Systems and methods related to customizable dunnage

Abstract

Embodiments of systems and methods according to the present invention relate generally to devices and methods for customizable dunnage. In particular, a system for customizable dunnage generally includes a sheet including tabs defined 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, deformed 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.

What is claimed is: 
     
         1 . A system comprising:
 a unitary sheet comprising a plurality of tabs, each tab defined by a plurality of stress risers,   wherein each tab further comprises at least one dome, and   wherein of the sheet has a first substantially uniform thickness defined by the stress risers and a second substantially uniform thickness throughout the remainder of the sheet.   
     
     
         2 . The system of  claim 1 , wherein the plurality of stress risers comprise grooves formed into the sheet. 
     
     
         3 . The system of  claim 2 , wherein 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 into the first side of the sheet. 
     
     
         4 . The system of  claim 3 , wherein the first set of stress risers comprise a V-shaped cross-section. 
     
     
         5 . The system of  claim 4 , wherein the second set of stress risers comprise a U-shaped cross-section. 
     
     
         6 . The system of  claim 3 , wherein the second side of the sheet comprises a third set and a fourth set of stress risers formed therein. 
     
     
         7 . The system of  claim 6 , wherein the first set and second set of stress risers are substantially aligned with the third set and fourth set, respectively. 
     
     
         8 . The system of  claim 1 , wherein each tab comprises a plurality of domes and wherein the domes of each tab are connected by a bridge formed integrally with the tab. 
     
     
         9 . The system of  claim 8 , wherein each dome comprises a substantially hollow concave surface. 
     
     
         10 . The system of  claim 9 , wherein each bridge comprises a substantially hollow concave surface. 
     
     
         11 . The system of  claim 9 , wherein the system further comprises 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 the hollow concave surface of a respective dome on a second sheet in the plurality of sheets. 
     
     
         12 . The system of  claim 8 , wherein each dome comprises a substantially solid cross-section. 
     
     
         13 . The system of  claim 12 , wherein each bridge comprises a substantially solid cross-section. 
     
     
         14 . A method comprising the steps of:
 providing a first unitary sheet including at least one dome;   placing an item into a container;   inserting the sheet into the container between the item and a first inner wall of the container; and,   closing the container.   
     
     
         15 . The method of  claim 14 , the method further comprising the step of altering the sheet to fit into the container. 
     
     
         16 . The method of  claim 14 , the unitary sheet comprising a plurality of domes disposed on opposite sides of a stress riser. 
     
     
         17 . The method of  claim 15 , the altering step comprising the step of bending the sheet along the stress riser. 
     
     
         18 . The method of  claim 15 , the altering step comprising the step of dividing the sheet along the stress riser by at least one of cutting the sheet and ripping the sheet. 
     
     
         19 . The method of  claim 14 , the method further comprising 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.   
     
     
         20 . The method of  claim 14 , the method further comprising 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.