Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CORNER BOARDS, CONTAINER ASSEMBLIES INCLUDING THE SAME, AND
METHODS OF MAKING AND USING THE SAME
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of corner
boards and
methods of making and using the same. More specifically, embodiments of the
present
invention pertain to a corner board with a slit and/or a notch near an end,
and methods of
manufacturing and using such corner boards.
DISCUSSION OF THE BACKGROUND
[0003] Containers are used for holding and/or storing materials. Multiple
containers
can be stacked together as a single unit for various reasons, such as storage,
transportation, or
other operations involving multiple containers. For instance, multiple
containers may be
placed onto a pallet, for storage in a warehouse and/or loading onto a trailer
for transportation
(e.g., from a distribution warehouse to a store). When moving a pallet of
containers by
forklift, the forklift operator may inadvertently strike the edge of the
pallet into a wall,
shelving bracket, vehicle or even other container(s). Unexpected movement
during
transportation of the containers can also cause stacks to become unstable or
fall, or otherwise
become damaged. As a result, the manipulation of such containers or container
stacks may
result in damage to the exterior of the container(s) and/or the contents
therein.
[0004] Corner boards may be placed on corners of container stacks to hold
the stacks
in place and/or mitigate damage to the containers. Conventionally, corner
boards are
attached to the exterior edges of the container stacks using staples or tape.
However, this
method for attaching corner boards is relatively time-consuming and requires
additional
materials to be used with the corner boards. Further, this method of attaching
corner boards
may create safety risks; for example, a person could become injured from the
staple(s) that
may protrude from the corner board when removing the stapled corner board(s)
from the
group of containers, or be cut when cutting the tape with a knife or box
cutter. These
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methods for affixing corner boards may also damage the container(s) and/or
their contents.
For example, the staple used to attach the corner board may pierce the
contents within the
underlying container, or the tape may tear the exterior surface of the
container, which
frequently has a protective, moisture resistant or finished/decorative outer
surface. Therefore,
it is desirable to provide a corner board in which the corner board is easily
placed on a
container stack without the need to use additional means to affix the corner
board to the
container(s).
[0005] This
"Discussion of the Background" section is provided for background
information only. The statements in this "Discussion of the Background" are
not an
admission that the subject matter disclosed in this "Discussion of the
Background" section
constitutes prior art to the present disclosure, and no part of this
"Discussion of the
Background" section may be used as an admission that any part of this
application, including
this "Discussion of the Background" section, constitutes prior art to the
present disclosure.
SUMMARY OF THE INVENTION
[0006]
Embodiments of the present invention relate to a corner board that
advantageously holds container stacks in place, eliminates and/or minimizes
damage to the
containers, and reduces or minimizes expenses due to damaged containers and/or
container
contents. In addition, the present corner board eliminates the need for costly
corner board
attachment materials and the risks associated with such attachment materials.
[0007] One
aspect of the present invention relates to a corner board, comprising first
and second sides, each including a board material; a bend between the first
and second sides,
joining first and second sides together; and a slit near or adjacent to a
first end of the corner
board, the slit completely crossing the bend and partially crossing the first
and second sides.
In various embodiments of the present invention, the corner board has a notch
comprising a
portion of the corner board between the slit and the first end of the corner
board, the notch
forming an opening along the slit and/or between the slit and the first end of
the corner board.
The notch (e.g., the portion of the corner board between the slit and the
first end of the corner
board) extends inward from the bend of the corner board.
[0008] Another
aspect of the present invention relates to a method of manufacturing a
corner board that includes bending a board stock to form first and second
sides of the corner
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board, the first and second sides having an angle therebetween; cutting the
board stock into
fixed lengths, the bent and cut board stock forming the corner board; and
forming a slit near a
first end of the corner board. Further embodiments of the method include
forming a notch at
the first end of the corner board by pushing the portion of the bent board
stock between the
slit and the first end of the corner board inward from the angle, thereby
forming an opening
between the slit and the first end of the corner board.
