Abstract:
An edge or corner protector comprises an apex portion and a pair of leg members extending away from the apex portion so as to define an angle of approximately 90° therebetween. The apex portion and leg members are defined by a plurality of paper plies which have at least two different width dimensions. Relatively narrow and relatively broad paper plies are alternatively arranged with respect to each other whereby the apex portion and proximal portions of the leg members are formed by both the broad and narrow paper plies whereas distal portions of the leg members are formed only by the broad paper plies. In this manner, increased thickness and strength is provided within the apex and proximal portions of the leg members as needed, the distal portions of the leg members nevertheless facilitate mounting, positioning, and orientation of the edge or corner protectors upon edge or corner regions of articles to be protected, and a substantial reduction in the overall raw material cost is achieved.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to angleboard edge protectors for protecting the corner or edge regions of individual packages, fragile articles or products, palletized loads, and the like, and more particularly to a new and improved angleboard edge protector which is uniquely constructed so as to protectively surround or envelop a corner or edge region of an individual package, fragile article or product, palletized load, or the like, yet simultaneously facilitates the reduction in the amount of paper required in order to fabricate the angleboard edge protector without sacrificing the integrity, strength, and protective qualities of the angleboard edge protector. 
     BACKGROUND OF THE INVENTION 
     Package, article, palletized load edge or corner protectors, corner post supports, and the like, are of course well-known in the packaging and shipping industries, and are accordingly widely used in connection with the shipping and transportation of various packages, articles, products, palletized loads, and the like, in order to protect the same during transit, wherein it is particularly desirable to protect the corner or edge portions or regions thereof. Typical or conventional edge or corner protectors, or corner post supports, are disclosed, for example, within U.S. Pat. No. 5,307,928 which issued to Bishop on May 3, 1994, U.S. Pat. No. 5,181,611 which issued to Liebel on Jan. 26, 1993, U.S. Pat. No. 5,175,041 which issued to Webb et al. on Dec. 29, 1992, U.S. Pat. No. 5,161,692 which issued to Knierim on Nov. 10, 1992, U.S. Pat. No. 5,131,541 which issued to Liebel on July.21, 1992, U.S. Pat. No. 5,048,689 which issued to McFarland on Sep. 17, 1991, U.S. Pat. No. 4,771,893 which issued to Liebel on Sep. 20, 1988, U.S. Pat. No. 4,399,915 which issued to Sorenson on Aug. 23, 1983, U.S. Pat. No. 3,955,677 which issued to Collingwood on May 11, 1976, and U.S. Pat. No. 3,536,245 which issued to Palmer on Oct. 27, 1970. 
     All of the aforenoted patented implements are basically similar to each other and representative of conventional corner or edge protectors in that the same comprise two laminated leg structures disposed at 90° with respect to each other so as to effectively define an interior region within which the corner or edge portion, of the particular article, product, package, or palletized load, to be protected is adapted to be disposed. The number of layers of paper, fiber board, corrugated board, or the like, from which the particular edge or corner protector is fabricated, plays an inherent part in determining or predetermining the strength of the particular edge or corner protector, or corner post support. However, it is also well-known in the packaging and shipping industries that the largest cost component inherent in connection with the manufacture of fabrication of the corner or edge protectors is the cost of the paper components per se or raw materials. It would therefore be desirable to substantially reduce the amount of paper raw materials that are required in connection with the manufacture or fabrication of such corner or edge protectors, however, care must be taken so as to ensure that the structural integrity and strength characteristics of the corner or edge protectors are not adversely compromised. 
     A need therefore exists in the art for a new and improved corner or edge protector wherein the amount of paper raw materials that are required in connection with the manufacture or fabrication of corner or edge protectors can be substantially reduced while simultaneously preserving the structural integrity and strength characteristics of each manufacture or fabricated edge or corner protector. 
     OBJECTS OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a new and improved angleboard edge or corner protector for use in connection with the protection of corner or edge regions of various articles, packages, products, palletized loads, and the like. 
     Another object of the present invention is to provide a new and improved angleboard edge or corner protector for use in connection with the protection of corner or edge regions of various articles, packages, products, palletized loads, and the like, whereby the new and improved angleboard edge or corner protector overcomes the various economic disadvantages characteristic of similar conventional or PRIOR ART edge or corner protectors. 
