HONEYCOMB PROTECTOR WITH SELF-LOCKING PANELS

Abstract: A honeycomb protector (100) for protecting the corners, edges or other surfaces of articles during shipping of such articles comprising self-locking panels. In one embodiment, the protector includes first and second unitary panels (144, 146) separated by a channel (168) about which the panels are foldable. The first panel includes a lip (150) which fits into a slit (162) in the second panel to connect and lock the first and second panels in position.

Description: HONEYCOMB PROTECTOR WITH SELF-LOCKING PANELS Technical Field This invention relates generally to a protector for an article to be packaged and, more particularly, to a honeycomb protector with self-locking panels. Background ofthe Invention For many years, protectors have been secured to the edges and corners and other surfaces of manufactured articles such as appliances, electronic articles and doors, prior to such articles being packaged to protect the edges, corners and other surfaces of such articles from damage during handling and shipment. A type of edge and corner protector currently in use is made of paper honeycomb material and is supplied to the manufacturer ofthe articles to be packaged in flat form. The panels ofthe protector are thereafter folded by the manufacturer, then taped, glued or stapled so that the protector remains folded, and then is applied to the edges or corners of the article to be shipped. A problem associated with the use of this type of corner protector is that it requires an extra manufacturing step, i.e., taping, gluing, or stapling during the folding operation. There is also a tendency to unfold and fall off the article prior to the article being packaged, thus complicating and unnecessarily decreasing the efficiency ofthe packing operation. Thus, there remains a need for a corner protector which does not require taping, gluing, or stapling during the folding operation and which will not unfold and fall off the edge or corner ofthe article prior to or during packaging the article. U.S. Patent No. 5,51 1,667 to Carder discloses a honeycomb corner protector which is supplied to the manufacturer in a flat form. The protector comprises a panel including panel portions which are folded along crush slit scores and then interlocked by means of fingers and notches therein. Although this corner protector has proven to be extremely effective and reliable in that it dispenses the need for taping, gluing and stapling, its use is limited to the protection ofthe corners of articles. Additionally, all current protectors comprise panels foldable into a peφendicular relationship thus limiting their use to the corners or edges of an article. The present invention solves these problems by providing a self-locking honeycomb protector with foldable or connectable honeycomb panels which can be used on the edges, corners or other surfaces of an article to be packaged and which is easy to manufacture and assemble. Summary ofthe Invention The present invention is a honeycomb protector for protecting the corners, edges or other surfaces of articles during shipping of such articles which comprises first and second panels, each ofthe panels including a core having opposite faces and a face sheet secured to one ofthe faces and defining a peripheral edge. Each ofthe first and second panels include sidewalls defined by the core. One ofthe sidewalls ofthe first panel is offset inwardly from the respective peripheral edge ofthe face sheet such that the face sheet defines a longitudinally extending lip. The second panel includes a slit extending through the face sheet, the lip on the first panel fitting within the slit in the second panel to connect and self-lock the first and second panels together. In one embodiment suitable for protecting the edges or other surfaces ofthe article, the protector includes first and second panels separated by a channel about which the panels are foldable. The first panel includes a lip which fits into a slit in the second panel to connect the first and second panels in the folded position. The width ofthe channel may be varied to vary the angular relationship between the first and second panels in the folded position. In another embodiment, the protector includes a first panel including one or more lips or prongs and a separately connectable second panel including one or more slits defining sockets for receiving the lips ofthe first panel and securing the first and second panels together in various angular and positional configurations. In yet another embodiment, the protector includes a third panel foldably connected to the first and second panel. The third panel includes a lip insertable into a second slit in the second panel to hold the first, second and third panels in the folded position. Finally, several methods and an apparatus is disclosed for making the protector of the present invention. The honeycomb protector ofthe present invention initially solves the problems with gluing, taping or stapling by providing self-locking panels. The invention further provides a protector which can be used for many applications including, but not limited to, the protection of edges and comers of articles, the protection of articles having a variety of angular configurations, and the stacking or arrangement of articles such as bottles in side-by-side relationship for shipping. There are other advantages and features ofthe present invention which will be more readily apparent from the following detailed description ofthe preferred embodiments ofthe invention, the drawings, and the appended claims. Brief Description ofthe Drawings In the accompanying drawings which form a portion of this disclosure: FIGURE 1 is a perspective view of a box-like article with alternate embodiments of protectors constructed in accordance with the present invention positioned over the comers and edges thereof; FIGURE 2 is a plan view of a first embodiment of a protector in its flat form; FIGURE 3 is an enlarged, fragmentary end view ofthe edge protector taken along the lines 3-3 of FIGURE 2; FIGURE 4 is a perspective view ofthe protector of FIGURE 2 in its folded position; FIGURE 5 is an end elevational view ofthe protector of FIGURE 4 in its folded position; FIGURE 6 is an end elevational view of a second embodiment of a protector in its folded position; FIGURE 7 is an end elevational