[0009] A
further aspect(s) of the present invention relates to an apparatus for forming
a slit corner board that simultaneously cuts the board stock and forms the
slit. In various
embodiments of the apparatus, an attachment is configured to form the notch
simultaneously
with or immediately after cutting the board stock and/or forming the slit. An
additional
aspect of the present invention relates to a method of securing a plurality of
stacked
containers using the present corner board.
[0010] These
and other advantages of the present invention will become readily
apparent from the detailed description of various embodiments below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. lA
is a perspective view of an exemplary corner board according to one
embodiment of the present invention.
[0012] FIG. 1B
is a perspective view of an exemplary corner board according to
another embodiment of the present invention.
[0013] FIG. 2
is an end view of the corner board according to the embodiment of
FIG. 1.
[0014] FIG. 3
is a side view of an exemplary "pre-notched" corner board according to
another embodiment of the present invention.
[0015] FIG. 4
is a perspective view of an exemplary corner board on a container
stack.
[0016] FIGS. 5A-
5C are structural diagrams of an exemplary apparatus and/or
exemplary parts of an apparatus for manufacturing the corner board of FIG. 3,
in accordance
with the present invention.
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[0017] FIG. SD is a
structural diagram of an exemplary apparatus or apparatus part
for manufacturing the corner board of FIG. 1, in accordance with the present
invention.
[0018] FIG. 6 is a
flow chart of an exemplary method of manufacturing the corner
board of FIG. 1, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0019] Reference
will now be made in detail to various embodiments of the
invention, examples of which are illustrated in the accompanying drawing(s).
In order to
achieve the objectives, technical solutions and advantages of the present
invention more
clearly, further details of the invention are described below with regard to
the Figure(s).
While the invention will be described in conjunction with the following
embodiments, it will
be understood that the descriptions are not intended to limit the invention to
these
embodiments. On the contrary, the invention is intended to cover alternatives,
modifications
and equivalents that may be included within the scope of the
invention as defined
by the appended claims. Furthermore, in the following detailed description,
numerous
specific details are set forth in order to provide a thorough understanding of
the present
invention. However, it will be readily apparent to one skilled in the art that
the present
invention may be practiced without these specific details. In other instances,
well-known
methods, procedures, components, and attachment equipment have not been
described in
detail so as not to unnecessarily obscure aspects of the present invention.
The embodiments
described here are only used to explain, rather than limit, the invention.
[0020] In the
context of this application, and for the sake of convenience and
simplicity, the terms corner board, cornerboard, edge board, edgeboard, angle
board, and
angleboard may be used interchangeably herein, and use of one such term
generally includes
the others, unless indicated otherwise from the context of its use herein.
[0021] Thus,
technical aspects of embodiments of the present invention will be more
fully and clearly described in conjunction with the drawings in the following
embodiments.
It will be understood that the descriptions are not intended to limit the
invention to these
embodiments. Based on the described embodiments of the present invention,
other
embodiments can be obtained and/or derived by one skilled in the art without
creative
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contribution or effort, and are considered within the scope of legal
protection given to the
present invention.
[0022]
Furthermore, all characteristics, measures or processes disclosed in this
document, except characteristics and/or processes that are mutually exclusive,
can be
combined in any manner and in any combination possible, either with each other
or with
structures in the prior art. Any characteristic disclosed in the present
specification, claims,
Abstract and Figures can be replaced by other equivalent characteristics or
characteristics
with similar objectives, purposes and/or functions, unless specified
otherwise. Each
characteristic is generally only an embodiment of the invention disclosed
herein.
[0023]
Embodiments of the present invention can advantageously provide a corner
board that may be rested or placed along a vertical edge of a container or
stack of containers,
without the need for additional material or steps (e.g., staples or tape) for
affixing the corner
board to the container or stack. These and other advantages of the present
invention will
become readily apparent from the detailed description below.
Exemplary Corner Board(s)
[0024] FIG. lA
illustrates an exemplary corner board 100 according to the present
invention. In a first aspect of the present invention, the corner board 100
(which may also be
known as a v-board, edge board, edge protector, corner post, ag board,
protecting or
protectant edge, angle board or other similar term) may comprise a stiff,
angled piece of
material. A portion of the corner board may have a slit (e.g., a cutout) 110
and a notch 120 at
or near one end of the corner board 100. In various embodiments of the present
invention,
the slit 110 is located near or adjacent to one end of the board 100, and the
notch 120 is
between the slit 110 and end of the corner board. The notch 120 generally
extends inward
from the point of origin of the angle a, as shown in FIG. 2.