     An additional object of the present invention is to provide a new and improved angleboard edge or corner protector for use in connection with the protection of corner or edge regions of various articles, packages, products, palletized loads, and the like, wherein the unique and novel structure characteristic of the new and improved angleboard edge or corner protector constructed in accordance with the principles and teachings of the present invention enables edge or corner protector manufacturers to realize or achieve substantial savings in costs incurred in connection with the fabrication or manufacture of the edge or corner protectors. 
     A further object of the present invention is to provide a new and improved angleboard edge or corner protector for use in connection with the protection of corner or edge regions of various articles, packages, products, palletized loads, and the like, wherein the unique and novel structure characteristic of the new and improved angleboard edge or corner protector constructed in accordance with the principles and teachings of the present invention enables edge or corner protector manufacturers to realize or achieve substantial savings in costs incurred in connection with the fabrication or manufacture of the edge or corner protectors as a result of a reduction in the amount of raw material paper that is required to in fact fabricate or manufacture the edge or corner protectors. 
     A last object of the present invention is to provide a new and improved angleboard edge or corner protector for use in connection with the protection of corner or edge regions of various articles, packages, products, palletized loads, and the like, wherein the unique and novel structure characteristic of the new and improved angleboard edge or corner protector constructed in accordance with the principles and teachings of the present invention enables edge or corner protector manufacturers to realize or achieve substantial savings in costs incurred in connection with the fabrication or manufacture of the edge or corner protectors as a result of a reduction in the amount of raw material paper that is required to in fact fabricate or manufacture the edge or corner protectors, and yet, the structural integrity and strength characteristics of the fabricated or manufactured edge or corner protectors are not adversely compromised. 
     SUMMARY OF THE INVENTION 
     The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved edge or corner protector which comprises a predetermined number of plies of paper serially disposed atop each other so as to form a laminate when glued together, and wherein, alternative layers or lamina of the overall laminated edge or corner protector have different width dimensions. More particularly, for example, the edge or corner protector will be fabricated or manufactured from a plurality of alternating paper plies which have alternative width dimensions, and the paper plies are bent at a common central portion through means of an angle of 90° such that the resulting edge or corner protector comprises a common central apex portion and two leg portions disposed at an angle of 90° with respect to each other. The outermost paper plies of the edge or corner protector will have a width dimension of, for example, six inches (6.00″) and the remaining alternating intermediate paper plies will have width dimensions of, for example, three inches (3.00″) and six inches (6.00″). 
     In this manner, the first half or proximal section of each leg portion which is disposed closest to the commmon apex portion of the edge or corner protector will comprise all of the paper plies forming the edge or corner protector whereby such first half or proximal section of each leg portion of the edge or corner protector will have a first predetermined caliper or thickness dimension, whereas the second half or distal section of each leg portion which is disposed furthest from the commmon apex portion of the edge or corner protector will comprise only the widest paper plies forming the edge or corner protector whereby such second half or distal section of each leg portion of the edge or corner protector will have a second predetermined caliper or thickness dimension which is less than the aforenoted first predetermined caliper or thickness dimension characteristic of the first half or proximal section of each leg portion of the edge or corner protector. In this manner, a substantial cost savings in paper raw materials can be achieved or realized while simultaneously preserving the structural integrity and strength characteristics of the edge or corner protector. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Various other objects, features, and attendant advantages of the present invention will be more fully appreciated from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein: 
     FIG. 1 is a schematic illustration, shown upon a relatively enlarged or exaggerated scale, of a new and improved edge or corner protector as constructed in accordance with the principles and teachings of the present invention and showing the cooperative parts thereof comprising the alternating relatively wide and relatively narrow width paper ply components wherein the paper plies have not as yet been glued and compressed together; 
     FIG. 2 is a schematic view corresponding substantially to the view of FIG. 1 showing, however, the new and improved edge or corner protector wherein the paper plies have been glued together but not necessarily compressed together in their finalized form so as to in fact form or define the commercially useable edge or corner protector; and 
