Patent Publication Number: US-2011062040-A1

Title: Edge protector

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/241,732, filed Sep. 11, 2009. 
    
    
     BACKGROUND 
     Shipping containers, such as boxes and the like, are at constant risk of being damaged about their ends and corners, which presents a concomitant risk of damaging the containers&#39; contents. If the container is dropped, there is a risk of damage to the articles being transported. This risk is particularly great at the edges and corners of the container because they typically receive the bulk of adverse impacts encountered during transit and are the most susceptible to damage. This is a particular problem where the articles being transported are individual or stacked flat sheets, e.g., particleboard, plywood, glass, ceramic, fiber and other tiles, cardboard, fiberboard, posterboard, and any other articles that may be stacked for shipping or storage. In the event that the container is dropped or sustains some other impact, the edge or corner of the flat article is at risk of sustaining acute damage. Because the flat articles are often stacked for transport, where the container dropped on its edge, the impact will be felt by the articles&#39; edges and corners, maximizing potential damage to the articles. Moreover, stacked flat articles may shift, slide or slip during transport. Where a flat article has slipped, that article has an increased likelihood of sustaining damage. 
     To resist such damage, various products and methods have been used to protect the corners and edges of articles during shipment or transit. Such products and methods often involve placing molded protectors on the inside of the shipping container in order to sustain the brunt of any impact, such that the protector absorbs the damage that would otherwise transfer to the article in transit. Interior package protective materials currently in use in packaging products for shipping and distribution are various types of plastic foams, e.g., polystyrene (commonly known as “Styrofoam”). Styrofoam is advantageous in that it may be molded to a specific shape in order to protect from damage while simultaneously minimizing shifting of the container&#39;s contents. However, Styrofoam presents significant environmental disadvantages. First, Styrofoam is a major contributor to municipal solid waste, and is neither biodegradable nor compostable. Also, Styrofoam itself is made from petroleum-based sources, and thus is inherently non-renewable. 
     Styrofoam also presents disadvantages in the way in which it absorbs damage from impact. Styrofoam&#39;s ability to absorb an impact is dependent on the Styrofoam&#39;s density. Due to its nature, Styrofoam&#39;s ability to cushion is affected by spring constant parameters, which limit Styrofoam&#39;s ability to protect from all types of damage. 
     One alternative to Styrofoam protectors is pulp fiber, which can be molded into desirable shapes. Compared to Styrofoam, pulp fiber is environmentally friendly and biodegradable. Pulp fiber can be formed with recesses complementary with the article or articles to be shipped, thus minimizing displacement of articles during shipment. Depending on the desired application, the thickness of molded pulp fiber can be varied either to resist crushing or to absorb the energy from impact by crushing, either of which can absorb the impact energy from edge and corner drops and thus can protect damage to articles being transported 
     Moreover, whereas the means by which Styrofoam provides protection is through density, molded pulp fiber is able to provide protection advantages through its configuration. By utilizing particular geometries, molded pulp protectors can be designed to target damage protection where needed, while preventing slippage or other movement by the articles. 
     Current molded pulp edge protectors are limited in their effectiveness to protect the corners of stacked, flat articles. Molded pulp edge protectors may be heavy-walled (typically 3/16 inch to ½ inch in thickness) or thin-walled (about 1/16 inch in thickness). Heavy-walled protectors are used for relatively hard and heavy objects. Although heavy-walled protectors can be used to protect the corners and edges of stacked flat articles, the protection they offer is limited because heavy-walled protectors have limited ability to absorb the energy from impact by crushing. Thus, articles, and particularly stacked flat articles, may be damaged by an impact notwithstanding the use of heavy-walled protectors. Heavy-walled molded protectors transfer more impact energy to the article or product being protected compared to thin-walled molded protectors, thus increasing the risk of damage to the article or product during transport. For this reason, heavy-walled molded pulp edge protectors are generally not suitable for relatively fragile articles, such as stacked particleboard or cardboard. 