view of a third embodiment of a protector in its connected position; FIGURE 8 is an end elevational view of a alternate connection ofthe panels of the protector of FIGURE 7; FIGURE 9 is an end elevational view of a third embodiment of a protector in its connected position; FIGURE 10 is a plan view of a comer protector embodiment ofthe protector of FIGURE 2; FIGURE 1 1 is an enlarged, fragmentary end view of the comer protector taken along the lines 11-11 of FIGURE 10; FIGURE 12 is an enlarged, fragmentary end view ofthe comer protector taken along the lines 12-12 of FIGURE 10; FIGURE 13 is a perspective view ofthe comer protector of FIGURE 10 in its folded position; FIGURE 14 is a simplified, schematic perspective view of an apparatus for making the protector; and FIGURE 15 is a simplified, schematic front elevational view of the apparatus of FIGURE 14. Description ofthe Preferred Embodiments An article A is shown in FIGURE 1 with protectors 100 and 500 ofthe present invention positioned over its edges and comers for protecting the comers and edges of the article A from damage during handling and shipping. The article A may be a manufactured good such as an appliance or electronic article such as a television. A self-locking edge protector 100 is depicted in FIGURES 2-5. Referring to FIGURES 2 and 3, protector 100 comprises a generally rectangular panel 120 including separate and spaced apart first and second core portions 122 and 124 sandwiched between and adhesively secured to a first or bottom face sheet 126 and first and second top face sheets 128 and 130 respectively. Each ofthe first and second core portions 122 and 124 respectively is a honeycomb core comprised of a plurality of abutting partition walls 132 which are positioned perpendicularly to the bottom face sheet 126 and the first and second top face sheets 128 and 130. The partition walls 132 form hexagonal cells 134 having opposed hollow-cell faces 136 to which the bottom face sheet 126 and the first and second top face sheets 128 and 130 are adhesively secured. Preferably, the core portions 122 and 124 and the face sheets 126, 128 and 130 are made of a kraft paper. The face sheets can be made of different weights of paper with 42 pound, 69 pound and 90 pound being preferred. Materials other than paper can also be used. The panel 120 in its flat form (FIGURE 2) preferably measures about 6x10 inches (about 15 by 25 cm.) with a core thickness of about 1 inch (about 2.5 cm.). Although the above dimensions are preferable for most applications, they are not limiting. It is also understood that the invention is not limited to rectangularly shaped protectors and is applicable to any other shaped protectors such as, for example, the triangularly shaped protector 100 depicted in FIGURE 1. Referring back to FIGURE 2, panel 120 includes a central longitudinal axis 138 and a central transverse axis 140 and the core portions 122 and 124 divide the panel 120 into first and second panel portions 144 and 146. The first panel portion 144 includes an extended inner longitudinal sidewall 147 defined by the generally vertical partition walls 132 ofthe core portion 122 and terminating at the top face sheet 128 thereof in an extended longitudinal inner peripheral edge 148 defined by the inner peripheral edge ofthe top face sheet 128. Inner sidewall 147 and edge 148 extend longitudinally along the length of and offset from the central transverse axis 140 of panel 120. The inner sidewall 147 is offset inwardly from the inner edge 148 to define a lip or prong 150 including a tip 153 and upper and lower surfaces 152 and 154. Second panel portion 146 includes an extended inner longitudinal sidewall 156 defined by the generally vertical partition walls 132 ofthe core portion 124 which terminates at the top face sheet 130 thereof in an extended longitudinal inner peripheral edge 158 defined by the inner peripheral edge ofthe top face sheet 130. The inner sidewall 156 and edge 158 are disposed generally co-planarly with the central transverse axis 140 of panel 120. Second panel portion 146 also includes a slit 162 which extends through the top face sheet 130 and preferably a segment ofthe core portion 124. Slit 162 extends longitudinally along and parallel to the central transverse axis 140 ofthe panel 120 and the inner peripheral edge 158 of second panel portion 146. Slit 162 is offset from the central transverse axis 140 of panel 120 and the inner edge 158 of panel portion 146 by a distance approximately equal to the thickness ofthe first core portion 122. Slit 162 is defined by an opening 164 in the top face sheet 130, a socket 165 in the core portion 124, and a beveled surface 166 therebetween. The opening 164 is between the beveled surface 166 and the sidewall 156 of second panel portion 146. The slit 162 is configured to cooperatively receive and preferably retain the lip 150. The beveled surface 166 helps retain the lip 150 in the socket 165. Inner sidewalls 147 and 156 and inner edges 148 and 158 of first and second panel portions 144 and 146 respectively are opposed and spaced-apart from each other to define a cavity in the form of an extended channel 168 extending longitudinally along the length of and offset from the central transverse axis 140 of panel 120. Channel 168 has a width which is about equal to the thickness ofthe second core portion 124. Channel 168 is generally rectangularly shaped and includes a generally horizontal bottom surface 170 defined by the bottom face sheet 126, a first generally vertical side face defined by the inner sidewall 147 of first panel portion 144, an opposite generally vertical side face defined by the inner sidewall 156 of second panel portion 146, and a top opening defined by the inner longitudinal spaced-apart edges 148 and 158 of first and second panel portions 144 and 146 respectively. The portion of the bottom face sheet 126 comprising the bottom surface 170 of channel 168, in combination with the central transverse axis 140, define a hinge about which the panel portions 144 and 146 are folded to form the protector 100 shown in FIGURE 4. To form the protector 100, first and second panel portions 144 and 146 are rotated upwardly and inwardly towards each other about the channel 168 until the first and second panel portions 144 and 146 are positioned generally perpendicularly to each other as shown in FIGURES 4 and 5. The portion ofthe bottom face sheet 126 comprising the bottom surface 170 of channel 168 is then in abutting generally vertical relationship with the inner sidewall 156 of second panel portion 146 and the inner sidewall 147 of first panel portion 144 is in abutting generally horizontal relationship with the top inner periphery ofthe second panel portion 146. To lock the first and second panel portions 144 and 146 together in their generally peφendicular folded position, the lip 150 on the first panel portion 144 is inserted vertically downwardly into the slit 162 in the second panel portion 146. More particularly, the lip 150 is inserted through the opening 164 of slit 162 with the tip thereof in abutting relationship with the beveled surface 166 thereof to cause the lip 150 to slide into the socket 165. The use of a lip 150 cooperating and fitting within a slit 162 dispenses with the need to tape, glue, or staple the first and second panel portions 144 and 146 together during the folding operation. If desired, glue or tape can also be placed over the lip 150 to further lock the panels in a folded relationship. The protector 100 may be made without a lip 150 or cooperating slit 162 if desired. FIGURE 6 shows an alternate protector 200 which is similar to the comer protector 100 except that the channel 268 of panel 220 has a width that is less than the thickness ofthe second core portion 224. When the first and second panel portions 244 and 246 are folded together and the lip 250 on first panel portion 244 is inserted into the slit 262 in the second panel portion 246, the first and second panel portions 244 and 246 are locked together in a folded position where the included angle between the first and second panel portions 244 and 246 is greater than 90 degrees. The protector 200 is particularly applicable where it is desired to protect the comers or edges of articles having surfaces oriented at other than 90 degrees. The width ofthe channel 268 can be varied depending upon the angular characteristics of the surface of the article sought to be packaged. Additionally, in an application where extra cushioning or impact protection is desired, the second panel portion 246 can be constructed with two or more pieces of core (and possibly face sheets) to provide the core portions 224. In this application, the width ofthe channel 268 would be increased to about the thickness ofthe two stacked core portions 224. FIGURE 7 shows another protector embodiment 300 which is similar to protectors 100 and 200. Protector 300 differs from protectors 100 and 200 in that it comprises separately connectable first and second panels 344 and 346. Essentially, protector 300 comprises a protector 100 (FIGURE 2) where the bottom face sheet 126 has been cut in the region ofthe channel 168. The first and second panels can also be made separately. The first panel 344 of protector 300 is similar to the first panel portion 144 of protector 100 except that the bottom face sheet 326 thereof includes a peripheral edge 353. The sidewall 347 ofthe core portion 322 ofthe first panel 344 is offset inwardly from the peripheral edge 353 ofthe bottom face sheet 326 to define a lip 357 opposite the lip 350 defined by the top face sheet 328. Lip 357 includes inner and outer surfaces 361 and 363 respectively. The second panel 346 is similar to the second panel portion 146 of protector 100 except that the bottom face sheet 326 terminates at the inner sidewall 356. The distance between the slit 362 in the second panel 346 and the inner sidewall 356 thereof is approximately equal to the thickness ofthe core portion 322 of the first panel 344. To connect the first and second panels 344 and 346 together, the first and second panels 344 and 346 are initially positioned substantially peφendicularly to each other as shown in FIGURE 7. The first and second panels 344 and 346 are then connected together in a socket-like manner by inserting the lip or prong 350 ofthe first panel 344 into the slit 362 in the second panel 346 and placing the inner surface 361 ofthe lip 357 ofthe first panel 344 in abutting relationship with the inner sidewall 356 ofthe second panel 346 and then pushing the first and second panels 344 and 346 together until the lip 350 is fully inserted into the socket 365 defined by the slit 362 and the inner sidewall 347 of the first panel 344 is placed into abutting relationship with the top face sheet 330 of the second panel 346. FIGURE 8 shows an alternate connection ofthe first and second panels 344 and 346 of protector 300 where the lip 357 ofthe first panel 344 is inserted into the socket 365 defined by the slit 362 in the second panel 346. The tip ofthe opposite lip 350 ofthe first panel 344 is placed against the top face sheet 330 ofthe second panel 346 to form a protector 300, similar to the protector 200 of FIGURE 6, where the first and second panels 344 and 346 are positioned with respect to each other at an included angle greater than 90 degrees to suit the same puφoses as described earlier with the protector 200 of FIGURE 6. FIGURE 9 shows yet another protector embodiment 400 similar to protector 300. The first panel 444 of protector 400 is similar to the first panel 344 of protector 300 (FIGURE 7) and thus similar to the first panel portion 144 of protector 100 (FIGURE 2). The second panel 446 of protector 400 is similar to the second panel 346 of protector 300 (FIGURE 7) and thus similar to the second panel portion 146 of protector 100 (FIGURE 2) except that second panel 446 includes first and second spaced-apart slits 462 and 463 extending into the top face sheet 430 and a segment ofthe core portion 424 thereof to define first and second longitudinally extending sockets 465 and 467 respectively. The slits 462 and 463 include converging beveled surfaces 466 and 471 respectively. Slits 462 and 463 are spaced apart a distance approximately equal to the thickness ofthe core portion 422 ofthe first panel 444. The first and second panels 444 and 446 are connected in a socket-like manner as shown in FIGURE 9 by inserting the lips or prongs 450 and 457 on the first panel 444 into the sockets 465 and 467 respectively in the second panel 446. The beveled surfaces 466 and 471 of slits 462 and 463 respectively assist in guiding and sliding the lips 456 and 457 into the sockets. The first and second panels 444 and 446 are