 along fold line 398, which is generally perpendicular to and extends between fold line 382 and fold line 386. Panels 396 are connected together and extend from one another in series by fold lines 400, which are generally parallel to fold line 398. Panels 396 form the first brace panel 122 (e.g., each one of the panels 396 forms one of the panelportions 150 of the first brace panel 122) and each one of the fold lines 400 forms one of the flexural hinges 152 of the first brace panel 122 (e.g., as shown in Fig. 9).

[00116] In one or more examples, two or more panels 402 extend from and are foldably (e.g., hingedly) connected to panel 380 along fold line 404, which is generally perpendicular to and extends between fold line 382 and fold line 386 and which is generally parallel to and opposite fold line 398. Panels 402 are connected together and extend from one another in series by fold lines 406, which are generally parallel to fold line 404. Panels 402 form the second brace panel 144 (e.g., each one of the panels 402 forms one of the panel-portions 150 of the second brace panel 144) and each one of the fold lines 406 forms one of the flexural hinges 152 of the second brace panel 144 (e.g., as shown in Fig. 9). [00117] In one or more examples, panel 408 extends from and is foldably (e.g., hingedly) connected to panel 384 along fold line 410, which is generally perpendicular to and extends between fold line 386 and the second edge 310. Panel 408 forms the third brace panel 146.

[00118] In one or more examples, panel 412 extends from and is foldably (e.g., hingedly) connected to panel 384 along fold line 414, which is generally perpendicular to and extends between fold line 386 and the second edge 310 and which is generally parallel to and opposite fold line 410. Panel 412 forms the fourth brace panel 148.

[00119] In one or more examples, the blank 300 also includes one or more closure flaps 362. Each one of the closure flaps 362 extends from and is foldably (e.g., hingedly) connected to a corresponding one of the panels 302 (e.g., panels 366,370, 378, 388, 392) along a corresponding one of the fold lines 304 or to another one of the closure flaps 362. In one or more examples, one or more of the closure flaps 362 is a lip flap or end flap that is configured to be folded into a face-to-face and generally parallel position with and optionally, mechanically joined to, a corresponding one of the panels 302 to provide strength and/or rigidity to the product container 110 and/or to secure the product container 110 in the assembled state. In one or more examples, one of the closure flaps 362 is configured to be folded into a face-to-face and generally parallel position relative to one of the panels 302 (e.g., panels 388, 392) to capture or sandwich another one of the closure flaps 362 therebetween.

[00120] In one or more examples, the blank 300 include one or more closure tabs 364a and one or more closure apertures 364b to mechanically joint one of the panels 302 or one of the closure flaps 362 to a corresponding one of the panels 302 or one of the closure flaps 362. At least a portion of the closure tab 364a is configured to be received by and to fit within the closure aperture 364b to secure the blank 300 in the assembled state after construction of the product container 110. In one or more examples, the closure tab 364a extends from an edge of at least one of the closure flaps 362 (e.g., the closure flaps 362 connected to panels 388, 392) and the closure aperture 364b, corresponding to the closure tab 364a, is formed through the blank 300 along at least one of the fold lines 304 (e.g., fold lines 390, 394).

[00121] Turning now to construction of the product container 110 from the blank 300 and generally referring to Figs. 6-10, each one of the panels 302 and the closure flaps 362 is folded about a corresponding fold line 304 relative to another one of the panels 302 or closure flaps 362 to construct the product container 110. Generally, the panels 302 and the closure flaps 362 are folded into a generally perpendicular orientation relative to a corresponding panel 302 to which it is connected.

[00122] As best illustrated in Figs. 7 and 9, in one or more examples, panel 380 (e.g., forming the first dunnage panel 210) is folded to be generally parallel to panel 374 (e.g., forming the bottom wall 140). Panels 396 (e.g., forming the first brace panel 122) are folded to be generally perpendicular to panel 380 (e.g., forming the first dunnage panel 210) and are folded relative to each other to extend between panel 380 (e.g., forming the first dunnage panel 210) and panel 374 (e.g., forming the bottom wall 140). Panels 402 (e.g., forming the second brace panel 144) are folded to be generally perpendicular to panel 380 (e.g., forming the first dunnage panel 210) and are folded relative to each other to extend between panel 380 (e.g., forming the first dunnage panel 210) and panel 374 (e.g., forming the bottom wall 140).

