Corrugated Container With Integrated Dunnage Panels
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Solution Overview
Problem
Conventional product packaging relies heavily on non-recyclable supplemental materials like plastic molds and packaging peanuts, leading to material waste and inefficiencies in shipping containers, which need to be minimized for cost and environmental reasons while ensuring product protection and strength.
Innovation Solution
A product container design featuring a container body with aligned, laterally spaced dunnage panels that include discontinuous lines of weakness, allowing for flexible deformation to secure articles without additional packaging materials, made entirely from recyclable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If supplemental packaging materials (plastic molds, packaging peanuts, bubble wrap) are used to secure product and prevent damage during shipping, then product protection is improved, but material waste increases and recyclability decreases
Solution Approach 1:
The patent combines the container body and dunnage panels into a single integrated structure made from one piece of corrugated board. The dunnage panels are formed directly from the container body material through folding and creasing, eliminating the need for separate supplemental packaging materials like plastic molds or packaging peanuts. This merging approach maintains product protection while eliminating material waste from additional components.
Solution Approach 2:
The patent enables full recyclability by using only corrugated board material for both the container body and dunnage panels. The discontinuous lines of weakness allow the dunnage panels to be easily separated and discarded with the container body, which can be recycled together as a single material stream. This eliminates the need to dispose of mixed materials and enables complete recovery and recycling of the packaging system.
2Reliability
If additional packaging materials are used to secure product, then product protection is improved, but device complexity increases
Solution Approach 1:
The patent integrates the dunnage panels as integral parts of the container body, both being formed from the same corrugated board material. The dunnage panels are created by folding and creasing the container body itself, eliminating the need for separate supplemental packaging components. This integration simplifies the overall packaging structure while maintaining effective product protection through the aligned, laterally spaced dunnage panels.
3Strength
If more material is used to form shipping containers, then container strength is improved, but material cost and waste increase
Solution Approach 1:
The patent segments the container body into multiple functional zones including sidewalls, end walls, bottom wall, and integrated dunnage panels. The dunnage panels are positioned in specific locations within the container interior to provide structural support and product protection. This segmentation allows the container to achieve necessary strength through strategic material placement rather than uniformly increasing material usage throughout the entire structure.
Solution Approach 2:
The patent utilizes the composite structure of corrugated board itself, which combines outer linerboards with an inner fluted medium to achieve high strength-to-weight ratio. The dunnage panels leverage this composite material properties to provide structural support and product protection without requiring additional materials. The aligned, laterally spaced dunnage panels work together with the container body to distribute loads and enhance overall container strength while minimizing material usage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables secure product protection during shipping without supplemental materials, reduces waste by using entirely recyclable materials, and optimizes material usage for strength and efficiency.
Implementation Method 1
The first dunnage panel includes a plurality of 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
Data Source
AI summary
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.