Patent Application
20180022525
The present invention relates to packaging for large articles. More particularly, it relates to a corner piece which can be used to form protective assemblies for packaging an article and protecting exterior edges of the article.
Large or heavy articles generally require specialized packaging for storage and transport to avoid damage. A popular means for packaging large articles involves the use of L-shaped cardboard corner posts, also known as edge protectors. These posts can be secured between a lid and a base, and can serve to protect the corners of the article while also providing vertical support when the article is palletized and stacked.
Existing designs have sought to increase the axial compression strength of the corner posts. These designs involve varying the shape and contour of the posts, and providing means for maintaining their shape while supporting a load.
Some existing designs also provide additional protection to a packaged article by creating spacing between the article and its outer packaging, such as a stretch wrap for example. In this fashion, the exterior of the appliance has a reduced risk of damage when the packaging is opened using a box cutter, for example. These types of corner posts generally have an inner wall and an outer wall separated by an air gap. When assembled, the inner wall is in contact with the appliance, and the outer wall is in contact with an outer packaging. The outer packaging is thus distanced from the appliance by the spacing formed by the air gap in the corner posts.
Disadvantageously, this type of corner post can be difficult to transport. The presence of an air gap makes it such that the corner post is voluminous, with up to 80% of its body being empty space. Additionally, these types of posts are not always reusable. Once damaged, the corner post may be unable to support axial and/or radial compression, and the entire post will need to be recycled at a paper mill.
Gaylord containers are another popular packaging means for appliances and other large or bulk article. These are large containers made of double or triple-walled corrugated cardboard, generally sized to fit on a pallet. Disadvantageously, these types of containers cannot be disassembled and are of a fixed size. Additionally, for large items, these containers may need to be combined with corner posts, such as those described above, in order to provide adequate support. This increases the number of components required to assemble the packaging.
According to an aspect, a corner piece configured to retain an exterior edge protector and space it apart from an external edge of an article is provided. The corner piece has a body including: an inner member having an apex; an outer member having an apex; a connecting member connecting the inner member to the outer member and substantially aligning their respective apexes, the outer member and the inner member being spaced apart from one another; and a securing element provided in the outer member, the securing element having substantially U-shaped retaining walls engageable with the exterior edge protector to retain the exterior edge protector along the outer member.
In an embodiment, the securing element provided in the outer member is a first securing element, and the body further includes a second securing element provided in the inner member, the second securing element including substantially U-shaped retaining walls engageable with an interior edge protector to retain the interior edge protector along the inner member.
In an embodiment, the body further includes first and second retaining cavities defined in a spacing between the outer member and the inner member on opposite sides of the connecting member, for respectively engaging first and second container walls.
In an embodiment, the retaining cavities are substantially rectangular in shape and have a width of at least 5 mm and at most 100 mm.
In an embodiment, the outer member includes outer and inner sidewalls spaced apart from one another, the inner and outer sidewalls together defining the substantially U-shaped retaining walls.
In an embodiment, the outer sidewalls are partial sidewalls extending parallel to the inner sidewalls along a partial length thereof.
In an embodiment, the outer sidewalls extend parallel to the inner sidewalls along a full length thereof, the outer and inner sidewalls together defining an L-shaped cavity for receiving the exterior edge protector.
In an embodiment, the inner and outer sidewalls are spaced apart from one another by at least 2 mm and at most 15 mm.
In an embodiment, the inner and outer members are spaced apart from one another by at least 10 mm.
In an embodiment, the inner and outer members are substantially L-shaped.
In an embodiment, the body is formed from extruded plastic.
According to an aspect, a method for assembling a protective assembly for protecting an external edge of an article during transport is provided. The method includes the steps of: a) providing an elongated edge protector; b) providing at least one corner piece having a body including: an inner member having an apex; an outer member having an apex; a connecting member connecting the inner member to the outer member and substantially aligning their respective apexes, the outer member and the inner member being spaced apart from one another; and a securing element provided in the outer member, the securing element having substantially U-shaped retaining walls; and c) inserting the elongated edge protector into the U-shaped retaining walls of the securing element.