[00123] As best illustrated in Figs. 7 and 9, in one or more examples, panel 384 (e.g., forming the second dunnage panel 212) is folded to be generally parallel to and in face-to-face relationship with panel 380 (e.g., forming the first dunnage panel 210). Panel 408 (e.g., forming the third brace panel 146) is folded to be generally perpendicular to panel 384 (e.g., forming the second dunnage panel 212) to extend between panel 384 (e.g., forming the second dunnage panel 212) and panel 366 (e.g., forming the lid 116 or the top wall 142). Panel 412 (e.g., forming the fourth brace panel 148) is folded to be generally perpendicular to panel 384 (e.g., forming the second dunnage panel 212) to extend between panel 384 (e.g., forming the second dunnage panel 212) and panel 366 (e.g., forming the lid 116 or the top wall 142).

[00124] As best illustrated in Figs. 8 and 10, in one or more examples, panel 366 (e.g., forming the lid 116) is folded to be generally perpendicular to panel 370 (e.g., forming the second sidewall 130) and generally parallel to panel 374 (e.g., forming the bottom wall 140) to form the top wall 142 of the product container 110. Panel 366 (e.g., forming the top wall 142) engages and applies a force to panel 408 (e.g., forming the third brace panel 146) and to panel 412 (e.g., forming the fourth brace panel 148) to urge panel 384 (e.g., forming the second dunnage panel 212) toward panel 380 (e.g., forming the first dunnage panel 210). The force applied to panel 408 (e.g., forming the third brace panel 146) and to panel 412 (e.g., forming the fourth brace panel 148) by panel 408 (e.g., forming the third brace panel 146), when the lid 116 is closed, provides a clamping force that secures the article 102 between the first dunnage panel 210 and the second dunnage panel 212.

[00125] By way of examples, the present disclosure is also directed to a method for forming (e.g., making, assembling, or constructing) the product container 110 from the blank 300.

[00126] In one or more examples, the method includes a step of forming the plurality of discontinuous lines of weakness 218 in a first one of the plurality of panels 302 (e.g., panel 320 as shown in Fig. 1 or panel 380 shown in Fig. 6) connected along the plurality of fold lines 304. In one or more examples, the method optionally includes a step of forming the plurality of second discontinuous lines of weakness 220 in a second one of the series of panels 302 (e.g., panel 342 as shown in Fig. 1 or panel 384 shown in Fig. 6). In one or more examples, the method includes a step of folding the panels 502 about the plurality of fold lines 304 to form the product container 110, including, but not limited to, forming the container body 114 that defines the internal volume 112 from a portion or set of the plurality of panels 302, forming the first dunnage panel 210 located in the internal volume 112 of the container body 114 from the first one of the panels 302, and forming the second dunnage panel 212 located in the internal volume 112 of the container body 114 from the second one of panels 302. The first dunnage panel 210 and the second dunnage panel 212 are substantially aligned with each other and are laterally spaced apart from each other.

[00127] By way of examples, the present disclosure is also directed to a method for packaging product (e.g., one or more articles 102). In one or more examples, the method includes a step of partially assembling the packaging system 100 by folding the plurality of panels 302 of the blank 300 along the plurality of fold lines 304 provided therein to form the product container 110 that includes the container body 114 that defines the internal volume 112, the first dunnage panel 210 that is located in the internal volume 112 of the container body 114 and that includes the plurality of discontinuous lines of weakness 218, and the second dunnage panel 212 that is located in the internal volume 112 of the container body 114 and, optionally, that includes the plurality of second discontinuous lines of weakness 220. The first dunnage panel 210 and the second dunnage panel 212 are substantially aligned with each other and are laterally spaced apart from each other. In one or more examples, the method also includes a step of securing the article 102 between the first dunnage panel 210 and the second dunnage panel 212.

[00128] As such, the disclosed product container 110 beneficially provides for the packaging system 100 and packaging method that secures and protects the article 102 during shipping without the need for supplemental packaging materials. The product container 110 is made entirely of recyclable materials, which beneficially reduces waste.

[00129] For the purpose of the present disclosure, as used herein, the term “container” refers to and/or includes any one of various types of packaging structures suitable for containing product, such as, but not limited to, a carton, a box, a case, a pack, a holder, or other suitable packaging structure.

