Patent Abstract:
A corner protector is provided for protecting a corner of an object. The corner protector includes first and second spaced sidewalls. Each sidewall includes an outer edge having a notch formed therein in order to allow sidewalls to flex. A connection element interconnects the first and second sidewalls such that the inner surfaces of the first and second sidewalls define an object receiving cavity therebetween. Support shoulders are provided within the object receiving cavity of the corner protector to support the corner of the object when inserted therein.

Full Description:
FIELD OF THE INVENTION 
     This invention relates generally to corner protections, and in particular, to a corner protector for protecting a corner of an object such as a window or the like during shipment. 
     BACKGROUND AND SUMMARY OF THE INVENTION 
     Heretofore, a wide variety of corner protectors have been manufactured to protect the corners of various types of objects such as windows or the like during shipment of the objects. However, these prior art corner protectors have significant drawbacks which limit their use and/or effectiveness. For example, prior art expanded polystyrene corner protectors are often perceived to be environmentally unfriendly. As is known, expanded polystyrene is not biodegradable, and hence, may be banned from landfills or the like. Many insurance companies refuse to allow their clients to store expanded polystyrene in factories and warehouses due to fire related concerns. As such, users of corner protectors have sought a more environmentally sound alternative to the expanded polystyrene products. 
     In order to address environmental concerns, corner protectors have been developed which are manufactured from other types of material such as molded pulp. However, these molded pulp corner protectors often times do not have sufficient strength to protect the corners of an object from possible damage during shipment thereof. Further, due to the substantial flexibility of products manufactured from molded pulp, these types of prior art corner protectors tend to be too flexible thereby compromising, the amount of protection provided for the corners of the object. 
     Therefore, it is a primary object and feature of the present invention to provide a molded pulp corner protector which optimizes the strength and the flexibility thereof in order to protect the corners of an object during shipment. 
     It is a still further object and feature of the present invention to provide a corner protector which is inexpensive to manufacture and simple to utilize. 
     It is a still further object and feature of the present invention to provide a corner protector which is biodegradable, and hence, environmentally friendly. 
     In accordance with the present invention, a corner protector is provided for protecting a corner of an object such as a window or the like. The corner protector includes a first end wall lying in a first plane. The first end wall has first and second sides and first and second ends. The second end wall lies in a second plane which is perpendicular to the first plane. The second end wall also has first and second sides. A first sidewall interconnects the first sides of the first and second end walls, and has an outer edge extending between the second ends of the first and second end walls. The outer edge includes a notch formed therein. A second sidewall interconnects the second sides of the first and second end walls. The second sidewall has an outer edge extending between the second ends of the first and second end walls. The outer edge of the second sidewall also includes a notch therein. 
     The first and second sidewalls of the corner protector include inner surfaces which define an object receiving cavity therebetween for receiving the corner of the object. A first support shoulder extends inwardly from the inner surface of the first sidewall. The first support shoulder is defined by an object engaging surface and an inwardly directed surface. A second support shoulder extends inwardly from the inner surface of the first sidewall. The second support shoulder is defined by an object engaging surface and an inwardly directing surface. The object engaging surface of the first support shoulder is generally perpendicular to the object engaging surface of the second support shoulder. Alternatively, the second support shoulder extends inwardly from the inner surface of the second sidewall. As such, the object engaging inner surface of the first shoulder lies in a parallel plane with the object engaging surface of the second support shoulder. 
     The notch in the outer edge of the first sidewall is defined by a first edge portion which is generally parallel to the first end wall and a second edge portion which is generally parallel to the second end wall. The first end wall includes the inner surface directed towards the object receiving cavity. The inner surface of the first end wall and the inner surface of the first sidewall are interconnected by a rib. 
