SYSTEMS AND METHODS RELATED TO CUSTOMIZABLE DUNNAGE

Description

BACKGROUND OF THE INVENTION

It has long been known in the world of cargo transportation that one cannot simply pack a box with loose articles and call it a day. For some more robust cargo, this strategy may be sufficient, although some cargo may damage others in transportation. Yet, for fragile cargo especially, goods cannot be left without some sort of protection from jostling, friction, and blunt damage from hitting the box, the wall, itself, or other cargo. After all, no transporter would make any money if everything they shipped was broken or damaged on arrival. For these reasons, various forms of dunnage have been invented.

Dunnage is a produced or waste byproduct material that is used to load and secure cargo during transportation. Essentially, dunnage is a buffer to fill space in a shipping container (e.g., a box) between cargo items and/or between one or more cargo items and the container, which is meant to absorb shock and movement to prevent any damage to the actual cargo being shipped. Dunnage became essential as during the industrial revolution, as mass cargo shipments by ship, and later by rail and air, became standard. When goods were jostled by the movement of the ship, or train or plane, dunnage was paramount in protecting the goods for damage and being able to sell them at full value at the destination.

Historically, waste products such as scrap wood or old linen or leather would be used as dunnage, stuck in between cargo loads in ship hulls or train cars. In more modern times, and for more fragile cargo, other forms of dunnage with better shock absorption properties have been invented. For example, modern dunnage may include bubble wrap, wadded or crumpled paper, Styrofoam “peanuts,” or inflated air packs.

Not all forms of dunnage are adequate for different sizes of cargo disposed in different sizes of shipping containers. That is, prior sheet dunnage was provided in particular sizes for use in particular containers. Thus, packers/shippers may have (and be required to stock and store) several standard forms of dunnage to be used with specific cargo, due to characteristics of the cargo and/or dunnage, size or shape requirements, or a host of other factors. These problems can be exceedingly costly and/or time consuming for shipping companies. Therefore, more efficient systems and methods for customizable dunnage are sought in the art.

SUMMARY OF THE INVENTION

Embodiments of systems and methods according to the present invention relate generally to methods and devices for customizable dunnage. In particular, a system for customizable dunnage generally including a sheet divided into tabs by stress risers. Each tab further comprises domes, which act as first or primary crumple zones to absorb impact, the domes being preferably spanned by a bridge structure, which may serve as a secondary crumple zone. The stress risers allow the sheet to be bent and/or preferably manually torn in various sizes and configurations as needed, making the system customizable to a particular container size and/or void-filling need of the user.

According to an aspect of an embodiment of a system according to the present invention, a sheet (a preferably unitary sheet) comprises a plurality of tabs, each tab being defined by at least one, but preferably a plurality of stress riser(s) (e.g., grooves, crimps, perforations, notches, etc.). Each tab preferably includes at least one dome (preferably extending about an axis disposed generally perpendicular to the sheet) extending from a first surface of the tab. The sheet has a first substantially uniform thickness defined by the stress risers and a second substantially uniform thickness of the tabs (and preferably the domes).

According to another aspect of an embodiment of a system according to the present invention, the sheet further comprises a first side and a second side and wherein the plurality of stress risers comprise a first set and a second set of stress risers formed, cast, or pressed into the first side of the sheet. A set of stress risers may include the same general cross-section, such as a V-shaped cross-section or a U-shaped cross-section. Other stress risers may be formed, cast, or pressed into the second side of the sheet, and may be aligned with the stress risers formed on the first side.

According to still another aspect of an embodiment of a system according to the present invention, each tab preferably includes a plurality of domes and wherein two of the domes are connected by a bridge (or rib) portion formed integrally with the tab. The domes and/or bridges may be generally formed in the nature of a shell, having a substantially hollow concave surface, or the domes and/or bridges may have a substantially solid cross-section. Where the domes include a hollow concave surface, the system may include a plurality of sheets arranged in a stack, wherein each dome from a first sheet in the plurality of sheets extends towards and is received against or extends into the hollow concave surface of a respective dome on a second sheet in the plurality of sheets.