then pushed together until the sidewall 447 ofthe first panel 444 abuts the top face sheet 430 ofthe second panel 446. In this configuration, articles to be packaged such as bottles or like can be placed on the surface ofthe panel 446 on opposite sides ofthe first panel 444. Although not shown, it is understood that the second or bottom panel 346 can include additional sets of slits spaced along the length thereof adapted to receive additional first panels 344 for packaging several articles such as bottles or the like in side-by-side relationship. Moreover, the protector 400 can be made into the protector 300 by adding a slit in the second panel 446 adjacent the sidewall 456 thereof. FIGURES 10-13 depict a self-locking comer protector embodiment 500 ofthe self-locking edge protector 100. Referring to FIGURES 10-12, protector 500 comprises a panel 520 including separate and spaced apart core portions 522, 524 and 525 sandwiched between and adhesively secured to a first or bottom face sheet 526 and three top face sheets 528, 530 and 531 respectively. Each ofthe core portions 522, 524 and 525 is a honeycomb core similar to the honeycomb core of protector 100. Panel 520 includes a central longitudinal axis 538 and a central transverse axis 540. The core portions 522, 524 and 525 divide the panel 520 into first, second and third panel portions 544, 546 and 549. The first panel portion 544 is similar to the first panel portion 144 of protector 100 (FIGURES 2 and 3) and includes an extended inner longitudinal sidewall 547 defined by the generally vertical partition walls 532 ofthe first core portion 522 and terminating at the top face sheet 528 thereof in an extended longitudinal inner peripheral edge 548 defined by the inner peripheral edge ofthe top face sheet 528. Inner sidewall 547 and edge 548 extend longitudinally along the length of and offset from the central transverse axis 540 of panel 520. The inner sidewall 547 is offset inwardly from the inner edge 548 to define a lip 550 including upper and lower surfaces 552 and 554. First panel portion 544 further includes a second inner peripheral edge 590 and an inclined surface 591 which converges into and is generally peφendicular to the inner peripheral edge 548. Inner peripheral edge 590 extends parallel along and is offset from the central longitudinal axis 538. Second panel portion 546 is similar to the second panel portion 146 of protector 100 (FIGURES 2 and 3) and includes an extended inner longitudinal sidewall 556 defined by the generally vertical partition walls 532 ofthe core portion 524 that terminates at the top face sheet 530 thereof in an extended longitudinal inner peripheral edge 558 defined by the inner peripheral edge ofthe top face sheet 530. The inner sidewall 556 and edge 558 are disposed generally co-planar with the central transverse axis 540 of panel 520. Second panel portion 546 also includes a slit 562 which extends generally vertically downwardly through the top face sheet 530 and a segment ofthe core portion 524. Slit 562 extends longitudinally along and parallel to the central transverse axis 540 ofthe panel portion 546. Slit 562 is offset from the central transverse axis 540 of panel 520 and the inner edge 558 of second panel portion 546 a distance approximately equal to the thickness ofthe first core portion 522. The slit 562 is defined by an opening 564 in the top face sheet 530, a socket 565 in the second core portion 524 and a beveled surface 566 therebetween. The second panel portion 546 additionally includes an extended inner longitudinal sidewall 580 defined by the generally vertical partition walls 532 ofthe second core portion 524 and terminating at the top face sheet 530 in an extended longitudinal edge 582. Sidewall 580 and edge 582 extend longitudinally along and generally co-planarly with the central longitudinal axis 538 of panel 520. The second panel portion 546 includes a second slit 584 which extends generally vertically downwardly through the top face sheet 530 and a segment ofthe second core portion 524 and extends longitudinally along and parallel to the central longitudinal axis 538 of panel 520. Slit 584 is offset from the inner longitudinal edge 582 of second panel portion 546 a distance of about the thickness ofthe third core portion 525. Slit 584 is defined by an opening 586 in the top face sheet 530 and a beveled surface 588 extending inwardly in the direction of inner sidewall 580. Slit 584 converges into and is positioned generally peφendicularly to the slit 562 in the second panel portion 546. Inner sidewalls 547 and 556 and inner edges 548 and 558 of first and second panel portions 544 and 546 respectively are opposed and spaced-apart from each other to define a cavity in the form of an extended channel 568 similar to the channel 168 of protector 100 (FIGURE 3). Channel 568 extends longitudinally along the length of and is offset from the central transverse axis 540 of panel 520. Channel 568 has a width which is about equal to the thickness ofthe second core portion 524. Channel 568 is generally rectangularly shaped and includes a generally horizontal bottom surface 570 defined by the bottom face sheet 526, a first generally vertical side face defined by the inner sidewall 547 of first panel portion 544, an opposite generally vertical side face defined by the inner sidewall 556 of second panel portion 546, and a top opening defined by the inner longitudinal space-apart edges 548 and 558 of panel portions 544 and 546 respectively. The portion ofthe bottom face sheet 526 comprising the bottom surface 570 of channel 568, in combination with the central transverse axis 540, define a hinge about which the panel portions 544 and 546 are folded. The third panel portion 549 is a generally rectangular member including an inner peripheral edge 592 and an inclined surface 593. Inner peripheral edge 592 extends generally parallel to and offset from the central longitudinal axis 538. Inner peripheral edge 592 and surface 593 are disposed opposite inner peripheral edge 590 and surface 591 of first panel portion 544. Third panel portion 549 further includes an inner sidewall 594 defined by the upstanding partition walls 532 of third core portion 525 and terminating at the top face sheet 531 in an extended longitudinal inner edge 595 which converges into and is generally peφendicular to the peripheral edge 592. Inner sidewall 594 and edge 595 extend along and are offset from the central transverse axis 540 of panel 520. Inner sidewall 594 is offset inwardly from the inner edge 595 thereof to O 97/41047 P S97/ 15 - 12 - define a longitudinally extending lip 596 including upper and lower surfaces 597 and 598 respectively. The third panel portion 549 is connected to the first panel portion 544 by a cavity in the form of an angle crush slit score 599 comprised of a longitudinally extending central slit 600 which is cut through the top face sheets 528 and 531 , and the opposed inclined surfaces 591 and 593 ofthe first and third panel portions 544 and 547 respectively. As is described in detail in U.S. Patent No. 5,511 ,667 to Carder, the surfaces 591 and 593 are inclined at a bevel angle to provide a spring biasing action between the surfaces when the first and third panel portions 544 and 549 are folded and connected together as shown in FIGURE 13. It is also possible to combine the lip and slit arrangement with angle crush slit score by placing additional cuts in surfaces 591 and 593 (or the flat ofthe face sheet if desired) to form the lip out of part of one ofthe inclined surfaces which fits into the slit associated with the opposing inclined surface. The comer protector 500 is shown in FIGURE 13 in its folded and connected position. Preferably, the comer protector 500 is assembled by initially rotating the first and second panel portions 544 and 546, respectively, upwardly and inwardly about the channel 568 until the first and second panel portions 544 and 546 are positioned generally peφendicularly to each other and the bottom face sheet 526 is in abutting generally vertical relationship with the inner sidewall 556 of second panel portion 546 and the inner sidewall 547 of first panel portion 544 is in abutting generally horizontal relationship with the top inner peripheral portion of second panel portion 546. The first and second panel portions 544 and 546 are then locked together in their folded position by inserting the lip 550 on the first panel portion 544 into the slit 562 in the second panel portion 546. The third panel portion 549 is connected to the first panel portion 444 in a similar fashion. More particularly, the third panel portion 549 is rotated upwardly and inwardly in the direction ofthe first panel portion 444 about the angle crush slit score 599 until the surfaces 591 and 593 ofthe first and third panel portions 544 and 549 are placed in abutting relation. The first, second and third panel portions 544, 546 and 549 are then locked together by inserting the lip 596 on the third panel portion 549 into the slit 584 in the second panel portion 546. The spring biasing action provided by the angle crush slit score 599 enhances the locking ofthe lip 596 in the slit 584. The comer protector 500 may then be applied to the comer ofthe article to be protected. It is understood that although the comer protector 500 has been described as including cavities in the form of a channel 568 and a crush slit score 599 dividing the first and second portions and the first and third portions respectively, the invention contemplates and encompasses comer protector embodiments where a cavity in the form of a crush slit score is substituted for the channel 568 or, alternatively, a cavity in the form of a channel is substituted for the angle crush slit score 599. The channels and crush slit scores may also be substituted altogether and replaced with any other suitable cavity or structure which allows for the folding of panel portions. The folding structure selected would determine which ofthe panel portions would include the slits and lips covered by the invention. The methods for making the self-locking protectors 100 and 500 will now be described with reference to FIGURES 14 and 15 which show, in schematic form, an apparatus 700 and method for making the protector 100. Initially, and although not shown, a panel 120 is preferably formed by feeding an extended length of core through an "in-line" continuous flow panel line where top and bottom face sheets are adhesively secured to the top and bottom hollow cell faces ofthe core. The resulting panel 120 is then introduced into the apparatus 700 which includes slitting means such as rotary saws or circular knife slitters 702, 704 and 706. The first and second slitters 702 and 704 are positioned with respect to the panel 120 in a spaced apart side-by-side relationship to cut first and second spaced-apart parallel slits in the top face sheet and the core of panel 120 to define the inner edges 148 and 158 and the inner sidewalls 147 and 156 of first and second panel portions 144 and 146 respectively. The third slitter 706 is positioned parallel to the first and second slitters 702 and 704 to cut the slit 162 in the second panel portion 146 of panel 120. After the slitters 702 and 704 have cut through the top face sheet and core of panel 120, a separator 710 in the form of a scrapper or the like is used to separate and strip the core which has been cut from the bottom face sheet 126. A wedge 712 mounted to the top surface ofthe separator 710 is then used to push the inner sidewall 147 of first panel portion 144 inwardly so as to form the lip 150. Alternatively, a roller can be used. The glue that remains on the bottom ofthe lip 150 reinforces it and strengthens the paper. It is preferred that this operation be conducted before the glue is dry. Removal means in the form of a vacuum 716 or the like is then used to remove the core and face sheet segment which has been separated from the bottom face sheet 126 to define the cavity 168 in panel 120. In accordance with this method, and to make the separation and removal ofthe core segment easier, it is desirable that the core segment of panel 120 which is cut and removed to form the cavity 168 not be adhesively secured to the strip ofthe bottom face sheet 126 beneath the core segment. Although not shown, it is understood that this can be accomplished by damming the glue spreader, which spreads the glue onto the top and bottom hollow cell faces of the core prior to the top and bottom face sheets being secured thereto, in the area ofthe core comprising the core segment to be later removed. Alternatively, and in lieu of damming the glue spreader, the core segment to be removed can be punched at predetermined spaced intervals