Patent Application
20230068590
The present invention relates to protective packaging materials, and more particularly to an edge protector for placement on the interior or exterior of an article or container, which is uniquely constructed and arranged to maintain its shape for providing reinforcement and protection to the corners of articles and container while also being simple, fast and economical to assemble.
Edge protectors, corner posts, and the like are generally known in the packaging industry to prevent damage to the edges of articles, as well as add strength to lightweight containers such as cardboard boxes to prevent crushing when stacked.
The prior art is replete with edge or corner protectors, or corner post supports. Examples can be found in U.S. Pat. Nos. 3,613,985; 3,982,682; 4,247,289; 4,399,915; 4,771,893; 5,431,985; 5,813,537; and 6,595,367, each of which have one or more of the following problems. While some provide good cushioning protection, they do not provide a load bearing capacity that strengthens a lightweight container sufficiently to allow for heavy stacking of multiple containers. Others that do provide structural reinforcement tend to be bulky, requiring large amounts of material that waste valuable packaging space and add unwanted weight to the container. In either case, most protectors are typically expensive and time consuming to manufacture. Additionally, and perhaps the worst problem with most corner protectors is that they fail to hold their shape, causing them to be difficult to handle and properly place in a container or around the edge of an article. Sometimes, the edge protector may deform after it is placed in the container, leading to a structural collapse of the container and damage to the item contained therein.
Accordingly, it is an object of the present invention to provide an edge protector that maintains its shape once folded.
It is another object of the present invention to provide an edge protector that is easy and fast to assemble while being economical to produce.
It is another object of the present invention to provide an edge protector that works both as a cushioning member to protect articles, as well as a structural reinforcing member when placed in a container.
The above objectives are accomplished according to the present invention by first providing a blank sheet of foldable material having a top side and a bottom side. A plurality of fold lines scored into the sheet dividing the sheet into a plurality of consecutive panels to allow for easy folding of the panels into overlapping engagement. A notched edge protecting section is formed by folding at least two panels into an overlapping engagement and removing material from at least two panels folded in an overlapping engagement. An un-notched edge protecting section is formed by folding at least two panels into an overlapping engagement. The sheet of foldable material is folded so that the un-notched edge protecting section extends outwardly from the notched edge protecting section and in at least one embodiment extends outwardly at approximately 90 degrees. In one embodiment, a first leg and a second leg are included in the notched edge protecting section wherein the second leg mirrors the first leg, and each of the first leg and the second leg have an inner longitudinal edge, an outer longitudinal edge and an outside edge interconnecting the inner longitudinal edge and the outer longitudinal edge wherein the angle between the first longitudinal edge and the outside edge is greater than 90 degrees. In one embodiment, a third and a fourth leg are formed from the folding of the un-notched edge protecting section so that at least a portion of the inner longitudinal edge of the first leg contacts at least a portion of the inner longitudinal edge of the second leg.
In at least one embodiment, the first and second legs are perpendicular to the third and fourth legs and the outside edge of the first leg is perpendicular to the outside edge of the second leg. In this embodiment, the angle between the notched edge protecting section and the un-notched edge protecting section is approximately 90°.
In at least one embodiment, the blank sheet of foldable material comprises corrugated paperboard, which is divided into six consecutive panels and one of the notched edge protecting section and the un-notched edge protecting section is formed from the overlapping of panels one, four, and five so that a top side of panel one is placed in face-to-face contact with a top side of panel four, and a top side of panel five is placed in face-to-face contact with a bottom side of panel one while one of the notched edge protecting section and the un-notched edge protecting section is formed from the overlapping of panels two, three, and six so that a top side of panel two is placed in face-to-face contact with a top side of panel three, and a top side of panel six is placed in face-to-face contact with a bottom side of panel two.
In one embodiment, panels three and four are of unequal width so that the notched edge protecting section may be formed with a width that is different than the width of the un-notched edge protecting section, and wherein panel two has a width less than that of panel three. In at least one embodiment, panel one has a width less than that of panel four, panel five has a width greater than that of panel one and less than that of panel four, and panel six has a width less than that of panels two and three.
In at least one embodiment, the edge protector includes a securing member interconnecting the first leg and the second leg so that contact between at least a portion of the first leg and at least a portion of the second leg is maintained.
In one embodiment, the un-notched edge protecting section includes a first side leg and a second side leg, each comprising at least two panels folded into an overlapping engagement wherein the second side leg is integrally connected to the first side leg and is perpendicular to the first side leg. In one embodiment, the notched edge protecting section forms a top section comprising at least two panels folded into an overlapping engagement, wherein the top section is integrally connected to the first side leg and the second side leg and is perpendicular to both the first side leg and the second side leg.
The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
With reference to the drawings, the invention will now be described in more detail. Referring to
Referring to
To prepare sheet 10 for folding, a plurality of parallel fold lines 16a-d are created into sheet 10 and laterally spaced to divide the sheet into five consecutive panels numbered 1-5. As is true for all embodiments of the present invention described herein, these fold lines can be created by any means, including scoring, denting, depressing and/or perforating the sheet so as to make it more foldable along the fold lines. The panels are accordingly hinged together at the scored fold lines to allow for easy folding of the panels into overlapping engagement. For the embodiment shown in 1-3, it is of particular importance that fold line 16a scored between panels 1 and 2 be scored on bottom side 14 of sheet 10, while the rest of fold lines 16b-d are scored on top side 12 of sheet 10. As is described in detail below, it is necessary for panel 1 to fold in an opposite manner as the rest of the panels, thereby necessitating fold line 16a to be scored on the bottom side of the sheet.
As shown in
Referring to
Generally, after sheet 10 has been scored, the sheet is then folded at fold line 16b between panels 2 and 3 to overlap panels 3 and 4 with panels 1 and 2 so that top side 12 of panel 2 is placed in face-to-face contact with top side 12 of panel 3, and top side 12 of panel 1 is placed in face-to-face contact with top side 12 of panel 4. As shown in
Referring to
Next, sheet 10 is folded at fold line 16d between panels 4 and 5 so that top side 12 of panel 5 is placed in face-to-face contact with bottom side 14 of panel 1, which locks the panels together in position through a combination of the folding arrangement and the adhesive discussed above provided in the form of glue lines 22a-c. This forms second leg 20 intersecting with first leg 18. Accordingly, second leg 20 is thus formed from folding sheet 10 to overlap panels 1, 4, and 5 so that the top side of panel 1 is placed in face-to-face contact with the top side of panel 4, and the top side of panel 5 is placed in face-to-face contact with the bottom side of panel 1.
Preferably, the first leg and the second leg intersect at approximately a 90° angle with each other to provide an edge protector for right angles, as well as to reinforce the edges of paperboard boxes and the like. Accordingly, referring to
Referring to
Referring to
It is advantageous to score fold lines 16a and 16e on bottom side 14 of sheet 10, while the rest of fold lines 16b-d are scored on top side 12 of sheet 10. As noted above, it is necessary for panel 1 to fold in an opposite manner from panels two, three, four and five, thereby necessitating fold line 16a to be scored on the bottom side of the sheet. Panel 6 also folds in an opposite direction from all the panels except panel 1, thus requiring a score line on the bottom 14 of sheet 10 to promote folding. While placing score lines 16a and 16e on bottom side 10 is preferable, it is not essential and the folding arrangement described herein can be accomplished regardless.
Glue lines 22a-d are placed on top side 12 of panels 3, 4, 5 and 6. As compared to the five panel embodiment, the addition of glue line 22d is preferred to secure panel 6 to bottom side 14 of panel 2 when folded. By placing glue line 22d on top side 12 of panel 6, all the glue can be place on a single side of sheet 10 during assembly so that additional glue does not have to be added during the folding process.
The preferred embodiment for the five panel embodiment described above sets forth that panels 3 and 4, which form the length of legs 18 and 20, are to be of equal length. However, for both the five and six panel embodiments, it is not necessary for panels 3 and 4 to be of equal lengths. This allows for unique applications in which one leg of the edge protector can be formed longer or shorter than the other leg (i.e. where it is preferred to have a 2″ by 4″ leg arrangement).
Referring to
In a further advantageous embodiment, panels 3 and 4 may be formed of an unequal width so that first leg 18 may be formed longer or shorter than second leg 20. Regardless of the length of panels 3 and 4, panel 2 will have a width less than that of panel 3, panel 1 will have a width less than that of panel 4, panel 5 will have a width greater than that of panel 1 and less than that of panel 4, and panel 6 has a width less than that of panels 2 and 3.
In an alternative embodiment, panels three and four may be constructed of equal width with panels 1, 2, 5 and 6 each have a width less than panels 3 and 4 individually.
In yet another embodiment, the sheet of foldable material 10, which has a top side 12 and a bottom side 14, may be provided with a plurality of parallel fold lines 16a-16c that divide the sheet into four consecutive panels numbered 1-4. In one embodiment, these fold lines 16a-16c are scored into the folding material. In alternate embodiments, however, these fold lines may be depressed or dented into the folding material by hand, gravity, machine or other means generally known in the art. The panels are accordingly hinged together at the fold lines to allow for easy folding of the panels into overlapping engagement. For the embodiment shown in
Prior to folding the sheet 10, it is advantageous to place adhesive 22a and 22b on the top side 12 of panels 3 and 4. That way, when the sheet 10 is folded, the sheet is held in place as folded. The methods for applying the adhesive are discussed above in relation to prior embodiments. As shown in
Referring to
Referring now to
Once a portion of the sheet 10 has been removed, the notched section 30 will include a first leg 32 and a second leg 34. In the shown embodiment, both the first and second legs 32 and 34 include an inner longitudinal edge 32a and 34a, an outer longitudinal edge 32b and 34b and an outside edge 32c and 34c. In at least one embodiment, the first and second legs 32 and 34 of the notched section 30 will mirror one another. In alternate embodiments, however, these legs may not be mirror images of one another.
In one embodiment, the angle θ1 between the first leg's inner longitudinal edge 32a and the second leg's inner longitudinal edge 34a is 90 degrees. In alternate embodiments, the angle of θ1 can be greater or less than 90 degrees. Where θ1 is equal to 90 degrees, angle θ2 and θ3 will both be 135 degrees, where θ2 is the angle between the inner longitudinal edge 32a and the outside edge 32c of the first leg 32 and θ3 is the angle between the inner longitudinal edge 34a and the outside edge 34c of the second leg 34. By varying the degree of θ1, the degrees of θ2 and θ3 will be varied. In at least one embodiment the degrees of θ2 and θ3 are equal, but that is not always the case. However, angles θ2 and θ3 will be greater than 90 degrees.
In the shown embodiment, an un-notched section 36 comprises the first leg 18 of the edge protector depicted in
The un-notched section 36 includes a latitudinal fold line 42 that in at least one embodiment is located at the longitudinal midpoint of the un-notched section 36. In at least one embodiment, fold line 42 is depressed or dented into the un-notched section 36 by striking the un-notched section with sufficient force to create an indention but not to cut or otherwise break the surface of the un-notched section. In alternate embodiments, fold line 42 may be scored into un-notched section by means discussed above or generally known. A first side leg 38 and a second side leg 40 (which are also referred to at times simply as a third and fourth leg respectively) are formed by folding the un-notched section 36 at fold line 42. Preferably, first side leg 38 and second side leg 40 are placed in a generally perpendicular angular relation to one another but this is not always the case. In at least one embodiment, the outside edges 32c and 34c are shorter in length than the first side leg 38 and second side leg with which such outside edges correspond such that outside edge 32c has a length that is less than that of first side leg 38 and outside edge 34c has a length that is less than that of second side leg 40.
Preferably, the un-notched section 36 is folded at fold line 42 until the inner longitudinal edges 32a and 34a of the first and second legs 32 and 34 of the notched section 30 contact one another. The degree of the angle θ1 will determine the angular relation between the first side leg 38 and the second side leg 40, when the un-notched section is folded to place the inner longitudinal edges 32a and 34a in contact with one another. This way, the corner piece edge protector B can be used on items that have corners that are less or greater than 90 degrees.
Once the un-notched section 36 is folded to create the first side leg 38 and the second side leg 40, at least a portion of the first and second legs 32 and 34 of the notched section contact one another to form a top leg 44. In at least one embodiment, the top leg 44 is perpendicular to both the first and second side legs 38 and 40. The edge protector B can be held in this folded position where at least a portion of the two inner longitudinal legs 32a and 34a are in contact by means generally known in the art, including adhesive, staples and/or friction fit (where the box in which the article is placed maintains the folded position of edge protector B). In the embodiment shown in
As shown in
While a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