     In addition, hardening agents are often used to manufacture heavy-walled molded edge protectors. In contrast, thin-walled molded-pulp edge protectors require little or no additional chemical agents, thereby making them more environmentally friendly. 
     Thin-walled molded pulp edge protectors have more flexibility and can be molded into more intricate shapes. This flexibility in molding allows thin-walled protectors to be crafted into shapes that fit the protector&#39;s specific use. Also, thin-walled protectors can be manufactured with shapes that are designed to absorb the energy from impact by crushing, thus adding further protection to articles not offered by heavy-walled protectors. The intricate shapes with which thin-walled molded pulp edge protectors can be designed allow the thin-walled molded pulp edge protector to crush upon impact. This crushing absorbs energy from an impact, thereby protecting the article or product from damage. 
     Current edge protectors—including current thin-walled edge protectors—are designed to protect edges that are part of a unitary structure, as in the edge of a single article. Where current edge protectors are used to protect multiple corners of a stacked sheet or flat articles that rest to form a line, they lack the ability to provide optimal protection to the corners of the stacked articles. Moreover, due to the geometry of the stacked flat articles, articles that have slipped have a greater susceptibility to damage from an impact. Current molded pulp protectors are not specifically designed for these particular risks, and as such they present inferior products and methods for protecting edges and corners during shipment. 
     Thus, there is a need to provide protection along the edges of a container to protect articles, including stacked, flat articles made of materials such as particle board, plywood, glass and tiles, etc., from impact and consequential damage. There is also a need to provide protection to prevent slippage of stacked, flat articles. 
     It is therefore an object of the present invention to provide new package cushioning structures or protectors that hold flat, stacked articles stationary during transport, while providing optimal protection from drops, particularly at the edges and corners. 
     BRIEF DESCRIPTION 
     One aspect of the present invention is a protector comprising a base having a plurality of base protrusions and an elongated edge having a flexible connection to the base, wherein the elongated edge has rib protrusions. Another aspect of the present invention is a protector comprising a base having a plurality of base protrusions and an elongated edge, wherein the elongated edge has a rigid connection to the base. Another aspect of the present invention is a method of protecting flat, stacked articles comprising placing a plurality of articles having edges into a container having an inside surface and arranging one or more edge protectors between edges of the articles and the inside surface of the container. Another aspect of the present invention is a method of transporting flat, stacked articles comprising placing a plurality of articles having edges into a container having an inside surface, arranging one or more edge protectors between edges of the articles and the inside surface of the container, and transporting the container. Another aspect of the present invention is a container comprising a plurality of flat stacked articles and one or more edge protectors, wherein the container has an inside surface and wherein the one or more edge protectors are positioned between the inside surface of the container and the stacked flat articles. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings: 
         FIG. 1  illustrates a top perspective view of a protector. 
         FIG. 2   a  is a side cross-section view of a protector. 
         FIG. 2   b  is a top perspective view of the protector of  FIG. 2   a.    
         FIGS. 2   c  and  e  are side views of the protector of  FIG. 2   a.    
         FIG. 2   d  is a bottom view of the protector of  FIG. 2   a.    
         FIG. 2   f  is a side cross-section view of the protector of  FIG. 2   a.    
         FIG. 2   g  is a side cross-sectional view of a product or article protected by the protector of  FIG. 2   a  and packed in a carton. 
         FIG. 3  is a perspective view of the bottom of a protector. 
         FIG. 4  is a perspective view of the top of a protector. 
         FIG. 5   a  is perspective view of the top of a foldable protector in an open position. 
         FIG. 5   b  is a perspective view of the protector of  FIG. 5   a  in a closed position. 
         FIG. 6   a  is a perspective view of the bottom of the protector of  FIG. 5   a  in a closed position. 
         FIG. 6   b  is a perspective view of the bottom of the protector of  FIG. 5   a  in an open position. 
         FIG. 7   a  is a side view of the protector of  FIG. 5   a  in a closed position. 
         FIG. 7   b  is a side view of the protector of  FIG. 5   a  in an open position. 
         FIG. 8  is a top perspective view and cross-sectional view of a protector. 
         FIG. 9  is a side cross-sectional view of a protector. 
         FIG. 10  is a side view of the elongated edge of a protector. 
         FIG. 11  is a top view of a protector. 
         FIG. 12  is a bottom perspective view of the protector of  FIG. 11 . 
         FIG. 13  is a top perspective view of the protector of  FIG. 11 . 
         FIG. 14  is a top perspective view of a protector. 
         FIG. 15  is a top perspective view of a protector. 
         FIG. 16   a  is a bottom view of a protector. 
         FIG. 16   b  is a perspective view of the bottom of the protector of  FIG. 16   a.    
         FIG. 16   c  is a side view of the front of the protector of  FIG. 16   a.    
         FIG. 16   d  is a side cross-sectional view of the side of the protector of  FIG. 16   a.    
         FIG. 17  is a perspective view of the protector of  FIG. 14  engaging flat stacked articles within a container. 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description, reference is made to the accompanying drawings and illustrations which form a part hereof, and in which are shown by way of illustration embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments will be defined by the claims and their equivalents. 
     The present invention is directed to protecting devices that are used to protect items such as furniture, table tops, stacked particleboard, plywood, glass, ceramic, fiber and other tiles, shelving, cardboard, fiberboard, posterboard, and other items from damage during transit, where the items have an edge or corner. In particular, the protecting devices are well-suited for flat articles that are stacked on top of each other during storage and shipment. Some examples of such flat items or articles are shelving, particle board and plywood. The protecting devices are particularly well-suited for use in shipment of ready-to-assemble furniture. In addition, the protecting devices are well-suited for use within a shipping container such as a box. 
     The protecting devices are preferably made from molded fiber or paper pulp. Processes for manufacturing thin-walled protectors from molded fiber or paper pulp are well known in the art. (See, e.g., U.S. Pat. No. 6,629,608 (filed Aug. 22, 2001); PCT Published Patent Application No. WO 93/16937 (filed Feb. 26, 1993), which are hereby incorporated by reference in their entirety.) Molded fiber or pulp is biodegradable and more environmentally friendly compared to other packaging materials, such as Styrofoam. Molded pulp or fiber can be made from recyclable material, may itself be recyclable, and is relatively easy to manufacture. 
       FIG. 1  illustrates a top perspective view of a commercially available molded pulp protector that is formed on a single mold form. The protector has a base  10  with protrusions  30  arranged in a grid pattern with horizontal and vertical rows of protrusions  30 . The protrusions  30  have four side-walls and are preferably square or rectangular in shape. The protector of  FIG. 1  may be placed between the article to be protected and a container in which the article is shipped, such as a box. The protrusions  30  absorb energy from an impact and provide a cushion for the article in the container. The protector of  FIG. 1  may be cut to a desired size and may be arranged between the edge or surface of the article being shipped and the walls of a shipping container. As used in this disclosure, the term “protrusion-free channel” refers to a linear channel in the base  10  having no protrusions  30 . As shown in  FIG. 1 , the arrangement of protrusions  30  leaves horizontal protrusion-free channels  12  and vertical protrusion-free channels  14 . One disadvantage of protector of  FIG. 1  is seen where this design is used to attempt to protect the edges or corners of stacked flat articles. In such a situation, the stacked flat articles might slip into the horizontal protrusion-free channels  12  or vertical protrusion-free channels  14 , which would cause the protector of  FIG. 1  to provide little protection from impact to the slipped articles. Articles which slip into the horizontal protrusion-free channels  12  or vertical protrusion-free channels  14  are thus more likely to be damaged from a drop or impact. Another disadvantage of this design is that multiple pieces of the protector need to be arranged around the article (or stacked flat articles) to protect its corners or edges. Multiple pieces are more likely to change position during transport and offer less support compared to a unitary structure used to protect edges or corners. Another disadvantage of this design is that it offers poor protection along the edges of the container holding the products or articles to be transported. Although this design is suitable for protecting a flat surface, in order to protect from edge or corner drops it must be cut or folded about the edge or corner. Where such cut or fold does not cross any protrusions, the benefit of protection from the protrusions is diminished at the edge or corner, where it is needed most. Where such cut or fold does cross protrusions, the protrusions themselves will be cut. Protrusions that have been cut are structurally weaker than protrusions that have not been cut, which results in the cut protrusions&#39; inferior capability to absorb the energy from impact. Thus, the edge or corner of the article remains vulnerable to damage. 
