CA2268296A1

CA2268296A1 - Article protector and method of use and manufacture

Info

Publication number: CA2268296A1
Application number: CA002268296A
Authority: CA
Inventors: Timothy Corben Morley
Original assignee: Aston Packaging Ltd
Current assignee: Individual
Priority date: 1996-10-09
Filing date: 1997-10-09
Publication date: 1998-04-16
Also published as: AU4630797A; WO1998015472A1; JP2001501566A; GB9621038D0

Abstract

The invention relates to an article protector and method of use and manufacture, and in particular to a foldable multilayer shock-absorbing protector for a fragile and breakable article such as a glass mirror or the like. According to the invention there is provided an article protector (1) comprising a plurality of layers (10, 20, 30) of shock-absorbing material (11, 12), each layer having a first panel (15, 25, 35) foldable relative to a second panel (16, 26, 36) about a fold line (13, 23, 33) separating the panels, the first panel of one layer being connected to the first panel of the adjacent layer, characterised in that the second panel of said one layer is not connected to the second panel of the adjacent layer. There is also provided a method of manufacture and methods of use of the article protector.

Description

2 PCT/GB97/02784 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;

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.

- 3 -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

- 4 -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

- 5 -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.

- 6 -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;

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 _ g _ 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 _ g _ 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 WO 98/15472 PCTlGB97/02784 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 WO 98!1S472 PCT1GB9?/02784 - lI
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 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.

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.

Claims

1. An article protector (1) comprising a plurality of layers (10,20,30) of shock-absorbing material (11,12), each layer having a first panel (15,25,35) foldable relative to a second panel (16,26,36) about a fold line (13,23,33) separating the panels, the first panel of one layer being connected to the first panel of the adjacent layer, characterised in that the second panel of said one layer is not connected to the second panel of the adjacent layer.

2. A protector according to claim 1 characterised in that there are three layers (10,20,30), with the first panels (15, 25, 35) of the first and second layers being connected together and the first panels of the second and third layers being connected together.

3. A protector according to claim 1 characterised in that each layer (10,20,30) has three panels (15,16,17;
25,26,27; 35,36,37), in that the third panel (17,27,37) of each layer is not connected to the third panel of either of the other layers, in that the fold line (13,23,33) separating respective first and second panels is a first fold line, and in that a second fold line (14,24,34) of each panel separates the third panel (17,27,37) from the respective second panel (16,26,36), the third panel being foldable relative to the respective second panel so that the protector is formable into a channel.

4. A protector according to claim 3 characterised in that there are three layers (10,20,30), each layer having a thickness (w), in that one longitudinal edge (18,28,38) of each layer is aligned, the first fold line (23) of the second layer (20) being offset by said layer thickness (w) further from the longitudinal edges than the first fold line (33) of the third layer (30), the first fold line (13) of the first layer (10) being offset by a further layer thickness (w) from the longitudinal edges, and in that the second fold line (24) of the second layer is offset by two times said layer thickness (w) further from the longitudinal edges than the second fold line (34) of the third layer, the second fold line (14) of the first layer being offset by four times the layer thickness (w) further from the longitudinal edges than the second fold line (34) of the third layer.

5. A protector according to claim 1 characterised in that the layers (10,20,30) are of single-faced corrugated paper (11,12), and in that the corrugations face inwardly of the assembled protector.

6. A protector according to claim 1 having between two and ten layers.

7. A method of making an article protector (1) which includes {i} selecting two sheets (10,20) of shock-absorbing material, {ii} forming a fold line (13,23) in each sheet, {iii} overlying the sheets so that the fold lines are parallel but offset, and {iv} securing the sheets together to one side only of the fold line whereby upon hinging the 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 substantially perpendicular to the fold lines.

8. A method of use of an article protector (1) according to claim 3 internally of an article container (41,51) having a throat (40,50) defined by two inner surfaces of the container, which includes the steps of {i}
positioning the second panels (16,26,36) over the throat, {ii} positioning the article (42,52) into alignment with the second panels and feeding the article into contact with a second panel (36) whereby to press the second panels into the throat and with the first and third panels (15,17) of one layer (10) sliding into contact with the said inner surfaces.

9. A method of use of an article protector (1) according to claim 3 internally of an article container (41,51) having a throat (40,50) defined by two inner surfaces of the container, which includes the steps of {i}
engaging a second panel (36) with an edge of the article (42,52), {ii} bending the first (15,25,35) and third (17,27,37) panels around the said edge causing relative movement of the second and third panels of the respective layers (10,20,30) and {iii} feeding the article and fitted protector into the throat with the first and third panels (15,17) of one layer (10) sliding relative to the said inner surfaces.

10. A method of manufacture of an article protector (1) according to claim 1 characterised by the steps of {i}
applying one or more lines of adhesive to the first panel (15) of the first layer (10), the line(s) of adhesive being substantially parallel to the fold line (13), {ii} engaging the first panel (25) of the second layer (20) with the adhesive, with the longitudinal edge (28) of the second layer substantially overlying the longitudinal edge (18) of the first layer, {iii}
maintaining the engagement until the adhesive sets.

11. A method of manufacture according to claim 10 characterised by the addition of a third layer, the first panel of the third layer being adhered to the first panel of the second layer substantially simultaneously with the adherence of the second layer to the first layer, or subsequent thereto.