According to an aspect of an embodiment of a method according to the present invention, the method includes providing a first unitary sheet including at least one dome. An item or thing is placed into a container (e.g., shipping box or other container) and the sheet is inserted between the item and a first inner wall of the container. The container is closed, thereby enclosing the item and the sheet.

According to another aspect of an embodiment of a method according to the present invention, the method includes the step of altering the sheet, such as by bending, folding, ripping, tearing or cutting the sheet, which may include a plurality of domes disposed on opposite sides of a stress riser, which stress riser may serve as a folding or separation guide.

According to still another aspect of an embodiment of a method according to the present invention, the method further includes the steps of providing a second sheet substantially identical to the first sheet and positioning the second sheet in the container between the item and a second inner wall of the container.

According to still another aspect of an embodiment of a method according to the present invention, the method further includes the steps of providing a second sheet substantially identical to the first sheet and positioning the second sheet in the container between the item and the first inner wall of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a customizable dunnage system according to the present invention.

FIG. 2 is a left side elevation view of the system of FIG. 1.

FIG. 3 is a front elevation view of the system of FIG. 1.

FIG. 4 is a top plan view of the system of FIG. 1.

FIG. 5 is a bottom plan view of the system of FIG. 1.

FIG. 6 is a cross-sectional view of the system of FIG. 1, taken along line 6-6 of FIG. 4.

FIG. 7 is a cross-sectional view of the system of FIG. 1, taken along line 7-7 of FIG. 4.

FIG. 8 is a partial cross-sectional elevation view of the system of FIG. 1, taken along line 8-8 of FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention.

Turning now to the Figures, embodiments of systems and methods related to customizable dunnage may be seen. Specifically, as seen in FIGS. 1-8, a system 100 for customizable dunnage generally comprises a sheet 110 (preferably a unitary sheet) formed into tabs 130 which may be defined by stress risers (bend or break lines) 120. Each tab 130 further comprises one or more domes 132 stamped (or pressed or molded) into the tab 130. Even more preferably, each tab 130 specifically comprises two domes 132 and may further include a bridge 136, which may span a space between the domes 132 and be integrally formed therewith.

The sheet 110, and thus the whole system 100, is preferably made from mixing cellulosic pulp (virgin or preferably recycled, such as recycled paper pulp) that is mixed with an effective amount of water into a pulp slurry. The slurry is provided to a vacuum mold, provided in a respective shape, that draws or forms the slurry against the mold, forming the stress risers 120, the domes 132 and bridge 136 and allowing a discharge of excess slurry and extracting a majority of the water from the slurry. A wet pulp product is ejected from the mold and onto a conveyor to be dried, preferably through a thermal drying process. After drying, the sheet 110 is dry to the human touch and is ready to be stacked with other sheets 110.

Each sheet 110 preferably comprises a thickness 112 extending between a first side 114 and a second side 116. As seen most clearly in FIGS. 2-3 and 6-7, the thickness 112 is preferably substantially uniform throughout the sheet 110, even along domes 132 and bridges 136, with the exception of the stress risers 120. It should also be understood that, while the present FIGS. 1-8 feature a sheet 110 comprising 16 tabs 130 in a 2×8 pattern, the system 100 may be provided in different patterns, resulting in a different number of tabs 130 in a sheet 110. For example, a sheet 110 may be comprised of a 4×8 pattern having 32 tabs 130, a 6×10 pattern having 60 tabs 130, or even an 8×16 pattern having 128 tabs 130. Further, after production, the system 100 is highly customizable and may be formed to any pattern that is needed by a user at a given time, as explained further below.

Stress risers 120 are preferably grooves formed in the sheet 110, which allow the system 100 to be customized according to the user's needs. For example, the stress risers 120 allow a user to bend the sheet 110 along a riser 120. Additionally or alternatively, the risers 120 provide a convenient place to cut or tear (e.g., manually) the sheet 110 without damaging the domes 132 or bridge 136. To make cutting and/or tearing even easier, stress risers 120 may optionally be perforated, which would allow a user to easily cut and/or tear along the risers 120 to form their desired shape from the sheet 110. In the embodiment shown in FIGS. 1-8, the stress risers 120 are preferably formed in the first side 114 of the sheet 110. However, other embodiments may feature stress risers 120 formed in the second side 116 of the sheet 110 in addition to (and preferably aligned with) or alternatively to the first side 114.