[0025]
Referring back to FIG. 1A, the corner board 100 may be formed from any
material, such as paper, cardboard, pressboard, plastic, or any laminate or
other combination
thereof that has or can have a predetermined minimum stiffness. However,
laminated paper,
plastic or a combination thereof (such as commingled plastic) having a
predetermined
minimum stiffness is generally preferred. The listed materials comprise broad
categories.
For instance, "cardboard" may comprise any board material comprising paper
and/or fiber,
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such as pressed and/or corrugated cardboard, fiberboard, paperboard, boxboard
and/or
containerboard. The corner board 100 may further comprise an overwrap (e.g.,
paper) and/or
a laminate of cardboard and another material (such as plastic). In further
embodiments, the
overwrap may comprise either a full overwrap or a partial overwrap (e.g., with
edges of the
corner board being exposed). In some embodiments, the laminate may comprise
one or more
layers of paper and/or cardboard and one or more sheets or layers of plastic
and/or wax.
[0026] In the
embodiment of FIG. 1A, the corner board 100 comprises a plurality of
sides. Generally, the corner board 100 has two sides 101, 102. Each side 101,
102 of the
corner board 100 is generally rectangular. However, in other embodiments, the
sides of the
corner board can be square, triangular, trapezoidal, or any other suitable
shape.
[0027] The
corner board 100 can have any thickness suitable for protecting the edge
of a container and/or group (e.g., stack) of containers. In some embodiments,
the thickness of
the corner board 100 may be the same thickness as the material used to create
the corner
board 100. In one embodiment, the corner board 100 may have a thickness of
about 0.16 in.
(0.4 cm). In other embodiments, the thickness can be in the range of 0.08 in.
(0.2 cm) to 0.50
in. (1.3 cm), and can include a thickness of about 0.12 in. (0.3 cm), 0.2 in.
(0.5 cm) or 0.25 in.
(0.6 cm). Alternatively, the corner board 100 can have an inner thickness T2
less than an
outer thickness T1 (see, e.g., U.S. Pat. No. 5,813,537, which discloses a so-
called "apex"
board), or alternatively, greater than the outer thickness T1, as shown in
FIG. 1B. For
example, T2 may be in the range of 0.12 in. to 0.50 in. (e.g., about 0.16
in.), and T1 may be in
the range of 0.08 in. to 0.375 in. (e.g., about 0.12 in.), or vice versa.
[0028]
Referring back to FIG. 1A, a length Li of the sides 101, 102 of the corner
board 100 may be any length suitable for protecting the edge of a container
and/or group of
containers. In preferred embodiments, the length Li of the sides 101, 102 of
the corner board
100 is about 24 in. (60 cm) to about 90 in. (230 cm). However, it should be
readily
understood that the length Li of the sides 101, 102 of the corner board 100
can be any value
in the range, or more or less than such a range. In general, the thicker the
corner board 100,
the greater the length Li. For example, when the corner board 100 has a length
of about 24
in. (60 cm) to 36 in. (90 cm), the thickness may be from about 0.12 in. (0.3
cm) to about 0.2
in. (0.5 cm). When the corner board 100 has a length of about 36 in. (90 cm)
to 48 in. (120
cm), the thickness may be from about 0.16 in. (0.4 cm) to about 0.25 in.
(0.625 cm).
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Furthermore, when the corner board 100 has a length of about 48 in. (120 cm)
to 72 in. (180
cm), the thickness may be from about 0.25 in. (0.625 cm) to about 0.5 in (1.25
cm).
[0029]
Referring to FIG. 2, a width W1 of the sides 101, 102 of the corner board 200
may be any width suitable for protecting the edge of a container and/or group
of containers,
and facilitating support for a stack of containers. In preferred embodiments,
the width W1 of
each side 101, 102 of the corner board 100 is about 1 in. (2.5 cm) to about 4
in. (10 cm).