     In accordance with a further aspect of the present invention, a corner protector is provided for protecting a corner of an object such as a window or the like. The corner protector includes a first sidewall lying in a first plane. The first sidewall has an inner surface and an outer edge which includes a notch formed therein. A second sidewall lies in a second plane. The second sidewall has an inner surface and an outer edge which includes a notch formed therein. A first support shoulder extends from the inner surface of the first sidewall. The first support shoulder is defined by an object engaging surface and an inwardly directing surface. A second support shoulder extends from the second sidewall. The second support shoulder is also defined by an object engaging surface and an inwardly directed surface. A connection element interconnects the first sidewall and a second sidewall such that the inner surfaces of the first sidewall and second sidewall define an object receiving cavity therebetween. 
     The connection element includes a first end wall having a first side interconnected to the first sidewall and a second side interconnected to the second sidewall. The first end wall further includes first and second opposite ends. A second end wall extends from the second end of the first end wall. The second end wall includes a first side interconnected to the first sidewall and a second side interconnected to the second sidewall. The second sidewall also includes first and second opposite ends. The first end of the second end wall is interconnected to the first end of the first end wall. 
     The outer edge of the first sidewall extends between the second ends of the first and second end wall. Similarly, the outer edge of the second sidewall extends between the second ends of the first and second end walls. The notch in the outer edge of the first sidewall is defined by a first edge portion and is generally parallel to the first end wall and a second edge portion which is generally parallel to the second end wall. 
     The first end wall also includes an inner surface directed towards the object receiving cavity. The inner surface of the first end wall and the inner surface of the first sidewall are interconnected by a rib. In addition, the object engaging surface of the first support shoulder lies in parallel planes with the object engaging surface of the second support shoulder. 
     In accordance with a still further aspect of the present invention, a corner protector is provided for protecting a corner of an object. The corner protector includes a first sidewall lying in a first plane. The first sidewall has an inner surface and an outer edge which includes a notch formed therein. The second sidewall lies in a second plane. The second sidewall has an inner surface and an outer edge which includes a notch formed therein. A first support shoulder extends from the inner surface of the first sidewall. The first support shoulder is defined by an object engaging surface and an inwardly directing surface. A second support shoulder extends from the inner surface of the second sidewall. The second support shoulder is defined by an object engaging surface and an inwardly directing surface. A first end wall has a first side interconnected to the first sidewall and a second side interconnected to the second sidewall. The first end wall further includes first and second opposite ends. A second end wall has a first side interconnected to the first sidewall and a second side interconnected to the second sidewall. The second sidewall further includes first and second opposite ends. 
     It is contemplated that the first end of the first end wall be interconnected to the first end of the second end wall. In addition, the first and second end walls are generally perpendicular to each other. The notch of the outer edge of the first sidewall is defined by a first edge portion which is generally parallel to the first end wall and a second edge portion which is generally parallel to the second end wall. The first end wall includes an inner surface directed towards the object receiving cavity. The inner surface of the first sidewall and the inner surface of the first end wall are interconnected by a rib. The object engaging surface of the first support shoulder lies in a plane parallel to the object engaging surface of the second support shoulder. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The drawings furnished herewith illustrate a preferred construction of the present invention in which the above advantages and features are clearly disclosed as well as others which will be readily understood from the following description of the illustrated embodiment. 
     In the drawings: 
     FIG. 1 is the side elevational view of the first and second prior art corner protectors placed over corresponding corners of an object; 
     FIG. 2 is a side elevational view of first and second corner protectors in accordance with the present invention placed over corresponding corners of an object; 
     FIG. 3 is an end view taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is a cross-sectional view taken along line  4 — 4  of FIG. 2; 
     FIG. 5 is a cross-sectional view taken along line  5 — 5  of FIG. 4; 
     FIG. 6 is a cross-sectional view taken along line  6 — 6  of FIG. 4; 
     FIG. 7 is a cross-sectional view taken along line  7 — 7  of FIG. 5; 
     FIG. 8 is a cross-sectional view taken along line  8 — 8  of FIG. 5; and 
     FIG. 9 is a top plan view of a plurality of corner protectors in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, a prior art corner protector is, generally designated by the reference numeral  10 . Each prior art corner protector  10  is intended to be positioned about a corresponding corner  12  of an object, such as window  14 , in order to protect corners  12  during shipment. Each prior art corner protector includes generally triangular sidewalls  16  which define a corner receiving trough therebetween. Sidewalls  16  of prior art corner protectors  10  are generally flat such that the inner surfaces thereof are free of any projections, support structures or ribs. 