     FIG. 3 is a schematic view corresponding substantially to those views of FIGS. 1 and 2 showing, however, the finalized commercial form of the edge or corner protector wherein after compression together of the alternating plies having the different width dimensions, it is relatively difficult to discern the disposition of such alternating paper plies whereby the resulting commercially useable edge or corner protector will exhibit satisfactory structural integrity and strength characteristics. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, and more particularly to FIGS. 1-3 thereof, a new and improved edge or corner protector, constructed in accordance with the principles and teachings of the present invention, is disclosed and is generally indicated by the reference character  10 . As can best or most clearly be appreciated from FIG. 1, which comprises a view of the new and improved edge or corner protector  10  upon an enlarged or exaggerated scale, it is seen that the new and improved edge or corner protector  10  comprises a first set of paper plies  12  all of which have the same relatively large predetermined width dimension, and a second set of paper plies  14  all of which have the same relatively small predetermined width dimension. It is further appreciated that the first set of paper plies  12  and the second set of paper plies  14  are substantially disposed in an overlapped, alternating mode, and that all of the paper plies comprising the first and second sets of paper plies  12 , 14  are bent at a central portion thereof, as considered in the widthwise direction, such that a first half of the paper plies  12  and a first half of the paper plies  14  together define a first leg  16  of the new and improved edge or corner protector  10 , while a second half of the paper plies  12  and a second half of the paper plies  14  together define a second leg  18  of the new and improved edge or corner protector  10 . An apex or corner region  20  is defined at the common bend point or line of each one of the first and second sets of paper plies  12 , 14  such that the first and second legs  16 , 18  are disposed at an angle of 90° with respect to each other. 
     In accordance with current or conventional techniques utilized in connection with the manufacture or fabrication of edge or corner protectors, the individual paper plies that comprise such conventional or PRIOR ART edge or corner protectors have predetermined width dimensions. Accordingly, in accordance with the techniques utilized in connection with the manufacture or fabrication of the new and improved edge or corner protector  10  comprising the present invention, each one of the paper plies  12  utilized within the first set of paper plies, as well as each one of the paper plies  14  utilized within the second set of paper plies will comprise a paper ply having one of the standard or conventional predetermined width dimensions. The critical importance or significance of the unique and novel structure characterized by means of the edge or corner protector  10  of the present invention resides in the use of paper plies having at least two different width dimensions. It is initially and additionally noted that while the new and improved edge or corner protector  10  of the present invention is illustrated as comprising, for example, only two sets of paper plies  12 , 14  having two different width dimensions, an edge or corner protector, constructed in accordance with the principles and teachings of the present invention, could comprise, for example, three or more sets of paper plies having three or more different width dimensions. It is further noted that the reasons for utilizing the different sets of paper plies comprising the different width dimensions are several, and in addition, they are all operatively or functionally interrelated. 
     Firstly, for example, it is known that an edge or corner protector must have a predetermined thickness or number of paper plies within the corner or apex region thereof in order to in fact provide or exhibit the requisite amount of protection and cushioning functions, as well as strength, required in connection with the protection of an edge or corner region of an article, product, package, or palletized load when the edge or corner protector is applied to or secured upon the particular article, product, package, or palletized load. Secondly, the overall width dimension of the edge or corner protector must be sufficient so as to facilitate the handling of the edge or corner protector and the orientation and positioning of the same with respect to and upon the edge or corner region of the particular article, product, package, or palletized load. Thirdly, it has been recognized and appreciated that the single largest cost incurred in connection with the manufacture or fabrication of edge or corner protectors comprises the cost of the raw material paper plies. Accordingly, it would be desirable to significantly reduce such manufacturing or fabricating costs by effectively reducing the overall amount of paper comprising a single edge or corner protector if such could in fact be achieved without, obviously, adversely affecting the structural integrity, strength, and protection properties of the edge or corner protector. As a result of the unique and novel structure comprising the edge or corner protector  10  of the present invention, the aforenoted objectives have in fact been achieved. 