to create dimples or hourglass-shaped inner recesses into which glue is not received when the glue is spread onto the hollow-cell face thereof. As a result, a hollow-cell face area is created with a smaller adhesive core surface area making it easier to separate from the bottom face sheet 126. In an alternative method, and although not shown, panel 120 can be made by securing two core portions 122 and 124 in a spaced-apart relationship on a bottom face sheet 126 and then applying the top face sheets 128 and 130 to the top ofthe core portions 122 and 124 respectively to form a panel 120 including panel portions 144 and 146 separated by a cavity 168. Alternatively, two panel portions 144 and 146 already including core sections and top and bottom face sheets can be secured to a backing member in a spaced apart relationship to create a cavity therebetween. A roller apparatus (not shown) could then be used to push in the sidewall ofthe selected panel portion to form the desired lip and a slitter would be used to form the slit in the other panel portion. This method eliminates several manufacturing steps such as the need to slit and remove a core segment to form the cavity 168 and thus the glue damming or core dimple forming steps. It also reduces the amount of paper material which is wasted during the manufacturing operation. It is understood that the methods described above can be performed by an "in¬ line" apparatus such as an "in-line" continuous feed panel line where core is provided and fed on a conveyor through a first station where top and bottom face sheets are provided and applied thereto, a second station where stationary slitters 702, 704 and 706 would cut the panel as its travels past the slitters, and a third station where the core segment would be separated and removed from the panel 120 by a stationary separator 710 and vacuum 716. Alternatively, the core and face sheets could be fed into the panel line in spaced- apart segments so as to eliminate the need to cut out any core or face sheet segments from the panel. As a still further alternative, a die press can used. The method of making a comer protector with first, second and third panel portions is similar to the methods described herein for making the protector with first and second panel portions. The foregoing is illustrative ofthe principles ofthe invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact constmction and operation shown and described. Accordingly, all suitable modifications and equivalents may be resorted to while still falling within the scope ofthe invention.

Claims: WHAT IS CLAIMED IS: 1. A protector comprising first and second panels, each ofthe panels including a core having opposite faces and a face sheet secured to one ofthe faces and defining a peripheral edge, each ofthe first and second panels including sidewalls defined by the core, one ofthe sidewalls ofthe first panel being offset inwardly from the respective peripheral edge ofthe face sheet such that the face sheet defines a longitudinally extending lip, the second panel including a slit extending through the face sheet, the lip on the first panel fitting within the slit in the second panel to connect the first and second panels together. 2. The protector of claim 1 wherein the first and second panels are peφendicularly positioned when connected together. 3. The protector of claim 1 further comprising a second face sheet, the panels being secured to the second face sheet in spaced-apart relationship to create a cavity between the first and second panels, the first and second panels being foldable about the cavity, the lip in the first panel fitting within the slit in the second panel when the first and second panels are folded to hold the first and second panels in the folded position. 4. The protector of claim 3 wherein the first and second panels are positioned peφendicularly to each other in the folded position. 5. The protector of claim 3 wherein the first and second panel portions are positioned at an angle greater than 90 degrees in the folded position. 6. The protector of claim 1 wherein each ofthe first and second panels include another face sheet secured to the other ofthe faces ofthe core of each ofthe first and second panels, the two sheets on the first panel defining two spaced apart longitudinally extending lips, the second panel including a second slit parallel to and spaced apart from the slit in the second panel, the lips on the first panel fitting within the slits respectively in the second panel to connect the first and second panels together. 7. The protector of claim 1 wherein the first and second panels are positioned peφendicularly to each other when connected together. 8. The protector of claim 1 wherein each ofthe first and second panels include another face sheet secured to the other ofthe faces ofthe core of each ofthe first and second panels, the two sheets on the first panel defining two spaced apart lips, the slit on the second panel portion being spaced apart from the peripheral edge a distance about equal to the distance between the two lips on the first panel portion, such that when the first and second panels are connected together, one ofthe lips on the first panel fits into the slit in the second panel portion and the other lip on the first panel extends over the peripheral edge ofthe second panel to form a protector having a comer. 9. The protector of claim 1 wherein the core comprises a honeycomb core including a plurality of abutting partition walls positioned generally peφendicularly to the face sheet. 10. The protector of claim 1 wherein the inner sidewalls ofthe first and second panels define a first cavity dividing and foldably connecting the first and second panels, the protector further comprising a third panel including a face sheet secured thereto and foldably connected to the first panel by a second cavity, the third panel including an inner sidewall and an inner peripheral edge defined by the face sheet, the inner sidewall ofthe third panel being offset inwardly from the inner peripheral edge thereof to define a lip, the second panel including a second slit, such that when the first, second, and third panels are folded together, the lip in the third panels are folded together, the lip in the third panel fits into the second slit in the second panel to hold the first, second and third panels together in the folded position. 