EDGE PROTECTOR

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Serial No. 63/710,094, EDGE PROTECTOR, filed October 22, 2024, the disclosure of which is incorporated in its entirety by reference.

TECHNICAL FIELD

The present application relates generally to packaging for shipping and more particularly to an edge protector for packaging.

BACKGROUND OF THE INVENTION

It is important to manufacturers that a product is shipped in an efficient and economical manner while also sufficiently protecting the product from damage during the shipping process. Edges of the product, especially corners, are susceptible to damage during handling. Therefore, special attention is paid to protecting a product’s edges, including corners and sides of the product, which results in packaging that needs to be custom designed to accommodate the particular product being shipped. However, customized designs add complexity and cost to the packaging that is passed on to a consumer.

There is a need for an economical and efficient packaging that protects the product, and particularly edges of the product, without the need for redesigning packaging for multiple products. The inventive subject matter addresses this need and provides further related advantages.

SUMMARY OF THE INVENTION

In one general aspect, an edge protector may include a first side with a distal opening and a first bottom flap. The edge protector may also include a second side with a distal opening and a second bottom flap. Furthermore, the protector may include a divider portion between the first and second sides, defining a proximal opening. The divider portion is pivotable within the proximal opening.

Implementations may include one or more of the following features: an edge protector having a third side where the third side further includes a tongue on the first bottom flap, an opening on the second bottom flap that receives the tongue when the first bottom flap is folded onto the second bottom flap, and where the divider portion pivots to divide the proximal opening into first and second proximal openings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A is a top perspective view of one or more embodiments of an edge protector;

FIG. 1B is a bottom perspective view of one or more embodiments of an edge protector;

FIG. 2A is a top perspective view of one or more embodiments of an edge protector;

FIG. 2B is a bottom perspective view of one or more embodiments of an edge protector;

FIG. 3A is a perspective view of a partial packaging assembly incorporating an edge protector of FIGS. 2A & 2B;

FIG. 3B is a perspective view of a partial packaging assembly incorporating a plurality of edge protectors of FIGS. 2A & 2B.;

FIG. 4A is a perspective view of a partial packaging assembly having a first configuration of connecting pieces;

FIG. 4B is perspective view of a partial packaging assembly having a second configuration of connecting pieces;

FIG. 5 is a perspective view of an example product having a partially implemented packaging assembly; and

FIG. 6 is a pattern for two edge protectors of the inventive subject matter.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1A and 1B generally depict an edge protector 100 that, when assembled from a pattern, is a packaging component that protects an edge, such as a side or a corner, of a product (not shown in FIGS. 1A and 1B) during shipping. FIG. 1A is a top perspective view showing one or more embodiments of the edge protector 100 assembled in a first configuration with two-sides 102a,102b to protect, or extend protection of, a side portion of the product. FIGS. 2A and 2B are perspective views of one or more embodiments of the edge protector 100 assembled in a second configuration with three-sides 102a, 102b, 102c to protect a corner of the product (not shown).

Referring to FIG. 1A, the edge protector 100 is assembled showing one or more embodiments having two sides 102a, 102b. Each side 102a, 102b has a distal opening 104 defined by a first wall 103 and a second wall 105 (not visible in FIG. 1A). A divider portion 106 has a proximal opening 108. The edge protector 100 has a first bottom flap 110 and a second bottom flap 112 that extend perpendicular to the sides 102a and 102b, respectively. In one or more embodiments, an edge flap 122 (not visible in FIG. 1A) on the first wall 103 attaches, such as by gluing, when it is folded onto an inner surface of the first bottom flap 110 and the second bottom flap 112, thereby defining the distal openings 104. The distal openings 104 and the proximal opening 108 are configured to receive optional connecting pieces 114 that provide support and further protection for edges of the product being shipped. The connecting pieces 114 are optional and will be described later herein.