However, it should be readily understood that the width W1 of the sides 101,
102 of the
corner board 100 can be any value in the range, or more or less than such a
range.
[0030] The slit
110 as shown on the corner board 100 in FIG. lA may be located at
any suitable and/or a predetermined distance from the end (e.g., a first end)
of the corner
board 100, while still allowing the corner board 100 to rest on the container
(as subsequently
shown in FIG. 4). Also, the longer the corner board 100, the greater the
distance of the slit
110 from the end of the corner board 100. Similarly, the thicker the corner
board, the greater
the distance of the slit 110 from the end of the corner board 100. For
example, when the
corner board 100 has a length of about 24 in. (60 cm) to 48 in. (120 cm), the
distance may be
from about 0.12 in. (0.3 cm) to about 0.375 in. (0.95 cm). When the corner
board 100 has a
length of about 48 in. (120 cm) to 60 in. (150 cm), the distance may be from
about 0.375 in.
(0.95 cm) to about 0.5 in (1.25 cm).
[0031] The
notch 120 may comprise the material and/or a portion of the corner board
100 between the slit 110 and the end of the comer board 100. As shown in FIG.
2, the notch
120 may have an angle opposite to the angle a of the corner board 100.
Generally, the notch
extends inward from the bend, the bend has an angle a of less than 180 , and
the notch has an
angle of less than 180 facing the angle a of the bend of the corner board
100. In one
example, the bend may have an angle a of about 90 , and the notch has an angle
of about 90
facing the angle of the bend. However, due to variations in board quality and
the meeting
process, the notch may have an angle of from about 60 to about 120 facing
the angle of the
bend (typically between 90 and 105'). In another embodiment, if the comer
board 100 is
made from a molded material, such as plastic, the notch 120 may run generally
straight across
between the two end points of the slit 110 (e.g., the notch has an angle of 0
). An opening
111 is formed between the slit 100 and the end of the corner board 100, as
shown in FIG. 2.
The opening 111 may have, but is not limited to, a diamond shaped opening, an
A-shaped
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opening, or other various opening shapes, depending on the shape and/or size
of the corner
board, the slit in the corner board, the containers, and/or the stack of
containers.
Alternatively, the notch 120 may take on any form of a hanging notch or a
notch that has the
capability and adjustability to hang on the end of the corner board 100.
[0032]
Referring to FIG. 3, a distance (W2) from the end of the corner board 300 to
the slit 110 of FIG. 1 may vary, depending on the type and/or thickness of
material used to
create the corner board 100. For example, a width W2 of the notch 120 of FIG.
1 may be
from about 0.12 in. to about 1 in. (e.g., about 0.3 cm to about 2.5 cm). In
one embodiment,
the predetermined distance (W2) from the slit 110 to the end of the comer
board is about 0.37
in. (e.g., about 1 cm) when the corner board 100 has a thickness of about 0.16
in. (e.g., 0.6
cm) or greater. In various embodiments, the predetermined distance (W2) from
the slit 110
to the end of the corner board may be about 0.5 cm to about 2 cm. However, one
skilled in
the art will readily understand that the distance can be any suitable distance
that achieves the
objectives of the present invention. In further embodiments, when the corner
board 100 is
less than 0.16 in. (e.g. 0.6 cm), the slit 110 may be 0.63 in. (e.g. about 1.5
cm) from the end
of the comer board 100. In further embodiments, the predetermined distance
(W2) from the
slit 110 to the end of the comer board may be about 0.75 cm to about 3 cm when
the comer
board has a thickness of less than 0.6 cm.
[0033] The
length and/or depth (L2) of the slit 110 may be any suitable value that
provides for a suitable notch 120 and/or provides for the corner board 100 to
rest on one or
more containers. Generally, the depth (L2) of the slit 110 is a predetermined
percentage of
the width W1 of each side 101, 102 of the comer board 100. For example, depth
(L2) of the
slit 110 may be from 20-80% of the width W1 (see FIG. 2) of each side of the
comer board
100, or any value or range of values therein (e.g., 30-60%, about 50%, etc.),
preferably 30-
50% of the width of each of the first and second sides 101, 102. Typically,
first and second
sides 101, 102 have identical widths.
[0034]
Furthermore, the angle of the corner board 100 and the angle of the notch 120
may depend on the shape of the container and/or stack of containers.
Generally, the angle of
the notch 120 can be any value that provides or allows for the corner board
100 to rest on
and/or against the corner of a container, in which the angle of the notch 120
should be
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proportional to the angle of a commercially available container(s). However,
an angle a of
about 90 degrees is generally preferred.
An Exemplary Stack of Containers Protected with Corner Boards
[0035] FIG. 4
shows an exemplary use of the corner board 100 on a group of
containers 410, in which the corner board 100 rests on the vertical edge of
the group of
containers 410. Alternatively, the corner board 100 may rest on the edge or
corner of one or
more items and/or objects (e.g., a stack or arrangement of items or objects,
such as furniture),
instead of the group of containers 410. To properly secure the stacked
containers, the notch
120 of the corner board 100 is placed on an uppermost corner 115 of a stack of
containers
410 such that the surface of the uppermost corner or edge 115 of the stack of
containers 410
is exposed through the opening 111 (see FIG. 2) of the corner board 100. The
sides 101, 102
of the corner board 100 rest on the sides of the stack of containers 410
adjacent to the edge of
the stack of containers 410.
[0036] It will
be readily understood by those skilled in the art that the corner board
100 can extend any suitable length along the edge of the group of containers
410. While the
sides 101, 102 of the corner board 100 will generally be a length equal to or
less than the
length of the edge of the group of containers 410, it should be understood
that the corner
board 100 may be longer than the length of the edge of a single container
and/or the group of
containers 410. For instance, the corner board may have a length longer than
the length of
the vertical edge of a single container to protect the containers whose edges
are generally
vertically aligned with the container on which the corner board 100 is placed.
In this manner,
corner boards 100 may be placed on one or more containers (e.g., at each edge
or at a subset
of the edges) in a group of containers to mitigate damage to the edges of the
containers in the
group. The corner board 100 can also be useful for protecting other items or
objects (e.g.,
furniture, bathroom/kitchen fixtures, windows, stacked building materials such
as
wood/boards, bricks, sheet rock, etc.).
[0037] The
method may further comprise wrapping or banding the group of
containers 410, or other stacked or grouped items and/or objects, together
with the corner
board(s) 100 in place with a wrapping, roping, or banding material. Wrapping,
roping, or
banding the group of containers generally improves the stability, handling,
protection, and/or
tamper resistance of the group of containers 410. It will be readily
understood by those
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skilled in the art that the method may use any wrap, rope, band or strap
suitable for use on the
containers, items and/or objects to which it is applied. For instance, the
wrap may comprise a
stretch film, lay-flat film, roping film and/or strapping film, any of which
may be solid or
vented. Further still, the wrap, rope, and/or band may comprise shrink wrap,
stretch film,
roll(s) of stretch film on a spool, tape, one or more straps, one or more
bands, net, rope,
string, tarp, or any other suitable wrap (or combination of wraps and/or
bands) for a group of
(stacked) containers. Further still, the wrap, rope, or band may envelop any
and/or every
portion of the group of containers 410.
An Exemplary Apparatus for Manufacturing Slit or Notched Corner Boards
[0038] FIGS. 5A-
5B are structural diagrams showing parts of equipment 500 for
manufacturing the corner board of FIG. 3. FIG. 5C is an apparatus 500 for
manufacturing
either the corner board of FIG. 1 or the corner board of FIG. 3.
[0039] FIG. 5A
shows a side view of a first cutting device 530 and a second cutting
device 520, both attached to a center shaft 510 and secured by bolt 515. In
various
embodiments, the board stock is cut and the slit is formed simultaneously
using a "dual
purpose" cutting tool as shown in FIG. 5A. For example, the first cutting
device 530 may be
configured to cut board stock for the corner boards into individual sections.
The first cutting
device 530 may be, for example, a saw blade. The second cutting device 520 is
configured to
form a slit in the corner board near or adjacent to the cut end of the corner
board 100. The
second cutting device 520 may be selected from the group consisting of a knife
blade, a laser,
a saw blade, and a water jet.
[0040]
Generally, the second cutting device 520 is offset and/or spaced apart from
the
first cutting device 530 by a predetermined distance D1, and an edge or
cutting surface of the
second cutting device 520 is raised by a predetermined distance D2 relative to
an edge or
cutting surface of the first cutting device 530. Distance D1 is generally
equal to the width of
the notch (e.g., the width W2 in FIG. 2 of the notch 120 of FIG. 1, from about
0.12 in. to
about 1 in. [about 0.3 cm to about 2.5 cm]). In some embodiments, the distance
D1 from the
slit 110 to the end of the corner board may be about 0.5 cm to about 2 cm. For
example, the
distance from the slit 110 to the end of the corner board (which may be
predetermined) is
about 0.37 in. (e.g., about 1 cm) when the corner board 100 has a thickness of
about 0.16 in.
(e.g., 0.6 cm) or greater. However, one skilled in the art will readily
understand that the
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distance D1 can be any suitable distance that achieves the objectives of the
present invention.
The distance D2 is generally calculated according to the formula [W1 ¨ L2] sin
0, where 0 =
[1800 - a] / 2, and Wl, L2 and a are as described herein (e.g., W1 is the
width of a side of the
corner board, L2 is the length or depth of the slit into each side of the
corner board, and a is
the angle of the bend in the corner board).
[0041] FIG. 5B
shows a top down view of a table top 540 with a cutout 545 therein.
The table top 540 is the surface along which one or more corner board stock
pieces are fed
(e.g., along a direction substantially perpendicular to the cutout 545), and
the cutout 545 is an
area where the first cutting device 530 (e.g., a radial saw blade) moves
laterally during the
process of cutting the corner board 100. Generally, the width of the table top
540 depends on
the number of pieces of comer board stock being fed and cut. Typically, when
one piece (or
length) of comer board stock is fed and cut, the table top 540 is about 2 ft.
to about 4 ft. wide.
When two pieces (or lengths) of corner board stock are cut, the width of the
table top 540 is
generally about 2.5 ft. to about 5 ft. Furthermore, the length of the table
top should be
sufficient to enable a radial saw or other cutting apparatus to cut the fed
comer board stock
(e.g., about 3 ft. to 6 ft. or more). Typically, the width of the cutout 545
may be about 0.5 in.
to about 2 in. The length and width of the cutout 545 is sufficient for the
blade(s) of the
cutting apparatus to cut the comer board and clear the comer board on both
sides. Generally,
the length of the cutout 545 may be about 8 in. to about 24 in. (e.g., about
12 in. to about 16
in.), and the width of the cutout 545 may be about 0.5 in. to about 4 in.
(e.g., about 1 in. to
about 2 in).
[0042] FIG. 5C
shows a front view of a cutting apparatus 500 for making slit and/or
notched corner boards. The apparatus 500 includes an outer radial saw blade
530 (i.e., the
first cutting device) with a saw blade cover 560 attached to support (e.g., a
radial arm) 550.
The first cutting device 530 and the second cutting device 520 (not visible in
FIG. 5C) may
be attached to a shaft, rod or other device defining a radial axis (e.g.,
shaft 510, FIG. 5A) that
is driven or rotated by a motor in housing 555. The support 550 is generally
configured to
allow the first cutting device 530 and second cutting device 520 to move
laterally across the
corner board. As shown in FIGS. 5A and 5C, the cut across the corner board and
the slit into
the corner board may be made simultaneously. In one embodiment, when a first
corner board
is cut into a section (e.g., a free-standing corner board), a slit is formed
in the next corner
board. In a further embodiment, the cuts and slits are made automatically via
computer
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controlled movement of the radial arm saw across the corner board stock at
predetermined
intervals, as the corner board stock is fed along the table top 540 at a
predetermined rate (e.g.,
1-10 ft/s, or any rate or range of rates therein).
[0043] FIG. 5D
shows a side view of the dual purpose cutting apparatus with an
attachment 580 for simultaneously extending the notch (e.g., notch 120 in FIG.
1) inwardly
while cutting the corner board stock and forming the slit (e.g., slit 110 of
FIG. 1). For
example, a metal attachment 580 may be attached to the support 570 and/or saw
cover 560, in
a position between cutting devices 530 and 520 configured to form the notch
120 of FIG. 1
simultaneously with or immediately after the first cutting device 530 cuts the
board stock and
the second cutting device 520 forms the slit. Typically, the metal attachment
580 extends
between the end of the second cutting device 520 and the first cutting device
530, ending at a
rounded tip, the end of which is typically vertically closer to the edge or
end of the second
cutting device 520 than to the end or edge of first cutting device 530. As the
first cutting
device 530 cuts the leading corner board into a free-standing section and the
second cutting
device 520 forms the slit, the metal attachment 580 hits the edge of the
corner board with
sufficient force to invert the position and/or angle of the material at the
end of the corner
board between the slit and the cut end, thereby forming the notch. In one
embodiment, the
metal attachment 580 may comprise a roller (not shown) at the rounded end. In
one
embodiment, feature 575 depicts a metal cross-brace mounted or affixed to the
cover 560,
extending into and out from the plane of the page, which stabilizes the
attachment 580 against
the impact from the edge of the corner board.
[0044] In an
alternative embodiment, feature 575 is an attachment mechanism that
allows various attachments to be attached to the cover 560. Such attachments
can comprise
an air ram, air jet, air press, punch or other thrusting device, etc.
Generally, such attachments
do not extend past the outer edge of the second cutting device 520. Thus, the
inwardly
extending material (e.g., the notch 120) may be created using equipment that
does not come
into direct contact with the corner board, which may improve the run time of
the equipment
between maintenance or repair procedures.
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An Exemplary Method of Manufacturing Slit and/or Notched Corner Boards
[0045] Another
aspect of the present invention relates to a method of manufacturing
slit and/or notched corner boards. An exemplary method of manufacturing such
corner
boards (e.g., the corner boards of FIGS. 1 and 3) is described below.
[0046] In one
embodiment, the method of manufacturing a corner board comprises
bending a board stock to form first and second sides of the corner board,
cutting the board
stock into fixed lengths, and forming a slit near or adjacent to a first end
of the corner board.
The first and second sides of the corner board have an angle therebetween.
Also, the bent
and cut board stock forms the corner board. In a further embodiment of the
method, a notch
is formed near or adjacent to the first end of the corner board.
[0047] FIG. 6
shows a flow chart 600 of an exemplary method of manufacturing a
notched corner board (e.g., corner board 100 of FIG. 1). The method of
manufacturing a slit
corner board generally comprises forming a slit 110 near one end of the corner
board 100,
and the method of forming a notched corner board generally further comprises
forming a
notch 120 at the end of the corner board 100 from the material between the
slit 110 and the
end of the corner board.
[0048]
Referring back to FIG. 6, the method starts at 610, and at 620, board stock is
laminated with one or more layers of paper and/or plastic. The board stock may
comprise a
pre-laminated corner board stock, comprising a plurality of layers of paper,
and optionally
one or more layers of plastic, adhesively laminated to one or two adjacent
layers of paper
and/or (when present) plastic. In various embodiments, the blank (e.g., board
stock cut or
formed to a predetermined width) may comprise alternating layers of paper or
other feed
stock and adhesive, folded to the desired angle a.
[0049] In
further embodiments, the corner board comprises layers of paper and/or
other feed stock with uncured (i.e., wet or damp) adhesive between the layers.
In such
embodiments, the method may further comprise drying the corner board. For
instance, if the
material is a multi-ply paperboard, pressboard, or cardboard, the curing time
will provide
time for the adhesive (e.g., glue) between the layers to cure or dry.
Providing a suitable
curing period may allow for easier manipulation of the corner board during its
manufacture as
well as providing increased strength and/or durability of the corner board
during use. In
some embodiments, the curing period may depend on the time of year. For
instance, during
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winter months when the temperatures are cooler, it may take 10-14 days for the
corner boards
to cure, whereas it may take about 3-4 days during the warmer summer months.
[0050] At 630,
a corner board 100 is formed by bending the board stock at an angle a,
forming first and second sides (see, e.g., sides 101, 102 of FIG. 1) of the
corner board 100.
Alternatively, a preformed corner board having two sides 101, 102 at an angle
a running the
length of the corner board material may be used. Generally, the corner board
has an angle a
of about 90 .
[0051] At 640,
the corner board 100 is cut into fixed-length pieces. The fixed-length
pieces may have a predetermined length (e.g., Li in FIG. 1) of about 24 in.
(60 cm) to about
90 in. (230 cm). However, it should be readily understood that the
predetermined length
(e.g., Li in FIG. 1) of the sides (e.g., 101, 102 in FIG. 1) of the corner
board 100 can be any
value in the range, or more or less than such a range.
[0052] At 650,
the slits 110 are cut at a predetermined distance (e.g., width W2 in
FIG. 3) from the end of the corner board 100. Each slit 110 is generally cut
into each side
(101, 102 in FIG. 1) of the corner board 100 to a predetermined depth (e.g.,
length L2 in FIG.
3) from the point of origin of the angle a. The distance W2 may be about 0.3
cm to about 3
cm. Simultaneous formation of slits 110 and cuts of the corner board may be
performed as
discussed above. In one embodiment, a first corner board is cut into a section
and a slit is
formed in the next corner board simultaneously. In a further embodiment, the
cuts are made
and the slits are formed automatically via computer controlled movement of a
"dual purpose"
cutting apparatus across the corner board stock, at predetermined intervals as
the corner board
stock is fed into the apparatus (e.g., 500 in FIG. 5C) at a predetermined rate
(e.g., 1-10 ft/s).
[0053] The
corner board 100 and the slit 110 may be cut using any capable cutting
tool, such as a knife blade, laser, or saw, including a radial saw. In one
embodiment, the tool
for cutting the corner board and forming the slit includes two substantially
side-by-side
cutting devices. In such an example, the beam and/or blade(s) that cut the
corner board and
form the slit are offset from each other (e.g., spaced apart by distance W2),
with the edge of
the blade, beam, or other slit-forming tool that cuts the slit raised by
distance [W1 ¨ L2] sin 0,
where 0 = [180 - a] / 2 (and W 1, L2 and a are as described herein).
[0054] At 660,
a determination is made whether to form a notch or not. If a notch is
formed, then at 670, the notch (e.g., notch 120 of FIG. 1) is formed at, near,
or adjacent to the
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end of the board 100 by pushing or otherwise forcing the material of the bent
board stock
between the slit 110 and the cut end of the corner board 100 inward from the
angle and/or
edge of the corner board. For example, the bent board stock between the slit
110 (FIG. 1)
and the end of the corner board 100 is pushed inward from the angle a.
Generally, forming
the notch also forms an opening 111 between the slit 110 and the first end of
the corner board
100, as described above. Thus, forming the notch 120 at 670 in FIG. 6 also
forms an opening
111 in the corner board between the slit 110 and the end of the corner board.
After the notch
is formed, or if a notch is not being formed, then the method ends at 680.
CONCLUSION / SUMMARY
[0055]
Embodiments of the present invention can advantageously provide a corner
board that may be rested or placed along a vertical edge of a container or
stack of containers,
without the need for additional materials or steps (e.g., staples or tape) to
affix the corner
board to the container or stack of containers. Thus, the present corner board
advantageously
holds the container stacks in place when the stack is wrapped with appropriate
wrapping
material, and eliminates and/or minimizes the need for additional material,
the risk of injury
to the user and/or damage to the containers or materials therein, and cost and
expenses
associated therewith.
[0056] The
foregoing descriptions of specific embodiments of the present invention
have been presented for purposes of illustration and description. They are not
intended to be
exhaustive or to limit the invention to the precise forms disclosed, and
obviously many
modifications and variations are possible in light of the above teaching(s).
The embodiments
were chosen and described in order to best explain the principles of the
invention and its
practical application(s), to thereby enable others skilled in the art to best
utilize the invention
and various embodiments with various modifications as are suited to the
particular use
contemplated. It is intended that the scope of the invention be defined by the
claims
appended hereto and their equivalents.
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