       FIGS. 2   a - g  illustrate one embodiment of an edge protector having a base  10  with a foldable flap  20 . The foldable flap is connected to the base  10  by a flexible connection  22 . As illustrated in  FIG. 2   g , the base  10  of the protector is placed on the edges of stacked flat articles and the foldable flap  20  is folded such that the protector is positioned between the inside surface of the container and the product. In this embodiment, the protector has protrusions  30  arranged in a diagonal grid pattern relative to the base  10  of the protector, thereby eliminating the horizontal protrusion-free channels  12  and the vertical protrusion free channels  14  of the protector of  FIG. 1 . The arrangement of the protrusions  30  in a diagonal grid pattern is advantageous in that it helps to prevent stacked flat articles from slipping past or between protrusions  30  such that they receive less or no protection offered by the protrusions  30  in the event of an impact. As used in this disclosure, the term “horizontal protrusion-free channel” refers to a protrusion-free channel in the base  10 , where the protrusion-free channel is parallel to the plane in which stacked flat articles lie. Similarly, as used in this disclosure, the term “vertical protrusion-free channel” refers to a protrusion-free channel in the base  10 , where the protrusion free channel is perpendicular to the plane in which stacked flat articles lie. It should be noted that where stacked flat articles are arranged non-horizontally, e.g., vertically, a horizontal protrusion-free channel may not be horizontal as the term “horizontal” is customarily understood, and a vertical protrusion-free channel may not be vertical as the term “vertical” is customarily understood. Although in some embodiments, the protector has protrusions  30  that are arranged in a diagonal grid pattern, the protrusions  30  may be arranged in other patterns; as long as the base  10  is free of horizontal protrusion-free channels, the protector will be able to help prevent stacked flat articles from slipping between the protrusions  30 . In some embodiments, the presence of a vertical protrusion-free channel is advantageous. Where the base  10  is cut across protrusions  30  in order to customize the dimensions of the protector, the cut protrusions  30  provide inferior protection from impact. Thus, the presence of a vertical protrusion-free channel allows the protector to be cut at that channel, giving the protector desirable dimensions while avoiding the need to cut across protrusions  30 . 
     The protrusions  30  have four side-walls  32  and are preferably square or rectangular shaped. The four side-walls  32  are preferably angled inward so that the area of the protrusion  30  near the base of the protector is larger than area of the protrusion  30  at the top of the protector. As illustrated in  FIGS. 2   b ,  2   d  and  2   e , the protector preferably has smaller protrusions  40  along the edge of the foldable flap  20 . The smaller protrusions  40  along the edge of the foldable flap  20  are preferably smaller in height and have a side-wall  42  that is parallel to the edge of the foldable flap  20 . In the embodiment shown in  FIGS. 2   a - g , the smaller protrusions  40  are triangle shaped and are positioned so that one side-wall  42  is parallel to the foldable edge of the protector and the other side-walls are parallel to the diagonal grid pattern formed by the rows and columns of the protrusions  30 . 
       FIG. 3  is a bottom perspective view of another embodiment of an edge protector. The protector has square or rectangular-shaped hollow protrusions  30 . The protrusions  30  may be hollow or filled or partially filled with molded paper pulp, depending upon the amount of protection that is required. Preferably, the protrusions  30  are hollow and the thickness of the side-walls  32  of the protrusion may be varied depending upon the amount of protection required. For example, in the embodiment shown in  FIG. 3 , the centers of the sidewalls  32  are thicker, forming hollow protrusions  30  shaped like a four-leaf clover when viewed from the bottom.  FIG. 4  is a top perspective view of another embodiment of a protector having two foldable flaps  20 . 