Referring to FIG. 1B, the divider portion 106 of the edge protector is shown in more detail. The divider portion 106 has fold lines 107a, 107b, and 107c spaced apart and weakened, as by scoring or creasing, such that the edge protector 100 may be folded from the first configuration into the second configuration at the divider portion. A center fold line 107b, a first side fold line 107a spaced apart from the center fold line 107b, and a second side fold line 107c spaced apart from the center fold line 107b on the opposite side of the first side fold line 107a enable the divider portion to crease when folded so that it is pivotable at the first side fold line 107a or the second side fold line 107c between first and second positions in the proximal opening 108. This will be described in more detail later herein. Retaining flap 116 may be folded into the proximal opening 108. The retaining flaps 116, when folded into the proximal opening 108, push against first and second walls 103, 105 providing support and preventing the first and second walls 103, 105 of the edge protector 100 from folding flat, which would collapse the distal and proximal openings 104, 108.

Referring to FIG. 2A, a perspective view of the edge protector 100 assembled into one or more embodiments of a second configuration having three sides, 102a, 102b, 102c to protect a corner of the product (not shown). The first and second bottom flaps 110, 112 of the edge protector 100 are designed to interact with each other, when folded towards each other, to form the third side 102c. The connecting pieces 114 are not shown in FIG. 2A so that the distal opening 104 that is defined by the first wall 103 and the second wall 105 (shown in FIG. 2B) is visible.

When the first and second bottom flaps 110, 112 are folded over each other, the divider portion 106 divides the proximal opening (108 in FIG. 1A and FIG. 1B) into two proximal openings 108a and 108b. The first and second bottom flaps 110, 112 may be self-locking by way of a tongue 118 on the first bottom flap 110 and a slot opening 120 on the second bottom flap 110. The tongue 118 inserts into the slot opening 120 thereby interlocking to define the side 102c.

FIG. 2B is a bottom perspective view of the edge protector 100 assembled into three-sides 102a, 102b, 102c. The first and second bottom flaps 110, 112 each have a retaining tab 128 that is folded to interact with the connecting piece (not shown) when the connecting piece is inserted into the distal opening 104. When the tab 128 is folded towards the connecting piece it connects with a cellular feature (to be described in detail later herein) of the connecting pieces thereby retaining the connecting pieces (as shown in FIGS. 3A and 3B). A catch notch 130 is incorporated into a backside of the corner divider. The catch notch 130 is designed to catch wrapping material (not shown) that is used during packaging assembly.

The divider portion 106 pivots to accommodate two connecting pieces in the first and second proximal openings 108a, 108b (shown in FIG. 3A). Retaining flaps 116 are configured to retain the connecting pieces 114 (not shown) at the corner of the three-sided edge protector 100. In the example configuration shown in FIG. 2A, retaining flap 116, on a side 102a of the edge protector 100 with the first bottom flap 110, is shown folded into the first proximal opening 108a to create friction when the connecting piece 114 is inserted into the first proximal opening 108a. The other retaining flap 116, on a side 102b of the edge protector, stays in place (parallel to the side 102c) and ratchets to the connecting piece 114 when the connecting piece is inserted into the second proximal opening 108b. It should be noted that the configuration shown in FIG. 2A is for example purposes only and it is understood that the divider portion 106 may be positioned in an alternative manner. In such a configuration, the retaining flaps 116 would be adjusted accordingly to accommodate the connecting pieces 114.

FIG. 3A is a perspective view of a partial packaging assembly 300 of the edge protector 100 assembled into one or more embodiments with three sides (as shown in FIG. 2A) having connecting pieces 114 inserted into one of the distal openings 104 and the proximal openings 108a, 108b. FIG. 3B is a perspective view of a partial packaging assembly 300 showing four edge protectors 100a, 100b, 100c, 100d interconnected using connecting pieces 114 for the purpose of packaging a product to protect multiple corners of the product (not shown). In FIG. 3B, the retaining flap 116 is visible. The retaining flap 116 folds into the distal opening such that when the connecting piece 114 is inserted into the distal opening 104, the connecting piece is frictionally retained by the retaining flap 116.