In an embodiment, the elongated edge protector is a first edge protector and the securing element provided in the outer member is a first securing element, and the body of the at least one corner piece further includes a second securing element provided in the inner member, the second securing element having substantially U-shaped retaining walls; the method further including the steps of providing a second elongated edge protector and inserting the second elongated edge protector into the U-shaped retaining walls of the second securing element.
In an embodiment, in step b), the at least one corner piece is a plurality of corner pieces, and step c) includes inserting the elongated edge protector successively into the U-shaped retaining walls of the securing element in each of the plurality of corner pieces.
In an embodiment, the method further includes the step of evenly spacing the plurality of corner pieces along a length of the elongated edge protector.
In an embodiment, the body of the at least one corner piece further includes first and second retaining cavities defined in a spacing between the outer member and the inner member on opposite sides of the connecting member, the method further including the steps of: f) providing first and second container walls; and g) respectively inserting the first and second container walls into the first and second retaining cavities.
In an embodiment, the method further includes repeating steps a) through e) four times to create four protective assemblies, and assembling the four protective assemblies in a substantially rectangular configuration, thereby defining respective corners of a container box, wherein each of the four protective assemblies are connected to first and second adjacent corners of the container box via the first and second container walls, with each of the four protective assemblies sharing the first and second container walls respectively with the first and second adjacent corners of the container box.
In an embodiment, the method further includes the step of placing the assembled protective assembly along an external edge of an article, and wrapping the article and protective assembly in a protective film.
According to an aspect, a kit for assembling a protective assembly for protecting an external edge of an article during transport is provided. The kit includes: at least one elongated edge protector; and at least one corner piece configured to retain the at least one elongated edge protector, the at least one corner piece having a body including: an inner member having an apex; an outer member having an apex; a connecting member connecting the inner member to the outer member and substantially aligning their respective apexes, the outer member and the inner member being spaced apart from one another; and a securing element provided in the outer member, the securing element including substantially U-shaped retaining walls engageable with the at least one elongated edge protector to retain the at least one elongated edge protector along the outer member.
In an embodiment, the kit includes at least two container walls respectively engageable in a first and second retaining cavities defined in a spacing between the outer member and the inner member on opposite sides of the connecting member.
According to an aspect, a corner piece is provided. The corner piece has a body including an L-shaped outer member with substantially perpendicular sidewalls and an L-shaped inner member with substantially perpendicular sidewalls, the inner and outer members being spaced apart from one another and defining cavities between sidewalls of the outer member and the sidewalls of the inner member, the outer member including a first securing element sized to receive a first elongated L-shaped edge protector and secure it along the sidewalls of the outer member, and the inner member including a second securing element sized to receive a second elongated L-shaped edge protector and secure it along the sidewalls of the inner member.
In the following description, the same numerical references refer to similar elements. For the sake of simplicity and clarity, namely so as to not unduly burden the figures, certain reference numbers are not included in some figures when the features they represent can be easily inferred from other figures. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures or described in the present description are preferred embodiments only, given for exemplification purposes only.
Broadly described, and as better exemplified in the accompanying drawings, the present invention relates to a corner piece which can be used to form protective assemblies for packaging. The corner piece includes a body with an outer member and an inner member spaced apart from one another. At least the outer member is provided with a securing element for retaining and/or securing an edge protector (also referred to as edgeboard, cornerboard, angleboard, a corner post or a vertical support). An edge protector is typically made of cardboard, and can serve to protect the edges of an article, while also serving as a support column for making the article's packaging more resistant to vertical compression and thus more suitable for stacking. The spacing between the inner and outer members can be configured for receiving and securing container walls. The corner piece can be used to form several protective assemblies, also referred to as packaging elements.