11. A protector comprising a bottom face sheet, first and second core portions secured to the bottom face sheet in spaced apart relationship, the first and second core portions having opposing inner sidewalls defining a channel between the first and second core portions; first and second top face sheets secured to the top ofthe first and second core portions respectively, each ofthe first and second face sheets defining an inner peripheral edge adjacent to the channel, the inner sidewall ofthe first core portion being offset inwardly from the inner peripheral edge ofthe first face sheet to define a lip; and a slit extending through the second face sheet and a portion ofthe second core portion, the protector being foldable about the channel and the lip fitting within the slit to hold the protector in its folded position. 12. The protector of claim 1 1 wherein the core comprises a honeycomb core including a plurality of abutting partition walls positioned generally peφendicularly to the face sheets. 13. The protector of claim 12 wherein the inner sidewalls of the first and second core portions are defined by the partition walls of the core, the partition walls of the first core portion being offset inwardly from the peripheral edge ofthe first face sheet to define the lip. 14. The protector of claim 11 wherein the first and second core portions are the same thickness. 15. The protector of claim 1 1 wherein the width ofthe channel is about equal to the thickness ofthe second core portion and the slit in the second face sheet is spaced from the inner peripheral edge thereof a distance about equal to the thickness of the first core portion. 16. The protector of claim 1 1 wherein the width ofthe channel is about equal to the thickness ofthe second core portion, and the slit in the second face sheet is spaced from the inner peripheral edge thereof a distance less than the thickness ofthe first core portion. 17. The protector of claim 11 wherein the slit is defined by an opening in the second face sheet and a beveled surface on the second face sheet, the lip on the second face sheet being inserted through the opening and sliding down the beveled surface into the cavity in the second core portion. 18. The protector of claim 17 wherein the opening is between the beveled surface and the channel. 19. A protector comprising a foldable panel including a core disposed between first and second face sheets, the panel being divided into first and second foldable panel portions, the first panel portion including a lip and the second panel portion including a slit through one of its face sheets, such that when the first and second panel portions are folded together, the lip on the first panel portion fits into the slit in the second panel portion to hold the first and second panel portions together in the folded position. 20. The protector of claim 19 wherein the slit extends into the core. 21. The protector of claim 19 wherein the first panel portion includes an inner sidewall and an inner peripheral edge defined by the first face sheet, the inner sidewall being offset inwardly from the inner peripheral edge to define the lip. 22. The protector of claim 19 wherein the first and second panel portions include opposing inner sidewalls defining a cavity dividing the first and second panel portions, the protector further including a third panel portion foldably connected to the first panel portion, the third panel portion including an inner sidewall and an inner peripheral edge defined by the first face sheet, the inner sidewall ofthe third panel portion being offset inwardly from the inner peripheral edge thereof to define a lip, the second panel portion including a second slit, such that when the first, second, and third panel portions are folded together, the lip in the third panel portion fits into the second slit in the second panel portion to hold the first, second and third panel portions together in the folded position. 23. The protector of claim 22 wherein the first and second panels are connected by a crush slit score. 24. The protector of claim 22 wherein the second and third panels are connected by a crush slit score. 25. The protector of claim 22 wherein the first and second panels are connected by a channel. 26. A protector comprising a foldable panel including a core disposed between first and second face sheets, the panel being divided into first, second and third foldable panel portions, the second panel portion including a slit and the third panel portion including a lip, such that in the folded position, the first, second and third panel portions are positioned generally peφendicular to each other and the lip on the third panel portion fits into the slit in the second panel portion to hold the first, second and third panel portions together in the folded position. 27. The protector of claim 26 wherein the first and second panel portions and the first and third panel portions respectively are divided by a crush slit score. 28. The protector of claim 26 wherein the first and second panel portions are divided by a channel and the first and third panel portions are divided by a crush slit score, the second panel portion including a second slit and the first panel portion including a lip such that in the folded position, the lip in the first panel portion fits into the second slit in the second portion to hold the first and second panel portions together in the folded position. 29. A method of making a protector from a panel including a core and a bottom face sheet comprising the steps of: a) providing a bottom face sheet; b) providing core on the bottom face sheet to define the panel; and c) defining a cavity in the panel to divide the panel into first and second panel portions each including an inner generally upstanding vertical sidewall defined by the cavity with the first and second panel portions being foldable about the cavity to form the protector. 30. The method of claim 29 further comprising the step of folding the first and second panel portions about the cavity to form the protector. 31. The method of claim 30 wherein the first and second panel portions are positioned generally peφendicularly to each other in the folded position and the inner sidewall ofthe second panel portion is disposed generally horizontally against the top of the first panel portion. 