In FIGS. 3A and 3B the divider portion 106 defines proximal openings 108a, 108b that each receive a first end of the connecting piece 114. The connecting pieces 114 are at right angles to each other and a distal opening 104 of each of the edge protectors 100a receives an end of the connecting piece 114. Referring now to FIG. 3B, multiple edge protectors 100a, 100b, 100c, 100d are interconnected with multiple connecting pieces 114. Opposite ends of the connecting piece 114 are each inserted into a distal opening 104 or a proximal opening 108a, 108b of the edge protectors 100a, 100b, 100c 100d. The number of edge protectors 100 (with or without connecting pieces 114) used in a complete packaging assembly 300 will be determined by size and shape of the product being shipped. However, the edge protectors themselves have a fixed pattern that, when assembled, may be configurable as either a two-sided or a three-sided option.

FIG. 4A and FIG. 4B show perspective views of four edge protectors 100a-100d having connecting pieces 114. Each connecting piece 114 has liner board sides running parallel to each other that are connected by a honeycomb structure having a predetermined thickness. The connecting piece 114 is rigid and have a fixed, or predetermined, length. FIG. 4A shows a first configuration in which the connecting pieces 114 that are shown horizontally have a predetermined length and are positioned in the edge protectors 100a and 100b in such a manner that an end of the connecting piece 114 is inserted into the distal openings 104 to the point that it abuts the divider portion 106 and/or an inner corner edge of the edge protector 100. The horizontal dimension may be modified by sliding the connecting piece within the distal opening 104 to extend the distance between the edge protectors 100a and 100b and locking the connecting piece 114 in place by pushing the tab 128 into the honeycomb structure so that the connecting piece cannot slide horizontally anymore. For example, FIG. 4A shows a first configuration in which the connecting pieces 114 are fully inserted into the distal opening 104. It should be noted that the dimensions depicted in FIGS. 4A and 4B are for example purposes only. The example dimension shown in FIG. 4A is 189/16 inches. FIG. 4B shows a second configuration in which the connecting pieces 114 are moved a predetermined distance away from the corner end of the distal opening 104 and held in place by the tab 128 interlocking with the corrugation of the connecting piece 114 thereby expanding the horizontal dimension between edge protectors to length to 231/16”.

FIG. 5 is a perspective view of an example product 500 wherein a packaging assembly is partially implemented for protecting the product 500 during shipping. FIG. 5 shows six three-sided edge protectors 100. The edge protectors 100 have the connecting pieces 114 at proximal openings 108a, 108b. And one of the edge protectors 100 is shown with the connecting piece at the distal opening 104. The bottom flap 110 of the side 102c of the edge protector 100 is visible showing the self-locking feature wherein tongue 118 on the first bottom flap 110 and the opening 120 on the second bottom flap interact with each other when the bottom flaps 110, 112 are folded onto each other. The tab 128 is folded inward to engage the honeycomb structure of the connecting piece 114. By engaging the cellular feature of the connecting piece 114, the tab 128 retains the connecting piece 114 inside the opening 108a, 108b of the edge protector 100. The catch notch 130 is also visible in FIG. 5.

FIG. 6 is a pattern 600, formed from a blank, consisting of, for example, corrugated fiberboard or paperboard. The pattern 600 accommodates two edge protectors 100 from a single blank. The pattern has first and second walls 103, 105 and edge flaps 122 that, when folded, define the distal openings 104. The divider portion 106 is scored to create fold lines 107a, 107b, 107c so that the divider portion may be folded and pivoted between first and second positions to configure the proximal opening 108 as needed . The proximal opening 108 may be divided into openings 108a, 108b when the edge protector is assembled in the three-sided configuration. The pattern 600 has the first bottom flap 110, the second bottom flap 112, and the retaining flap 116 that may be folded into the distal opening 104 when the connecting piece (not shown) is inserted into the distal opening 104.

The edge flaps 122 may be glued to the first and second bottom flaps when the first and second side walls are folded to define the distal openings 104. The pattern 600 has tongue 118 and opening 120 for interlocking the first and second bottom flaps 110, 112 in the three-sided configuration. The tabs 128 for both edge protectors on the single blank. The catch notch 130 is cut into (or punched from) the second side wall 105. The catch notch 130 will “catch” packing material, such as plastic wrap, to further secure the completed packaging assembly around the product to be shipped.

Having described the inventive subject matter with reference to exemplary embodiments, it should be apparent to those of ordinary skill in the art that the embodiments may be modified in arrangement and detail with departing from the scope of the inventive subject. Modifications are embodied in this disclosure. We claim: