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ARTICLE PROTECTOR AND METHOI) OF USE AND MANUFACTURE
FIELD OF THE INVENTION
This invention relates to a article protector and method of
use and manufacture, and in particular to a foldable multi
layer shock-absorbing protector for a fragile and breakable
article such as a glass mirror or the like, and to a method
of use and to a method of manufacture of the article
protector.
The invention has particular utility for flat articles or
for articles with parallel face:a joined by an edge to form
a flat outer periphery.
BACKGROUND OF THE INVENTION
Many articles, such as those purchased from a catalogue,
are now despatched by mail or by an independent parcel
deliverer to the customer.
Such "catalogue shopping" has proved attractive for
purchasers living in remote locations, for purchasers
desiring a wider choice than is. available locally to them
and for purchasers with limited access to personal
transport, and there has thus in recent years been a
substantial growth in the numbers of articles despatched to
the home i.e. rather than bEsing carried home by the
purchaser.
This "home-despatch" trend has however caused problems to
the article manufacturers and sE~llers in that the articles
usually have to be individually packaged, and in a manner
providing "shock-absorbtion" whereby to protect the
articles against rough handling and consequent damage in
transit, and this can be times consuming and expensive;
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often the protective (shock-absorbing) article packaging is
within an outer "container" such as a box or a plastic
shrink-wrapping which can carry the purchaser's address.
The storage of the packaging by the article manufacturer,
or perhaps by the article seller, in readiness for its
eventual use is expensive and wasteful of space if, as is
usual, the packaging has been pre-formed to the required
shape by the packaging manufacturer.
Pre-formed packaging may necessitate additional vehicle
trips by the packaging manufacturer for delivery of the
required number of packaging pieces, since the transporting
of preformed packaging is often inefficient in utilising
the space inside the transporting vehicle.
The packaging is itself seldom re-used, but according to
the invention preferably is made of a semi-rigid re-usable
material such as single-faced corrugated cardboard sheet
i.e. with a corrugated layer adhered by the corrugation
tips to one piece of substantially planar paper, though in
an alternative arrangement there can be two planar paper
pieces sandwiching the corrugated sheet therebetween. Such
corrugated paper may be made from recycled paper, and is
itself recyclable, so that such packaging material is
attractive to those wishing to preserve global resources.
DISCLOSURE OF THE PRIOR ART
A pre-formed corner protector is disclosed in Sherman USA
Patent 2,068,771, made by dividing a formed edge protector
into two identical pieces. Longitudinal base boards are
adhered to a creased inner corrugated sheet, and
intermediate sidewall layers are then applied, followed by
the creased outer sheet. Thus a number of manufacturing
steps are needed, and a significant manufacturer's
component inventory.
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A pre-formed corner protector is also disclosed in Markham
USA Patent 2,896,833 which can be formed with legs at
right-angles. Each leg is of two-layer corrugated
paperboard manufactured as side panels separated by fold
lines or cuts; there is no teaching of a means to achieve
an odd number of layers, or of other than two layers. The
blank from which the protector is made is wasteful of
material, and complicated to work.
An edge protector which can be delivered flat and erected
by the user is disclosed in Knowles USA Patent 5,040,684.
However that edge protector requires a plurality of sheets
(of fiber board) to be laminated together, and then scored
and cut so as to be foldable, with a single continuous
laminate between a plurality of article-contacting members.
An outer layer has portions each intended to act as a leaf
spring to hold the leg portions i.n their erected condition.
Thus for this arrangement also a number of manufacturing
steps are needed, and a significant manufacturer's
component inventory. The utility of the arrangement
depends on the leaf spring acti~~n being operative. When
erected, there are protector "spaces" with reduced article
protection.
DISCLOSURE OF THE INVENTION
We now propose a multi-layer shock-absorbing protector for
a fragile article such as a glass mirror and the like, each
layer having a first panel foldable relative to a second
panel about a hinge or fold lime separating the panels,
wherein one of the f first and second panels of one layer is
connected to a corresponding one. of the first and second
panels of the second layer and wherein the other of the
first and second panels of the first layer is not connected
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to the other of the first and second panels of the second
layer (i.e. it is not directly connected thereto).
The protector may have three layers, with the first panels
of the first and second layers being interconnected and the
first panels of the second and third layers being
interconnected. In a less preferred embodiment the first
panels of the first and second layers are interconnected
and the second panels of the second and third layers are
interconnected.
The above arrangements can be used as angles (each layer
having two panels, usually at right-angles), or as channels
(each layer having three panels).
Thus the protector may have three panels, with the first
panel of the second (intermediate) layer being connected to
the corresponding first panel of the adjacent first and
third layers, with the remaining panels being unconnected
to panels of another layer. Such protector can have each
"free" second panel hingable relative to its respective
first panel, and each "free" third panel hingable relative
to the respective second panel so as to form a channel-
shaped protector.
Preferably the layers are of single-faced corrugated paper,
with the corrugations folded inwardly e.g. of the channel,
and thus with the substantially planar paper facing
outwardly towards the "container" e.g. the envelope, box or
shrink wrap.
We also propose a method of making an adjustable multi-
layer shock absorbing protector which includes selecting
two sheets of shock-absorbing material, forming a fold line
in each sheet, overlying the sheets so that the fold lines
are parallel but offset, and securing the sheets together
to one side only of the fold line whereby upon hinging the
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sheets about the respective fold lines there is relative
movement between the sheets at the other side of the fold
line, said relative movement being perpendicular to the
fold lines.
We further propose a method of use of a multi-layer shock
absorbing protector internally of an article container
having a throat defined by two inner surfaces of the
container, each layer having 'two parallel fold lines
defining first, second and third panels, the layers being
interconnected by their respective first panels but not by
the second or third panels, which includes the steps of
positioning the second panel over the throat, positioning
the article into alignment with the second panel and
feeding the article into contact with the second panel
whereby to press the second panel into the throat and with
the first and third panels sliding into contact with the
said inner surfaces.
We also propose an alternative method of use of a multi-
Iayer shock absorbing protector internally of an article
container having a throat defined by two inner surfaces of
the container, each layer having two parallel. fold lines
defining first, second and third panels, the layers being
interconnected by their respective first panels but not by
the second or third panels, which includes the steps of
engaging a second panel with a.n edge of the article,
bending the first and third panels around the said edge
causing relative movement of the second and third panels of
the layers, and feeding the article and fitted protector
into the throat with the first and third panels sliding
relative to the said inner surfaces.
The inner surfaces hold the panels in the position shown in
Fig.3.
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Preferably each layer is of single-faced corrugated paper,
with each layer folded so that the corrugations are
inwardly facing, towards the article.
Usefully whilst being so fed into the container side faces
of the article are supported by respective second and third
independent protectors, which are held against the side
faces and which are received within the container as the
article is fed thereinto. Preferably the article is
rectangular with the fourth (trailing) edge covered by an
independent protector before the article is fully received
within the container.
Because the layers are formed into a channel section at the
time of use, they seek to return to the flat condition and
so engage firmly but slidingly with the inner container
walls. Specifically the first protector to enter the
container is prevented by the resulting frictional grip
with the container inner walls from separating from the
article, and perhaps dropping into the container, and so
moves further into the container only when forced to do so
by continued insertion movement of the article.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described by way of example
with reference to the accompanying drawings, in which:-
Fig.l is a side view of one embodiment of the
invention, shortly after sheet hinging or folding
has begun;
Fig.2 is a perspective view of the embodiment of Fig. l,
when made of single-faced corrugated paper;
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Fig.3 is a side view of the embodiment of Fig.l in the
fully-hinged or assembled condition, shown
w upright;
Fig.4 is a perspective view of the embodiment of Fig.2,
immediately prior to use with a small depth
container;
Fig.5 is an end view of a protected article, inside the
small depth container of Fig.4, the end wall of
the container having been removed;
Fig.6 is a perspective view of the embodiment of Fig.2,
immediately prior to use with a large depth
container; and
Fig.7 is a side view of a protected article inside the
large depth container of Fig.6, the side wall of
the container having besan removed.
DESCRIPTION OF THE EXEMPLARY EMBOIIIMENTS
The invention will be described in relation to a three-
panel arrangement suitable for forming a channel section,
though it will be understood that a two panel arrangement
suitable for forming an angle section could also be
provided, as could more than three panel arrangements
suitable for protecting articles with complex edge
profiles.
The protector 1 is of three layer:, being formed from three
separate sheets 10,20,30 of single faced corrugated paper.
In this embodiment sheet 10 is slightly wider (left to
right as viewed in Fig.l) than sheet 20, and sheet 20 is
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slightly wider than sheet 30, so that in the fully-folded
condition of Fig.3 the sheets terminate at a common height.
In an alternative embodiment the sheets are of the same
width. If, for example, the sheets are of single-faced
corrugated paper as shown in Fig.2, and in which a
corrugated piece of paper 11 is adhered at its apices to a
single substantially planar piece of paper 12, the three
sheets of the protector may have been cut from the same
corrugated paper roll.
Sheet 10 has two score lines 13,14, which may be
depressions or may be cuts in the corrugated piece of paper
11. Sheet 20 also has two score lines 23,24, as has sheet
30 with score lines 33,34. These score lines extend into
the paper as viewed in Fig.l, and are parallel. As seen in
Fig.l, the score lines provide hinges, and divide the
sheets into separate but interconnected longitudinal panels
i.e. for sheet 10 into panels 15,16,17, for sheet 20 into
panels 25,26,27 and for sheet 30 into panels 35,36,37, in
each case such that panel 16,26,36 can be hinged relative
to respective panel 15,25,35 and so that panel 17,27,37 can
be hinged relative to respective panel 16,26,36.
With the respective left hand edges 18,28,38 aligned, score
line 23 is offset further from longitudinal edge 28 than is
score line 33 from edge 38, by the thickness "w" of the
sheet 10,20,30; whilst score line 13 is offset by a further
sheet thickness "w" from edge 18. The score line 24 is
offset by two times distance "w" from edge 28 as compared
to score line 34, whilst score line 14 is offset by four
times distance "w" from edge 18 as compared to score line
34. Thus the sheets can be folded into the formed
condition of Fig.3.
In a preferred embodiment score Lines 33,34 are spaced by
3mm, so that the protector can be fitted around the edge of
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a correspondingly thin article; in other embodiments the
spacing is greater, determined in accordance with the
dimensions of the edge of the article which is to be
protected.
In an alternative embodiment the protector has two layers;
in further alternative embodiments the protector has
between four and ten layers, depending upon the degree of
protection and shock absorbtion required.
In one method of manufacture, one: or more lines of adhesive
is/are applied, parallel to the score lines, to tips of the
corrugations upstanding from panel 15, and with edge 28
overlying edge 18 panel 25 is secured thereto by way of the
substantially planar piece of paper 12 comprising a part of
panel 25. One or more lines of adhesive is/are then
applied, again parallel to the score lines, to corrugations
upstanding from panel 25, and the substantially planar
piece of paper of sheet 30 is secured thereto (panel 35).
In an alternative method of manufacture the lines} of
adhesive is (are) applied to 'tips of the corrugations
panels 15,25, and then these panels are jointly pressed
together to be adhesively interconnected.
In further alternative embodiments the lines) of adhesive
is (are) applied to the plain paper under surfaces; to only
some of the corrugation tips; and as area "spots" rather
than as one or more lines. In less preferred embodiments,
the panels 15,25,35 are secured together either by adhesive
tape, by "sack stitching", by one or more staples, or by
any other suitable method.
It will be understood that as the: second panels are hinged
relative to the first panel, and the third panels are
hinged relative to the second panel, the second panels move
relative to each other, and the 1_hird panels move relative
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to each other until in the formed condition of the
protector as shown in Fig.3 the respective score lines and
the free ends of the sheets 10,20,30 are in alignment.
In one method of use, as seen in Fig.4 the assembled
protector (generally as seen in Fig.2) is positioned with
panel 16 over the open throat 40 of a container 41. The
article 42, in this embodiment a flat panel (e. g. a mirror)
of rectangular outline and of a height slightly less than
the height h of container 41 is fed downwardly until it
contacts the panel 36, with further downward article
movement drawing panels 15,25,35 and 17,27,37 into the
container 41, into the form shown in Fig.3. The panels
15,25,35 and 17,27,37 provide three layer protection to
each side face of the panel 42, and are selected so that in
the assembed protector condition their height is equal to
or slightly less than the height h of the container 41.
Fig.5 is an end view of the panel 42 protected by single
protector 1 inside container 41, the end wall of the
container having been removed. It will be understood that
the container 41 acts to hold the protector 1 in the
assembled condition, i.e. in the form shown, the container
in this embodiment being a box but in other embodiments
being of plastics shrink wrap, or one or more external
bands. This arrangement is suitable for articles requiring
little or no edge protection, or in which only the lower
edge (as drawn) requires edge protection, e.g. articles
with metal edges or the like. In an alternative embodiment
in which the upper edge also requires edge protection, a
length of protector according to the invention can be
fitted over the top of the article prior to the container
being closed.
In another method of use, as seen in Fig.6, the assembled
protector 1 (again generally in the lay-flat condition as
seen in Fig.2) is positioned over the throat 50 of a deep
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container 51. In this embodinnent the protector 1 when
pushed into the container by article insertion has a height
which is only a minor proportion of the height H of the
container. Thus as seen in Fig.7 there is a second
protector 2 and a third protector 3 by means of which the
article is held during insertion and which protect the left
and right hand edges of the article respectively; also in
this embodiment a fourth prote<aor 4 is applied to the
upper edge of the article innmediately prior to full
insertion of the article into container 51.
In alternative embodiments the container is at a different
angle e.g. horizontal, during article insertion, and in
such cases the directional terms (such as "height", "upper"
etc.) referred to above will be correspondingly altered.
In other embodiments the panels 15,25,35 can be
interconnected by the user of th.e protector i.e. prior to
inserting the article in the container, so that the sheets
10,20,30 are provided to the user separately.
If the user of the protector prefers a pre-formed protector
or wishes to avoid the facility for relative sliding and
thus self adjustment during article insertion of panels
16,26,36 and 17,27,37, the panels 17,27,37 (as well as
panels 15,25,35) can initially be interconnected in the
formed condition of Fig.3, as by .adhesive (liquid or tape),
stitching, or by stapling, so as to inhibit or prevent
relative movement of the panels, and thus overcome the
tendency of the sheets 10,20,30 to assume a substantially
flat condition. Thus, the protector 1 can be formed by the
user to its condition of Fig~.3, awaiting its later
application to an article.
As shown in Fig.7, the protectors 1 and 4 are of a greater
length (i.e. parallel to their score lines) than the
protectors 2 and 3, so that the protectors 1,2,3,4 together
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provide total edge protection for the square article 52.
Also, the protectors 1,2,3,4 do not totally cover the side
faces 53 of the panel (only one of which faces is seen).
In another embodiment, the protectors 2 and 3 can be
extended, i.e. their respective panels 15,25,35 and
17,27,37 can be elongated so that they cover the faces 53,
in which case the fitted edge protectors give total shock-
absorbing protection to the panel 52.
In the assembled condition, as seen in Fig.3, the
corrugations of the respective sheets 10,20,30 are parallel
and are a11 perpendicular to the hinge lines. For panels
15,25,35 and 17,27,37 the corrugations run vertically as
viewed, whilst those for panels 16,26,36 run from left to
right as viewed - giving strong columnar strength in these
respective directions, and shock absorbing strength against
impacts perpendicular thereto. The size and disposition of
the protectors 1,2,3,4 of Fig.7 may be varied according to
the stresses anticipated i.e. to which the respective
protectors may be subjected.
Whilst we prefer our protector to be of a readily
recyclable material such as corrugated paper, we do not
discount the use of less- or non-recyclable materials such
as a crushable or corrugated plastics material or the like,
where such material is desired by a particular user.
In an alternative method of manufacture, two protectors
could be manufactured side by side. For the manufacture of
two three-layer protectors for example, three sheets (of
equal or non-equal width) corrugated paper could be adhered
together to either side of their centre-lines, the sheets
subsequently being cut along the centre-lines (the cut
centre-lines corresponding to the edges 18,28,38 of the
protector of Fig.l. The sheets could be cut in this way
either before or after formation of the score lines.
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We also foresee a use of our edge protector to protect and
separate more than one article. For example, a three-layer
protector may be used to protect. a window frame and its
associated but separate pane or panes of glass, with the
' 5 frame being supported in the main channel of a three panel
protector, and the panels) of glass being supported between
the layers, i.e. the window frame could be protected as is
the article 42 of Fig. S, with a pane of glass being
protected between the third panels 27 and 37, and another
pane of glass (if required) being protected between the
third panels 17 and 27. In such an embodiment, it will be
understood that in the formed condition of the protector
not a11 of the third panels lie against each other, so that
the formed protector provides more than one channel. It
will be understood that some of the score lines of such a
protector would be formed at greater spacings than
previously indicated, to provide the required gap between
adjacent third panels.
It is also foreseen that a given protector might be desired
to be used with articles of different thicknesses, so that
a number of score lines could be provided on each sheet or
layer, with the user utilising they particular ,et of score
lines which are adapted to the article being protec'ced.