32. The method of claim 29 wherein a top face sheet is on the other side ofthe core of each panel portion. 33. The method of claim 29 wherein the steps of providing core includes the step of providing first and second core portions which are positioned and secured to the bottom face sheet in spaced apart relationship to define the cavity in the panel. 34. The method of claim 33 further comprising the step of providing first and second face sheet portions which are secured to the top ofthe first and second core portions respectively. 35. The method of claim 29 wherein the step of providing a bottom face sheet includes the step of providing first and second core portions and first and second bottom face sheet portions, the method further comprising the steps of securing the first and second bottom sheet portions respectively to define the first and second panel portions, the first and second panel portions being placed in spaced apart relationship on a bottom backing member to define the panel, the cavity being defined by the space between the first and second panel portions. 36. The method of claim 35 further comprising the step of providing first and second top face sheet portions which are secured to the top of the first and second panel portions respectively. 37. The method of claim 29 further comprising the steps of: providing and securing a top face sheet to the top ofthe core prior to step b, cutting first and second longitudinally extending spaced apart slits in the panel after step b, the first and second slits extending through the top face sheet and the core, and removing the core and the top face sheet from the panel to form the cavity. 38. A method of making a protector comprising the steps of: a) providing a panel including a core sandwiched between top and bottom face sheets; b) cutting first and second parallel slits in the panel, the first and second slits being spaced apart from each other and extending through the top face sheet and the core; and c) removing the core and the top face sheet between the first and second slits to form a panel including first and second spaced apart panel portions and a cavity therebetween, the first and second panel portions being foldable about the cavity to form the protector. 39. The method of claim 38 wherein the second panel portion includes an inner generally vertical sidewall terminating at the top face sheet in an inner longitudinally extending edge, the method further comprising the step of pushing the sidewall inwardly to form a lip at the inner edge. 40. The method of claim 39 further comprising the step of cutting a third slit in the first panel portion, the third slit being spaced from and parallel to the second slit and extending through the top face sheet and a portion ofthe core, the first and second portions being foldable about the cavity and the lip on the second panel portion fitting within the third slit to lock the first and second panel portions in the folded position. 41. The method of claim 38 wherein the panel includes a central longitudinal axis and a central transverse axis, the first and second slits being cut along the transverse axis, the method further comprising the steps of cutting third and fourth parallel slits along the central longitudinal axis, the third and fourth slits being spaced apart from each other and extending through the top face sheet and the core, and removing the core and the top face sheet between the third and fourth slits to form a panel including a third panel portion and second cavity therebetween, the first and third panel portions being foldable about the second cavity to form the protector. 42. The method of claim 41 wherein each ofthe second and third panel portions includes an inner generally vertical sidewall terminating at the top face sheet in an inner longitudinally extending edge, the method further comprising the step of pushing the sidewall ofthe second and third panel portions inwardly to form a lip at the edge of each ofthe second and third panel portions. 43. The method of claim 42 further comprising the step of cutting fifth and sixth slits in the first panel portion, the fifth slit being spaced from and parallel to the central transverse axis and extending through the top face sheet and a portion ofthe core, the first and second panel portions being foldable about the first cavity and the lip on the second panel portion fitting within the fifth slit in the first panel portion to lock the first and second panel portions in the folded position, the sixth slit being spaced from and parallel to the central longitudinal axis peφendicularly to the fifth slit and extending through the top face sheet and a portion ofthe core, the first and third panel portions being foldable about the second cavity and the lip on the third panel portion fitting within the sixth slit in the first panel portion to lock the first and third panel portions in the folded position to form the protector. 44. An apparatus for making a protector from a panel including a core sandwiched between top and bottom face sheets, the apparatus comprising: a) first and second slitters positioned in parallel and spaced apart relation for forming first and second parallel and spaced apart slits in the panel extending through the top face sheet; and b) a separator positioned adjacent the bottom face sheet ofthe panel and between the first and second slits for separating the slitted core from the bottom face sheet. 45. The apparatus of claim 44 including a conveyor for conveying a segment of the panel with respect to the slitters and the separator. 46. The apparatus of claim 44 further comprising a wedge associated with the separator for pushing the inner sidewall ofthe second panel portion inwardly so as to form a lip at the top edge thereof. 47. The apparatus of claim 45 further comprising third slit means parallel to the first and second slit means for forming a third slit in the first panel portion parallel to and spaced apart from the second slit, the third slit extending at least through the top face sheet. 48. The apparatus of claim 44 further comprising vacuum means for removing the slitted top face sheet and core from the panel.

Inventors: JAEGERS ROBERT E, KOWALSKI RAYMOND A, JAEGERS, ROBERT, E., KOWALSKI, RAYMOND, A.
Applicants: HEXACOMB CORP, HEXACOMB CORPORATION
Application year: 1997
Main classification: B65D81
IPC codes: B65D81