     More particularly, by constructing the edge or corner protector  10  in accordance with the principles and teachings as illustrated, for example, within FIG. 1, wherein the relatively narrow set of paper plies  14  have been used in conjunction with the relatively wide set of paper plies  12  in an alternating or interdigitated manner, it is seen, for example, that a relatively thick region of the edge or corner protector  10  is defined within the vicinity of the apex portion  20 . In particular, such apex portion  20 , as well as the regions disposed immediately upon opposite sides thereof, is comprised of seven plies of paper as comprising the first and second sets of paper plies  12 , 14 . It is of course to be noted that the precise number of paper plies, comprising the apex region  20  and those regions disposed immediately upon the opposite sides thereof, is not to be limited to seven. The important factor concerning the structure of the edge or corner protector  10  resides in the fact that the apex portion  20 , as well as the regions disposed immediately upon the opposite sides thereof, is comprised of the maximum number of paper plies comprising the edge or corner protector  10 , and in this manner, the maximum protection, cushioning, and strength characteristics are exhibited within the apex portion  20 , as well as the regions disposed immediately upon the opposite sides thereof, so as to in fact afford the maximum protection to the edge or corner region of the particular article, product, package, or palletized load being protected. 
     Continuing further, as a result of those distal portions of each leg member  16 , 18  of the edge or corner protector  10 , which are remote from the apex portion  20 , being structurally defined in effect solely by means of the relatively wide first set of paper plies  12 , although the protection, cushioning, and strength characteristics within such distal regions are not maximized as are such characteristics within the apex portion  20  and those proximal regions disposed immediately upon opposite sides of the apex portion  20 , the need for such maximized characteristics within such distal regions, which are effectively removed from the apex, edge, or corner regions of the article, product, package, or palletized load, is not as great. What is important however, and what is nevertheless provided by means of the edge or corner protector  10  of the present invention as a result of the use of the relatively wide paper plies  12 , is the provision to the edge or corner protector  10  of a sufficient overall width dimension which facilitates the handling, orientation, and positioning of the edge or corner protector upon the edge or corner region of the article, product, package, or palletized load prior to and in preparation for the fixed securement of the edge or corner protector upon the article, product, package, or palletized load by means of, for example, metal or plastic strapping, shrink or stretch wrapping, or the like. 
     Lastly, as a result of the aforenoted structure comprising the edge or corner protector  10  constructed in accordance with the principles and teachings of the present invention, a significant reduction in raw material paper costs is able to be achieved. For example, if each one of the paper plies comprising the first set of paper plies  12  has a width dimension of six inches (6.00″), and if each one of the paper plies comprising the second set of paper plies  14  has a width dimension of three inches (3.00″), then a paper cost savings of approximately twenty-five percent (25%) is able to be achieved. If, for example, each one of the paper plies comprising the second set of paper plies  14  has a width dimension of four inches (4.00″), then a paper cost savings of approximately seventeen percent (17%) is able to be achieved. It is to be further appreciated that the edge or corner protector  10  can be manufactured or fabricated from the aforenoted at least two sets of paper plies  12 , 14  having at least two different width dimensions wherein the particular width dimensions of either one of the first and second sets of paper plies  12 , 14  may vary as exemplified by means of the following examples: 
     EXAMPLE 1 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 6.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 5.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 2 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 6.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 4.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 3 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 6.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 3.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 4 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 6.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 2.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 5 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 5.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 4.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 6 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 5.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 3.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 7 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 5.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 2.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 8 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 4.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 3.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 9 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 4.00 Inches 
               
               
                   
                 The First Set of Paper Plies 12: 
               
               
                   
                 Width Dimension of Each Paper Ply Comprising 
                 2.00 Inches 
               
               
                   
                 The Second Set of Paper Plies 14: 
               
               
                   
                   
               
             
          
         
       
     
     With reference now being made specifically to FIGS. 2 and 3, it is lastly noted that in connection with the actual manufacture or fabrication of the edge or corner protector  10 , the entire outer peripheral surface of the edge or corner protector  10  is adapted to be wrapped within an outer wrapping layer  22 , and the outer wrapping layer  22 , as well as the individual paper plies  12 , 14 , are adapted to be glued together so as to form the integral composite edge or corner protector  10 . As shown in FIG. 2, for example, the various paper plies comprising the first and second sets of paper plies  12 , 14  are shown in their relative states before being compressed together, whereas as shown in FIG. 3, the first and second sets of paper plies  12 , 14  are shown in the their relative states after being compressed together whereby, once the first and second sets of paper plies  12 , 14  are in fact compressed together, it is difficult to discern the individual paper plies comprising the first and second sets of paper plies  12 , 14 . Accordingly, all of the paper plies comprising the first and second sets of paper plies  12 , 14  together form, in effect, an integrated one-piece edge or corner protector structure. It is additionally noted that when the first and second sets of paper plies  12 , 14 , together with the outer wrapping layer  22 , are compressed together, the leg portions  16 , 18  of the edge or corner protector  10  will exhibit predetermined thickness dimensions within those regions adjacent to the apex portion  20  as well as within the distal tip regions of the leg portions  16 , 18  as denoted by the thickness dimensions T and t, respectively. More particularly, exemplary thickness dimensions T,t may be as follows: 
     EXAMPLE 10 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Maximum Thickness T Within Proximal 
                 0.250 Inches 
               
               
                   
                 Regions of Each Leg Portion 16, 18 
               
               
                   
                 Minimum Thickness t Within Distal 
                 0.125 Inches 
               
               
                   
                 Tip Regions of Each Leg Portion 16, 18 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 11 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Maximum Thickness T Within Proximal 
                 0.225 Inches 
               
               
                   
                 Regions of Each Leg Portion 16, 18 
               
               
                   
                 Minimum Thickness t Within Distal 
                 0.120 Inches 
               
               
                   
                 Tip Regions of Each Leg Portion 16, 18 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 12 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Maximum Thickness T Within Proximal 
                 0.200 Inches 
               
               
                   
                 Regions of Each Leg Portion 16, 18 
               
               
                   
                 Minimum Thickness t Within Distal 
                 0.110 Inches 
               
               
                   
                 Tip Regions of Each Leg Portion 16, 18 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 13 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Maximum Thickness T Within Proximal 
                 0.180 Inches 
               
               
                   
                 Regions of Each Leg Portion 16, 18 
               
               
                   
                 Minimum Thickness t Within Distal 
                 0.100 Inches 
               
               
                   
                 Tip Regions of Each Leg Portion 16, 18 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 14 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Maximum Thickness T Within Proximal 
                 0.160 Inches 
               
               
                   
                 Regions of Each Leg Portion 16, 18 
               
               
                   
                 Minimum Thickness t Within Distal 
                 0.080 Inches 
               
               
                   
                 Tip Regions of Each Leg Portion 16, 18 
               
               
                   
                   
               
             
          
         
       
     
     Thus, it may be seen that in accordance with the principles and teachings of the present invention, there has been provided a new and improved edge or corner protector which substantially reduces the overall cost of fabrication or manufacture of the edge or corner protector by substantially reducing the amount of paper raw material required to be incorporated within the new and improved edge or corner protector without adversely affecting the protection, cushioning, strength, and structural integrity characteristics of the edge or corner protector and yet facilitating the handling, positioning, and orientation of the edge or corner protector upon a particular article, product, package, or palletized load. More particularly, the new and improved edge or corner protector comprises the use of two sets of paper plies characterized by two different width dimension values wherein both sets of paper plies are in effect present within the proximal apex corner portion of the edge or corner protector so as to provide the necessary protection to the edge or corner region of the particular article, product, package, or palletized load being protected, while only the wider width dimensioned paper plies are disposed within the distal regions of the leg members of the edge or corner protector so as to provide the edge or corner protector with the necessary width dimension in order to enable or facilitate the proper handling, orientation, and positioning of the edge or corner protector upon an edge or corner region of an article, product, package, or palletized load to be protected. 
     Obviously, many variations and modifications of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.