The system 100 preferably comprises two forms of stress risers 120, each designed for a different flexing function. V-risers 122, as seen in FIGS. 2, 7 & 8, allow the sheet 110 to be bent outward (i.e. the second side 116 of one tab 130 is rotated about the V-riser 122 towards the second side 116 of another tab 130). Conversely, U-risers 124, as seen in FIGS. 3 & 6, allow the sheet 110 to bend inward (i.e. the first side 114 of one tab 130 is rotated about the U-riser 124 towards the first side 114 of another tab 130). Further, as mentioned above, both V-risers 122 and U-risers 124 may act as break or cut guides for the user to further customize the sheet 110 to their particular needs, although the sheet 110 may be broken (i.e. ripped) or cut along any portion thereof (i.e. not along stress risers 120) according to the user's particular needs.

Each tab 130 preferably comprises at least one dome 132 formed in a molding process and most preferably comprises a plurality of (e.g., two domes 132). The dome(s) 132 preferably define a primary crumple zone, where deformation of the dome(s) 132 may occur by a first force component directed at least partially perpendicular to and towards the first side 114. A secondary crumple zone may be defined by additional structure, preferably extending from the same side 114,116 of the sheet 110, such as a bridge 136. The domes 132 preferably extend from the first side 114 of the sheet 110 to a primary dome radius 132a that is preferably substantially the same for every primary dome 132 on the sheet 110, regardless of the size of the sheet 110. Secondary domes may be provided, extending preferably from the same side of the sheet as the primary dome(s) 132 to a secondary (or even tertiary) dome radius that is less than the primary dome radius 132a.

Similar to the domes 132, the bridge 136 preferably extends from the first side 114 of the sheet 110 to a bridge height 136a that is preferably substantially the same for every bridge 136 on the sheet 110, but is preferably less than the dome radius 132a. Thus, there is preferably a height difference 140 between the dome radius 132a and the bridge height 136a. Each bridge 136 preferably further comprises a bridge length 136b that may vary depending on the size of the sheet 110 produced. For example, a sheet 110 having longer tabs 130, may have a greater bridge length 136b between domes 132 than one with shorter tabs 130. Each bridge 136 further preferably comprises a top surface 136c that runs substantially parallel to the sheet 110, such that the bridge height 136a is at least substantially constant along the bridge length 136b.

All domes 132 on a sheet 110 are preferably formed to extend from the same side 114,116 of the sheet 110. The domes 132 are substantially hollow, including a first cavity 134 accessible on the other side 116,114 of the sheet 110. Similarly, the bridge 136 preferably extends from the same side 114,116 as the dome(s) 132, extending therebetween, and is preferably formed to be substantially hollow in the molding process, leaving behind a second cavity 138 accessible on the other side 116,114 of the sheet 110. Alternatively, however, some embodiments of the system 100 may comprise domes 132 and/or bridges 136 that are substantially not hollow. For instance, in the manufacturing process, the first and/or second negative spaces 134,138 may instead be substantially solid, filled with pulp of the same material used to manufacture the system 100.

The function of the domes 132 and bridge 136 remain the same, whether they are substantially hollow or not. In use, the sheet 110 may be customizable by folding, breaking, and/or cutting along stress risers 120 to fit between goods in transportation, or between goods and a container. As transportation is occurring, the domes 132 act as crumple zones, which absorb impact energy and dissipate it, cushioning the goods. Further, when an impact is significant and causes the domes 132 to crumple down to the top surface 136c of the bridge 136, the bridge 136 preferably acts as a secondary crumple zone to further absorb impact energy and dissipate it. Further, the bridge 136 is relatively rigid as compared to the domes 132, thereby providing greater force resistance before crumpling than the domes 132. In this way, each sheet 110 may provide a multi-stage energy dissipation system 100 that acts to prevent goods from being damaged.