[00130] For the purpose of the present disclosure, as used herein, the term “product” generally refers to one or more articles that are typically shipped, for example, individually or as a group, using a shipping container. For the purpose of the present disclosure, as used herein, the terms “article” and “articles” refer to or include any one of various types of contents suitable to be contained by the product container 110, such as, but not limited to, consumer goods or other articles of manufacture. As specific, non-limiting, examples, the article 102 contained by the product container 110 and secured between the first dunnage panel 210 and the second dunnage panel 212 is a cosmetic product (e.g., makeup), a beauty product, or other personal care product. Further, the term “article” may refer to the primary product (e.g., lipstick, nail polish, cream, foundation, etc.) and the primary product packaging (e.g., tube, jar, bottle, etc.) that contains the primary product.

[00131] As used herein, relative positional and/or orientational terms, such as parallel, perpendicular, and similar terms include approximations of such positional and/or orientational (e.g., approximately parallel, approximately perpendicular, etc.) As used herein, the term “approximately” refers to or represents a condition that is close to, but not exactly, the stated condition that still performs the desired function or achieves the desired result. As an example, the term “approximately” refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as to a condition that is within 10% of the stated condition. However, the term “approximately” does not exclude a condition that is exactly the stated condition. 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.

[00132] It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks 300 may be employed, where suitable, for example, to provide the packaging structure for the product container 110, as described in more detail herein below.

[00133] In one or more examples, the blank 300 is constructed from sheet material. The product container 110 may be constructed from the blank 300 of the sheet material using a machine and/or by hand. In one example, the blank 300 is fabricated from a corrugated cardboard material. However, in other examples, the blank 300 may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative examples, the blank 300 is fabricated using cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.

[00134] In one or more examples, the product container 110 and/or the blank 300 includes at least one marking thereon including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. In other examples, the product container 110 is void of markings, such as, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product.

[00135] The examples of the product container 110 described herein and illustrated in Figs. 2-5 and 7-10 provide exemplary sizes, shapes, and/or configurations of the product container 110. However, in other examples, the product container 110 may have any suitable size, shape and/or configuration, i.e., any suitable number of sides having any suitable size, shape and/or configuration. Further, the examples of the product container 110 described herein and illustrated in Figs. 2-5 and 7-10 provide exemplary positions and orientations of structural components of the product container 110 (e.g., sidewalls, end walls, bottom wall, top wall, dunnage panels, brace panels, etc.) relative to other structural components of the product container 110. However, in other examples, the structural components of the product container 110 (e.g., sidewalls, end walls, bottom wall, top wall, dunnage panels, brace panels, etc.) may have any other suitable positions and/or orientations relative to other structural components of the product container 110.

[00136] The examples of the blank 300 described herein and illustrated in Figs. 1 and 6 provide exemplary layouts, sizes, shapes, and/or configurations of the blank 300. However, in other examples, the blank 300 may have any suitable layout size, shape and/or configuration, i.e., any suitable number of panels and fold lines having any suitable size, shape and/or configuration. Further, the examples of the blank 300 described herein and illustrated in Figs. 1 and 6 provide exemplary positions and orientations of structural components of the blank 300 (e.g., panels, fold lines, flaps, tabs, apertures, edges, etc.) relative to other structural components of the blank 300. However, in other examples, the structural components of the blank 300 (e.g., e.g., panels, fold lines, flaps, tabs, apertures, edges, etc.) may have any other suitable positions and/or orientations relative to other structural components of the blank 300.

[00137] In one or more examples, the product container 110 and/or the blank 300 is formed from a sheet material, such as a sheet of suitable substrate (e.g., paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like). In one or more examples, the sheet material is made of, or is coated with, materials to increase its strength. An example of such a sheet material is tear resistant NATRALOCK® paperboard made by WestRock Company. It should be noted that the tear resistant materials may be provided by more than one layer, to help improve the tear-resistance of the package.

[00138] In one or more examples, one surface of the sheet material (e.g., forming the product container 110 or the blank 300) has different characteristics to the other surface. For example, an exterior surface of the sheet material (e.g., that faces outwardly from an assembled product container 110) may be particularly smooth and/or may have a coating, such as a clay coating or other surface treatment, to provide good printability. An interior surface of the sheet material (e.g.., that faces inwardly) may be provided with a coating, a layer, a treatment, or be otherwise prepared to provide properties such as one or more of tear-resistance, good glue-ability, heat sealability, or other desired functional properties. Additional functional coatings and/or barrier coatings that provide other properties, such as liquid-resistance, moisture-resistance, and the like, may also be applied to one or both surfaces of the sheet material.

[00139] In one or more examples, the blank 300 and, thus, the product container 110 are formed from a sheet material, such as a paperboard substrate. The paperboard substrate may be, for example, a solid bleached sulfate (SBS) substrate, an uncoated natural kraft (UNC) substrate, or a coated natural kraft (CNK) substrate. The paperboard substrate may be formed from virgin fibers, recycled fibers, or combinations thereof.

[00140] In one or more examples, the blank 300 and, thus, the product container 110 are made of cardboard or other suitable heavy-duty paper-based material. In one or more examples, the blank 300 and, thus, the product container 110 are made of corrugated board, such as corrugated board that includes two liner sheets and an inner fluted corrugated material sandwiched between and coupled to the liner sheets. Use of corrugated board advantageously provides beneficial durability and other mechanical attributes, such as rigidity and foldability, to the product container 110.

[00141] The preceding detailed description refers to the accompanying drawings, which illustrate specific examples of the disclosed product container, blank, and methods described by the present disclosure. It will be understood that the disclosed examples are merely exemplary embodiments of the way in which certain aspects of the of the disclosed product container, packaging system, and methods can be implemented and do not represent an exhaustive list of all of the ways the of the disclosed product container, packaging system, and methods may be embodied. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Throughout the present disclosure, any one of a plurality of items may be referred to individually as the item and a plurality of items may be referred to collectively as the items. Moreover, as used herein, a feature, element, component, or step preceded with the word “a” or “an” should be understood as not excluding a plurality of features, elements, components or steps, unless such exclusion is explicitly recited.

[00142] Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided above. Reference herein to “example” means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” “one or more examples,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.

[00143] It is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular example described herein. Thus, for example, those skilled in the art will recognize that certain examples may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[00144] It should be appreciated that, when used to modify a structure, an element, an item, a component or a feature described herein, the terms “front,” “back,” “rear,” “bottom,” “top,” “left,” “right,” “side,” “end,” “upper,” “lower,” “inner,” “outer,” as well as similar terms or other forms of such terms, are relative and refer to an example of a spatial relationship between structures, elements, items, components or features. As such, examples of the blank 300 and the product container 110, described herein and illustrated in the figures, are not intended to be limited by the specific relative terms used to describe any structure, element, item, component or feature thereof.

[00145] As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. Any reference to “hinged connection” should not be construed as necessarily referring to a single fold line only; indeed, a hinged connection can be formed from two or more fold lines wherein each of the two or more fold lines may be either straight/linear or curved/curvilinear in shape. When linear fold lines form a hinged connection, they may be disposed generally parallel with each other or be slightly angled with respect to each other. When curvilinear fold lines form a hinged connection, they may intersect each other to define a shaped panel within the area surrounded by the curvilinear fold lines. A typical example of such a hinged connection may include a pair of arched or arcuate fold lines intersecting at two points such that they define an elliptical panel therebetween. A hinged connection may be formed from one or more linear fold lines and one or more curvilinear fold lines. A typical example of such a hinged connection may comprise a combination of a linear fold line and an arched or arcuate fold line which intersect at two points such that they define a half moon-shaped panel therebetween.

[00146] As used herein, the term “fold line” may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cutline, a line of aligned slits, a line of scores and any combination of the aforesaid options.

[00147] It should be understood that hinged connections and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cutline, an interrupted cutline, slits, scores, embossed lines, debossed lines, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

[00148] Conditional language such as, among others, “can” or “may,” unless specifically stated otherwise, are otherwise understood within the context as used in general to convey that certain examples include, while other examples do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more examples or that one or more examples necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular example.

[00149] 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.

[00150] Those skilled in the art will appreciate that not all elements described and illustrated in Figs. 1-11 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. 1-11 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.

[00151] 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.

[00152] 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 product container 110, the packaging system 100, the blank 300, and methods 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.