With reference to
In the illustrated embodiment, the body 101 of the corner piece 100 has an outer member 102 and an inner member 103. Preferably, the outer member 102 and inner member 103 are spaced apart from one another. Preferably still, the inner member 103 is configured for placing proximate to or along an exterior edge of an article, and can be L-shaped to conform to a perpendicular edge of an article. As can be appreciated, in this configuration, the spacing between the inner member 103 and the outer member 102 defines a separation between an exterior edge of an article and the outer member 102 when the corner piece 100 is placed or installed along an edge of an article.
In the present embodiment, each of the outer 102 and inner members 103 are substantially L-shaped, and can therefore be referred to as being “L-shaped members”. In alternate embodiments, however, the shape of the outer and inner members 102, 103 can vary, for example to accommodate different shapes of articles. Preferably, the shapes of the outer and inner members 102, 103 are complementary, in that they can be spaced apart by a nominal distance and arranged parallel to one another without intersecting. Preferably still, each of the outer and inner members 102, 103 comprise respective apexes 108, 109, allowing the corner piece to define a corner or angle.
The outer and inner members 102, 103 are secured to one via a securing member 130. In the present embodiment, the securing member 130 spaces outer and inner members 102, 103 apart from one another by a distance 132, while aligning their apexes 108, 109. Preferably, the securing member 130 rigidly secures the outer and inner members 102, 103 so that they do not move relative to one another when subject to a nominal force. However, in alternate embodiments, the securing element 130 can be configured such that it is partially flexible, allowing the securing element 130 to absorb a shock, for example.
In the illustrated embodiment, the securing element 130 includes first and second walls 134, 136, and is reinforced by reinforcing member 138. The first and second walls 134, 136 extend perpendicular to the outer and inner members 102, 103, on opposite sides of their respective apexes 108, 109. The first and second walls 134, 136 are also positioned perpendicular to one another, with the reinforcing member 138 extending diagonally there between. Other configurations of the securing element 130 are also possible. For example, the reinforcing member 138 can have a different shape or could comprise a more complex arrangement, such as a lattice. Preferably, however, securing member 130 is hollow, and may include inner cavities or empty spaces 140.
The outer and inner members 102, 103 respectively comprise inner sidewalls 104, 105. Each of the inner sidewalls 104, 105 can comprise distinct segments which meet at apexes 108, 109. For example, outer member 102 comprises a first segment 1410 and a second segment 142o which meet at apex 108. Similarly, inner member 102 comprises a first segment 141i and a second segment 142i which meet at apex 109. The first segments 141i, 1410 extend substantially perpendicular to second segments 142i, 142o, defining an L-shaped configuration. Each of the segments 141i, 141o, 142i, 142o extends along a length 117. Preferably, the length 117 of first and second segments is identical or similar, thereby forming a substantially symmetrical shape of the members 102, 103 when reflected along apexes 108, 109.
In the illustrated embodiment, the inner sidewall 104 of the outer member 102 extends parallel to the inner sidewall 105 of the inner member 103, and the two are spaced apart by a distance 132, defining first and second retaining cavities 120, 122 with width 132. Preferably, the retaining cavities 120, 122 are rectangular-shaped and configured to receive and secure container walls therein. For example, the retaining cavities 120, 122 preferably have a width of at least 5 mm and at most 100 mm, and preferably between 10 mm and 40 mm, to secure container walls of a corresponding thickness. Preferably still, the retaining cavities 120, 122 extend on opposite sides of the connecting member 130 and are arranged substantially perpendicular relative to one another, allowing container walls to be secured in a substantially perpendicular configuration. In the present embodiment, the retaining cavities 120, 122 are further defined by the first and second sidewalls 134, 136 of the connecting members, providing end-walls against which the container walls abut when inserted into the cavities 120, 122. Although in the present embodiment the cavities 120, 122 are rectangular in shape, other shapes are also possible, for example to more effectively retain container walls. For example, the cavities can be curved or can include textured sidewalls or ribs.
In the illustrated embodiment, both members 102, 103 and their inner sidewalls 104, 105 are the same size and have the same L-shaped configuration. However, in other embodiments, their relative sizes may vary. Additionally, although the members 102 and 103 are L-shaped in the present embodiment, other shapes are also possible without departing from the scope of the invention. Preferably, the shapes of the members 102 and 103 have complementary forms, and can therefore be arc-shaped or W-shaped, for example.
The outer and inner members 102, 103 are each provided with securing elements 110, 111. The securing elements 110, 111 engage with respective edge protectors and secure the edge protectors along the outer and inner members 102, 103, and preferably along the height 128 of the body 101. As can be appreciated, the securing elements 110, 111 can secure pre-shaped edge protectors, such as laminated cardboard, in a spaced-apart configuration. However, it should also be appreciated that the securing elements 110, 111 can secure a flattened or unshaped cardboard piece while forming it into a particular shape, for example to form the shape of an edge protector. For example, with the securing elements 110, 111 in an L-shaped configuration, a flattened piece of cardboard can be folded in half to form an L-shape. The folded cardboard can then be engaged with securing elements 110, 111, which will retain the cardboard in the folded L-shape. In this sense, the securing elements 110, 111 can also be referred to as shaping elements.
The securing elements 110, 111 in the outer and inner members 102, 103 preferably comprise U-shaped retaining walls 112, 113. The U-shaped retaining walls 112, 113 are configured to retain at least a distal end or wing of a corresponding edge protector. The U-shaped walls 112, 113 each include two parallel segments to fit a wing of the edge protector, and an end segment, facing the tip of the wing. Preferably, each securing element 110, 111 comprises two U-shaped retaining walls, each being for retaining a corresponding wing of an edge protector. For example, in the illustrated embodiment, outer member 102 includes first U-shaped retaining walls 112 for retaining a first wing of an edge protector, and second U-shaped retaining walls 112′ for retaining a second wing of an edge protector. Similarly, outer member 103 has respective first 113 and second 113′ U-shaped retaining walls.
Although the term U-shaped retaining walls is used, it should be appreciated that other retaining wall shapes and/or different types of retaining elements are also possible, as long as such shapes and/or elements allow to securely retain edge protectors. It should also be appreciated that the securing elements 110, 111 can be provided with more or fewer U-shaped retaining walls, for example to retain a different portion of an edge protector. For example, in some embodiments, the corner piece can be configured for inserting on opposite ends of an edge protector, and the U-shaped retaining elements can retain the ends of the edge protector.
The outer and inner members 102, 103 are further provided with outer sidewalls 106, 107 extending parallel to the inner sidewalls 104, 105, and spaced apart therefrom by a distance 114. The outer sidewalls 106, 107 define, together with the inner sidewalls 104, 105, the U-shaped retaining walls 112, 113. Preferably, the inner 104, 105 and outer sidewalls 106, 107 are spaced apart from one another by a distance 114 between 2 mm and 15 mm, so as to accommodate and secure an edge protector of a corresponding thickness.
In the present embodiment, the outer sidewalls 104, 105 extend along a full length 117 of the inner sidewalls 106, 107. In this fashion, the inner 104, 105 and outer 106, 107 sidewalls together define outer and inner edge protector retaining cavities 118, 119. Outer and inner edge protector retaining cavities 118, 119 are sized to receive respective edge protectors therein. Preferably, the retaining cavities 118, 119 are complementary in shape to a cross-section of the respective edge protectors. For example, in the illustrated embodiment, the retaining cavities 118, 119 are substantially L-shaped cavities for accommodating corresponding L-shaped edge protectors.