     Referring to FIGS. 2-9, a corner protector in accordance with the present invention is generally designated by the reference numeral  20 . In a preferred embodiment, corner protector  20  is manufactured from a molded pulp material. However, it is contemplated to manufacture corner protector  20  from other types of materials without deviating from the scope of the present invention. 
     As best seen in FIGS. 4-8, corner protector  20  includes a first sidewall  22  lying in a first plane and a second sidewall  24  lying in a second plane generally parallel to the first plane. First sidewall  22  is generally triangular in shape and includes a first side  26  and a second side  28  interconnected by an outer edge  30  extending along the hypotenuse thereof. A notch  32  is formed in outer edge  30  of first sidewall  22 . Notch  32  is defined by a first edge portion  34  and a second edge portion  36 . First notch portion  34  and second notch portion  36  are generally perpendicular to each other. First sidewall further includes an outer surface  38  and an inner surface  40  directed towards second sidewall  24 . 
     As best seen in FIG. 6, second sidewall  24  is generally triangular in shape and includes first and second sides  44  and  46 , respectively, interconnected by an outer edge  48  extending along the hypotenuse thereof. Outer edge  48  includes a notch  50  formed therein. Notch  50  is defined by a first edge portion  52  and a second edge portion  54 . First edge portion  52  and second edge portion  54  of outer edge  48  of second sidewall  24  are generally perpendicular to each other. Second sidewall  24  further includes an outer surface  56  and an inner surface  58  directed towards first sidewall  22 . Inner surface  58  of second sidewall  26  and inner surface  40  of first sidewall  24  define a corner receipt cavity  60 , FIG. 8, therebetween. 
     First and second sidewalls  22  and  24 , respectively, are interconnected by first and second end walls  62  and  64 , respectively. First end wall  62  includes first and second sides  66  and  68 , respectively, and first and second ends  70  and  72 , respectively. First side  66  of first end wall  62  is integrally molded with first side  26  of first sidewall  22 . Second side  68  of first end wall  62  is integrally molded with first side  44  of second sidewall  24 . In addition, first end  70  of first end wall  62  is integrally molded with first end  74  of second end wall  64 . 
     Similarly, second end wall  64  includes first and second sides  75  and  77 , respectively. First side  75  of second end wall  64  is integrally molded with second side  28  of second sidewall  24 . Second side  77  of second end wall  64  is integrally molded with second side  46  of second sidewall  26 . As described, outer edge  30  of first sidewall  22  extends between second end  72  of first end wall  62  and second end  76  of second end wall  64 . Similarly, outer edge  48  of second sidewall  24  extends between second end  72  of first end wall  62  and second end  76  of second sidewall  64 . 
     First and second end walls  62  and  64 , respectively, include corresponding inner surfaces  78  and  80 , respectively, which are directed towards and partially define corner receipt cavity  60 . Rib  82  extends between the inner surface  40  of first sidewall  22  and inner surface  78  of first end wall  62  at a location adjacent second end  72  of first end wall  62 . Rib  84  extends between inner surface  58  of second sidewall  24  and inner surface  78  of first end wall  62  at a location adjacent second end  72  of first end wall  62 . Ribs  82  and  84  add strength and stability to corner protector  20  and discourage damage to first end wall  62  during use of corner protector  20 . 
     Rib  86  extends between inner surface  40  of first sidewall  22  and inner surface  80  of second end wall  64 . Rib  88  extends between inner surface  58  of second sidewall  24  and inner surface  80  of second end wall  64 . Ribs  86  and  88  add strength and stability to corner protector  20  and discourage damage to second end wall  64  during use of corner protector  20 . 