     In some applications, the embodiments of an edge protector illustrated in  FIGS. 2   a - 2   g ,  FIG. 3 , and  FIG. 4  are limited in their effectiveness to protect the article to be shipped from an impact suffered at or near the foldable flap  20 . Moreover, the foldable flap  20  is susceptible to being torn or broken away from the base  10  in the event of an impact. In other applications, these embodiments are advantageous because the foldable flap  20  allows the protector to remain in its proper position while requiring minimal additional space between the article being transported and the inside surface of the container. Also, the foldable flap  20  allows the protector to be used to protect a wide variety of articles with corners of varying angles, due to the flexibility in the flexible connection  22  between the foldable flap  20  and the base  10 . 
       FIGS. 5   a  and  5   b  illustrate a top perspective view of an alternate embodiment of a protector with foldable flaps. In the embodiment shown in  FIGS. 5   a  and  5   b , the protrusions  30  form a diagonal grid on the base  10  of the protector. The protrusions  42  on the base  10  nearest the foldable flap  20 , however, are square or rectangular in shape with sidewalls that are parallel and perpendicular to the foldable flap  20 . The foldable flap  20  also has protrusions  40  that preferably have the same width as the height of the protrusions  42  on the base of the protector, such that when the foldable flap  20  is folded, the protrusions  40  on the flap  20  fill the gaps between the protrusions  42  on the base  10 , as shown in  FIG. 5   b . In the context of this disclosure, this aspect wherein the protrusions  40  fill the gaps between protrusions  42  on the base  10  when the foldable flap  20  is folded is referred to as being “adjacent.” In other words, when the foldable flap  20  is folded about its flexible connection  22  to the base  10 , the protrusions  40  are adjacent to the protrusions  42 . The base  10  of the protector also has protrusions  44  on the base  10  farthest the foldable flap  20 . In a preferred embodiment, the protrusions  44  have three side-walls  46  and are preferably triangular shaped.  FIGS. 6   a  and  6   b  illustrate a bottom perspective view of the protector shown in  FIGS. 5   a  and  5   b .  FIGS. 7   a  and  7   b  illustrate a side perspective view of the protector shown in  FIGS. 5   a  and  5   b . An advantage of the protector illustrated in  FIGS. 5   a  and  5   b  in some applications is that, because of the geometries of the protrusions  40  and  42 , the walls of these protrusions offer structural support in the same plane (or in close to the same plane) in which one or more flat articles lie. This provides added protection from impact and further protects the one or more stacked articles from damage. 
       FIG. 8  is a top perspective view and cross-sectional view of a protector with a foldable flap  20 , illustrating an alternate shape for the protrusion  42  on the base of the protector nearest the foldable flap  20 . 
       FIG. 9  is a side cross-sectional view of a protector molded as a unitary piece. In this embodiment the elongated end  50  at the end of the protector is not foldable, which makes the edge protector stronger and provides more protection to the article near an edge of the container. For the purposes of this disclosure, the connection of the base  10  to the elongated edge  50  can be described as being rigid.  FIG. 10  is a side view of the elongated edge  50  of a protector. As illustrated in  FIG. 10 , the elongated edge  50  is preferably ribbed with protrusions  52  that protrude inward into the gaps formed by the protrusions  30  on the base  10  of the protector. The elongated edge  50  is also preferably ribbed with rib protrusions  55  that protrude inward from elongated edge  50  and extend in elongated edge  50  beyond the height of protrusions  30 . In some embodiments, the rib protrusions  55  extend substantially the height of elongated edge  50  from its connection to the base  10 .  FIG. 11  is a top view of an alternate embodiment of a protector, wherein the protrusions  53  on the elongated edge  50  of the protector are molded so that they share a sidewall with the protrusions on the base  10  of the protector that are nearest to the elongated edge  50 .  FIG. 12  is a bottom perspective view of the protector of  FIG. 11 .  FIG. 13  is a top perspective view of the protector of  FIG. 11 . 
     In certain applications, the embodiments of edge protectors as illustrated in  FIG. 9  through  FIG. 13  are advantageous in that they provide additional protection to the article near an edge of the container, due to the fact that the elongated edge  50  is not foldable. Moreover, the rib protrusions  55  provide added strength to the elongated edge  50 , which assists the elongated edge  50  in absorbing the energy from impacts and thereby provides additional protection. 