It should be understood that in alternate embodiments, different configurations of the securing elements 110, 111 are possible. For example, with reference to
As a further example, and with reference to
As can be appreciated, the corner piece 100 can be assembled in several configurations in order to form packaging elements, also referred to as protective assemblies. With reference to
The edge protectors 202, 203 are preferably straight, rigid, elongated, and preformed into an L-shaped configuration. They can be made of cardboard, for example. In some embodiments, they can be unformed, and be rectangular in shape, while being able to bend around a central seam to form an L-shape. In such embodiments, when the edge protectors 202, 203 are inserted into L-shaped members 102, 103, the edge protectors 202, 203 take the L-shape form of said members. In this configuration, the edge protectors 202, 203 may better resist axial compression, and may be suited for protecting right-angled corners of an article being packaged.
When supported by members 102, 103, the edge protectors 202, 203 are evenly spaced apart along their length by a distance 232, corresponding to the spacing 132 between the outer and inner members 102, 103. In this fashion, if any damage occurs to the outer edge protector 102, the inner edge protector 103 may avoid the damage and protect the packaged article.
Several corner pieces 100 can be assembled in a vertical fashion in order to form a protective assembly. In this example, the protective assembly is an L-shaped corner post for packaging, as best shown in
As can be appreciated, and referring to
In other configurations, the corner piece may be used to form a corner of a storage container. With reference to
In this configuration, the container walls 402, 404 are secured perpendicularly to one another. Of course, in other configurations, for example if the corners of a desired container are not right angles, the corner piece 100 could be shaped such that the walls 402 and 404 are secured at an acute or oblique angle, or secured side-by-side.
In a preferred embodiment, the container walls 402 and 404 are made of a recyclable, rigid material, which is thick enough to fit snugly within the rectangular-shaped retaining cavities 120 and 122. For example, the walls 402 and 404 could be made of double- or triple-walled corrugated cardboard, and have a thickness of between 5 mm and 100 mm.
As can be appreciated, the protective assembly described above can be assembled according to the following steps. First, a corner piece 100 is provided. Next, first and second container walls 402, 404 are provided. Then, the first and second container walls 402, 404 are respectively inserted into the first and second retaining cavities 120, 122.
Several storage container corners can be assembled to form a storage container. With reference to
Although in the present embodiment the storage container 500 is square, other configurations are possible. For example, a pair of the walls could be elongated, such that the overall shape of the storage container is rectangular. In other configurations, if the corner pieces retain the walls at an obtuse angle, the corners can be used to assemble a storage container in the shape of an octagon, or other geometric shape.
As can be appreciated, the storage container described above can be assembled according to the following steps. First, four protective assemblies 400 are assembled as described above. Next, the four protective 400 are assembled in a substantially rectangular configuration, forming four corners of the box 500. In this configuration, each of the four protective assemblies 400 are connected to first and second adjacent corners of the container box via the first and second container walls, with each of the four protective assemblies sharing the first and second container walls respectively with the first and second adjacent corners of the container box.
In yet other configurations, the corner piece 100 may be used to form a corner of a storage container with integrated corner posts. With reference to
Several storage container corners with integrated corner posts can be assembled to form a storage container with integrated corner posts. With reference to
As can be appreciated, the described embodiments provide several advantages. The spacing of the vertical supports better protects the contents of the container. If any damage is done to the outer supports, for example if the container is opened using a box cutter, the inner support can better avoid this damage. The present invention also provides means to reuse packaging materials. If the vertical supports or box walls are damaged, they can simply be removed and replaced. When a box is disassembled, the corner pieces can be reused in other boxes or corner posts, without having to recycle the corner piece back into raw plastic. Finally, the present invention allows for the packaging materials to be transported more easily. When disassembled, the vertical supports do not have empty space, and are more space-efficient during transport. The supports can be assembled at their destination in the form of a corner post, where they will gain increased volume associated with the desired spacing between supports, as described.
The described configurations are but some possible embodiments for the corner piece of the present invention. Although not explicitly mentioned, other useful embodiments or configurations may be apparent to one skilled in the art upon reading the present disclosure. Additionally, although some advantages have been described herein, other advantages may become apparent to one skilled in the art upon reading the present disclosure.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CA2016/050153 | 2/19/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62117973 | Feb 2015 | US |