     Corner protector  20  further includes a first support shoulder  90  which projects inwardly from inner surface  40  of first sidewall  22 . First support shoulder  90  is defined by an object engaging surface  92  projecting from inner surface  40  and being generally parallel to inner surface  78  of first end wall  62 . Object engaging surface  92  of first support shoulder  90  is interconnected to inner surface  78  of first end wall  62  by inwardly directed surface  94  and by sides  96  and  98 . Second support shoulder  100  projects inwardly from inner surface  40  of first sidewall  22 . Second support shoulder  100  includes an object engaging surface  102  which extends from inner surface  40  of first sidewall  22  and is generally parallel to inner surface  80  of second end wall  64 . Object engaging surface  102  is interconnected to inner surface  78  by inwardly directed surface  104  and by sides  106  and  108 . As described, object engaging surface  102  of second support shoulder  100  and object engaging surface  92  of first support shoulder  90  are generally perpendicular to each other. 
     Second sidewall  24  includes a first support shoulder  116  projecting inwardly therefrom. First support shoulder  110  of second sidewall  24  includes an object engaging surface  112  projecting from inner surface  58  of second sidewall  24  and is generally parallel to inner surface  78  of first end wall  62 . Object engaging surface  112  of first support shoulder  110  is interconnected to inner surface  78  of first end wall  62  by inwardly directed surface  114  and by sides  116  and  118 . Second sidewall  24  includes a second support shoulder  120  projecting therefrom. Second support shoulder  120  of second sidewall  24  includes an object engaging surface  122  which extends from inner surface  58  of second sidewall  24  and is generally parallel to inner surface  80  of second end wall  64 . Object engaging surface  122  is interconnected to inner surface  80  of second end wall  64  by inwardly directed surface  124  and sides  126  and  128 . 
     In operation, corner protectors  20  are intended to protect the corners  12  of an object such as window  14 . Window  14  includes one or more transparent panes  130  mounted within a generally rectangular frame generally designated by the reference numeral  132 . Frame  132  of window  14  often is formed from multiple tubular elements  134   a-c , FIG. 4, which define the outer surface  136  of frame  132 . First and second mounting flanges  138  and  140  project radially from outer surface  136  of frame  132  to facilitate the mounting of window  14  within an opening. 
     Comer protector  20  is positioned over a corresponding corner  12  of window  14  such that corner  12  is received within corner receiving cavity  60  of corner protector  20 . By way of example, referring to FIGS. 5-6, corner  12  of window  14  is received within corner receiving cavity  60  in corner protector  20  such that a first side  132   a  of frame  132  engages object engaging surface  92  of first support shoulder  90  extending from first sidewall  22  and engages object engaging surface  112  of first shoulder  110  extending from first second sidewall  24 . In addition, the second side  132   b  of frame  132  of window  14  engages object engaging surface  102  of second support shoulder  100  extending from first sidewall  22  and engages object engaging surface  122  of second support shoulder  120  extending from second sidewall  24 . Notches  32  and  50  in first and second sidewalls  22  and  24 , respectively, allow first and second sidewalls  22  and  24 , respectively, to flex and snugly retain corner protector  20  on corner  12  on window  14 . 
     Referring to FIG. 3, it can be appreciated that corner protectors  20  may be positioned over the corners  12  of a plurality of windows  14   a-c , such that the plurality of windows  14   a-c  may be vertically stacked adjacent one another in a spaced relationship so as to prevent damage to the plurality of  14   a-c  during transport. Referring to FIG. 9, it can be further appreciated that due to their triangular shape, a group of four corner protectors  20   a - 20   d  may be arranged to form a generally rectangular configuration so as to minimize the space requirements of corner protectors  20   a-d  during transport and storage. 
     Various modes of carrying, out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.

Technology Classification (CPC): 4