       FIG. 14  is a top perspective view of a preferred embodiment of a protector. In this preferred embodiment, the protrusions  30  are preferably square or rectangular shaped and are arranged in a diagonal pattern to form a diagonal grid relative to the base  10  of the protector. On one end of the protector, there is preferably an elongated edge  50  with chair-shaped protrusions  54 . The height of the seat  56  of the chair-shaped protrusions  54  from the base  10  of the protector is approximately the same height as the protrusions  30  on the base  10  of the protector. The back  58  of the chair-shaped protrusions  54  provides a ribbed structure to the portion of elongated edge  50  that extends beyond the height of the seat  56 . The seat  56  is connected to the back  58  at a juncture; when the protector is in use, the juncture engages a corner or edge of an article to be protected. The sidewalls  60  of the chair-shaped protrusions  54  are perpendicular or nearly perpendicular to the elongated edge  50 , and preferably have a draft angle of about seven degrees compared to the base  10 . The sidewalls  60  add structural integrity to elongated edge  50 , which provides greater protection from impact while also helping to prevent breaking or tearing of the protector upon impact.  FIG. 15  is a top perspective view of an alternate preferred embodiment of a protector, which includes two elongated edges  50  on opposite sides of the base  30  and parallel to each other. The protector shown in  FIG. 15 . could either be cut in the center, between the elongated edges  50 , to fit a shipping container, or it could be designed to an appropriate length so that the protector fits snugly within a container having specific dimensions. In some embodiments, as shown in  FIG. 15 , the protrusions  30  in base  10  are arranged such that a vertical protrusion-free channel  14  exists between and parallel to the elongated edges  50 . It should be noted that whereas in this embodiment the protrusions  30  on base  10  are arranged to be free of horizontal protrusion-free channels, vertical protrusion-free channel  14  is perpendicular to the plane in which stacked flat articles protected by the protector would lie. Thus, if the stacked flat articles were lying horizontally, the vertical protrusion-free channel would be vertical; depending on the position of the stacked flat articles, the vertical protrusion-free channel may or may not be “vertical” as that term is commonly understood. 
     Preferred dimensions of a protector with chair shaped protrusions  54  are as follows. Base protrusions  30  are at a height of one inch above the base  10  and have a draft angle of about seven degrees. The elongated edge  50  extends to a height of about two inches above the base  10 . The seats  56  have a height of about one inch above the base  10 . Each of the seats  56  has a length of about 0.5 inch measured from each seat&#39;s  56  juncture with the back  58  of the chair-shaped protrusions  54  and extending into the base  10 . The backs  58  of the chair-shaped protrusions  54  extend about one inch above the seats  56  of the chair-shaped protrusions  54 . The distance between the chair-shaped protrusions  54 , measured center-to-center, is about 0.63 inch. The chair shaped protrusions  54  are about 0.22 inches wide, measured at the top of the chair-shaped protrusions  54 . The juncture of the seat  56  and the back  58  is about 0.39 inch from the elongated edge  50 . Each of the chair-shaped protrusions  54  has a draft angle of about seven degrees. 
       FIGS. 16   a  to  16   d  illustrate an alternate preferred embodiment of an edge protector.  FIG. 16   a  is a bottom view of the edge protector.  FIG. 16   b  is a perspective view of the bottom of the edge protector.  FIG. 16   c  is a side view of the front of the edge protector, and  FIG. 16   d  is a side view of the edge protector. 
     The edge protector is preferably manufactured from molded paper pulp. It can be in any color, but is preferably in standard gray. The average thickness of the walls of the protector are preferably about 1/16 of an inch, which is a standard thickness for thin-walled protectors. 
     The elongated edge  50  preferably has a draft angle of about seven degrees. It should be noted that the side-walls of the protrusions  30  and  54  are preferably angled inward so that the area of the protrusion at the base is larger than the area of the protrusion at the top. It should also be noted that the side-walls  60  of the chair-shaped protrusions  54  are preferably angled inward so that the distance between the side-walls  60  on either side of a chair-shaped protrusion  54  is greater at the base than it is at the top. The draft angle and the angled inward protrusions and chair-shaped protrusions allow the protectors to be stacked on top of each other, which not only saves space, but makes it easier and cheaper to store and transport the protectors of the present invention. 