Storage and combinatory use are also enhanced by the instant invention. That is, stacking and sheet registration (alignment) are enhanced when one sheet 110 is stacked on top of another (e.g., by introducing the first side 114 of one sheet 110 to the second side 116 of another), which is advantageous for storage and packaging of multiple sheets 110 for shipment (e.g. on a pallet). Further, a first sheet 110 (or one or more tabs 130 thereof) may be stacked on another by introducing the first side 114 of one sheet 110 to the second side 116 of another. Two or more sheets 110 in a stack may offer potentially greater protection for goods, as more sheet 110 layers provide more resistance and occupy greater void space in a shipping container. Alternatively, sheets 110 may be stacked and/or configured in other ways, such as with the first sides 114 of two sheets 110 facing each other or with the second sides 116 of two sheets 110 facing each other.

Accordingly, to use customizable dunnage according to the present invention, a shipping container (e.g., box) may be identified, and a size differential between an internal cavity of the shipping container and a first thing or item (product, good, cargo, etc.) to be inserted into the container may be measured or estimated. A first sheet 110 including one or more tabs 130 is provided or selected. If the first sheet 110 is larger in any dimension than a side of the container to be interfaced, the first sheet 110 may be bent, cut or trimmed (e.g., along stress risers 120, or otherwise). The thing and first sheet 110 are inserted into the container, one after the other, or substantially simultaneously, such that the first sheet 110 rests at least partially between the thing and a first inner wall of the shipping container. One or more additional sheets 110 (selectively trimmed or sized, if desired) including one or more tabs 130 may be placed between the thing and other inner wall(s) of the shipping container, or between the first sheet 110 and the first inner wall, or between the first thing and a second thing. Where a first sheet 110 and a second sheet 110 are combined between the first thing and the first inner wall (or are otherwise combined in a preferably substantially aligned or registered arrangement), the first surface 114 of the first sheet 110 may be placed in contact with the second surface 116 of the second sheet 110. Alternatively, where a first sheet 110 and a second sheet 110 are combined between the first thing and the first inner wall (or are otherwise combined in a preferably substantially aligned or registered arrangement), the first surface 114 of the first sheet 110 may be placed in contact with the first surface 114 of the second sheet 110. Alternatively, where a first sheet 110 and a second sheet 110 are combined between the first thing and the first inner wall, the second surface 116 of the first sheet 110 may be placed in contact with the second surface 116 of the second sheet 110 (or a single sheet 110 may be folded, such as along a stress riser 122, to dispose a second surface 116 of a first tab 130 against a second surface 116 of a second tab 130 of the same sheet). Additionally or alternatively, a first sheet 110 may be randomly situated with one or more additional tabs 130, such as by individual tabs 130 being selected or divided from a sheet 130, then randomly placed in the shipping container in locations between the first thing and the first inner wall, between the first thing and at least one other inner wall, and/or between the first thing and a second thing.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, because numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention. For instance, a preferred thickness 112 is about 0.2 inches to about 0.35 inches, with about 0.25 to about 0.31 inches preferred, but other thicknesses are contemplated. Also, for example, a preferred dome radius 132a is approximately one inch to approximately 1.5 inches, with about 1.2 inches to about 1.3 inches preferred, though other radii are contemplated. Preferred tabs 130 have a length preferably extending parallel to the direction of the bridge 136, the length being about 5 inches to about 6 inches, with about 5.25 inches to about 5.75 inches being preferred, though other lengths are contemplated between an outer edge and a stress riser 124, or between stress risers 124. Preferred tabs 130 have a width preferably extending perpendicular to the direction of the bridge 136 and parallel to its top surface 136c, the width being about 3 inches to about 4 inches, with about 3.25 inches being preferred, though other widths are contemplated between an outer edge and a stress riser 122, or between stress risers 122. Further, though shown as including two tabs 130 along a tab length direction between an outer edge and a stress riser 124 and eight tabs 130 along a tab width direction between an outer edge and a stress riser 122, it is to be understood that sheets having substantially rectangular outer edge may be formed with different numbers of tabs 130 (at least one, but more preferably at least two) along the tab length direction and (at least one, but more preferably at least two) along the tab width direction. Other regular and irregular outer edge shape configurations are contemplated.