     In the embodiments of an edge protector shown in  FIG. 1  through  FIG. 17 , it is generally preferable to fit as many protrusions  30  as possible on a given protector, such that the area of the base  10  covered by each individual protrusion  30  is small. Moreover, the height of protrusions  30  off of the base  10  is determined by the amount of protection required. Generally, the amount of protection increases with an increase in the height of protrusions  30 , although in some applications greater height of protrusions  30  can result in a higher manufacturing cost. Similarly, in the embodiments of an edge protector shown in  FIG. 14  through  FIG. 16   d , it is generally preferable that as many chair-shaped protrusions  54  be placed along elongated edge  50  as possible, such that the width of each individual chair-shaped protrusion  54  is small. It is also preferable that the height of the seat  56  of the chair-shaped protrusions  54  off of the base  10  matches the height of the protrusions  30 . Due to manufacturing constraints, the applicant has found the dimensions given in paragraph [0056] to be well-suited in applications requiring protection of stacked flat particleboard sheets having a thickness of ½ inch or ⅝ inch, as well as in applications requiring protection of stacked flat sheets having other thicknesses. 
     To demonstrate an example of protectors in use,  FIG. 17  shows the protector of  FIG. 14  engaging stacked flat articles  70  within a container  80 , such as a box.  FIG. 17  shows four protectors, each engaging an edge of a stack of flat articles.  FIG. 17  illustrates the diagonal arrangement of the protrusions  30  with respect to the plane of the stacked flat articles. Specifically, the arrangement of protrusions  30  in base  10  is free of horizontal protrusion-free channels, and the stacked flat articles are inhibited from slipping between or past the protrusions  30 . Also, side-walls  60  lie in the same plane or in nearly the same plane as the stacked flat articles  70 . In this way, the protectors protect the stacked flat articles  70  from damage from impact, while at the same time positioning the stacked flat articles  70  within the container  80 . Although  FIG. 17  shows an example of the protector of  FIG. 14  in use, other protectors as described herein operate in similar or identical ways to protect articles such as stacked flat articles. 
     A short edge drop test was performed according to the guidelines set for such a test by the International Safe Transit Association (“ISTA”). A Model 273 shipping carton, which is a cardboard box typically used to ship ready-to-assemble furniture, was used for the ISTA drop test. Particle boards were cut to simulate the flat stacked articles in a Model 273 shipping carton. A Model 273 shipping carton packed with flat stacked particle boards and 1 inch foam end pads was dropped on its shortest edges. The results were evaluated and used as a control. Multiple other Model 273 shipping cartons were packed using flat stacked particle boards to compare the protection offered by different embodiments of edge protectors. The following embodiments were tested and compared to each other and the control: (1) the protector with a foldable flap as illustrated in  FIGS. 5-8 ; (2) the protector illustrated in  FIGS. 9-13 ; and (3) the protector illustrated in  FIG. 14 . The results of the ISTA drop test show that the embodiment illustrated in  FIG. 14  performs better than the other embodiments tested and performs better than the 1 inch foam protector. The results of the ISTA test are listed in the table below. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Results of ISTA Drop Test. 
               
            
           
           
               
               
               
            
               
                   
                 Type of Protector 
                 Result 
               
               
                   
                   
               
               
                   
                 1 inch foam pads 
                 Significant Damage 
               
               
                   
                 Embodiment Illustrated in FIGS. 5 to 8 
                 Significant Damage 
               
               
                   
                 Embodiment Illustrated in FIGS. 9 to 13 
                 Some Damage 
               
               
                   
                 Embodiment Illustrated in FIG. 14 
                 Minor to No Damage 
               
               
                   
                   
               
            
           
         
       
     
     Although certain embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the present invention. Those with skill in the art will readily appreciate that embodiments in accordance with the present invention may be implemented in a wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments in accordance of the present invention be limited only by the claims and the equivalents thereof.