GB2559053A

GB2559053A - Improved corner protector

Info

Publication number: GB2559053A
Application number: GB1800487.9A
Authority: GB
Inventors: Bowes Jonathan
Original assignee: Plastic Parts Direct Ltd
Current assignee: Plastic Parts Direct Ltd
Priority date: 2017-01-11
Filing date: 2018-01-11
Publication date: 2018-07-25
Anticipated expiration: 2038-01-11
Also published as: GB201800487D0; GB2559053B; GB201700464D0

Abstract

A substantially rigid corner protector 10 suitable for protecting a frame comprising perpendicular first and second walls, 12 and 14, connected at a wall joint 20. The corner protector 10 also comprises first and second connecting walls or webs, 22 and 24, connected to both walls and each having an inspection opening 46. The opening 46 may be a window or an open-ended slot located at the centreline of the connecting wall, which permits inspection of a mitre weld of a uPVC window frame (40, figure 5) without removal of the corner protector 10. The walls 12, 14 may have a further inspection opening and/or a fastener hole. The corner protector 10 may comprise outwardly projecting protective ribs 52 that comprise local deformations of the wall material. The ribs 52 may comprise a further protective rib (154, figure 6). The interior surfaces of the corner protector 10 may be substantially flat. The connecting walls 22, 24 may be triangular in shape. The corner protector 10 may be made of a recyclable plastic material, such as HDPE, possibly 2mm thick.

Description

(56) Documents Cited:

EP 2620390 A1 DE 020200677 U US 20090230009 A1 JP S6092968

B65D 85/30 (2006.01)

WO 2012/076830 A1 US 20090250367 A1 (71) Applicant(s):

Plastic Parts Direct Limited (Incorporated in the United Kingdom)

Unit 6B Thorpe Drive, Banbury, OX16 4UZ, United Kingdom (58) Field of Search:

INT CL B65D Other: WPI, EPODOC (72) Inventor(s):

Jonathan Bowes (74) Agent and/or Address for Service:

Fairfield IP Limited

South Lynn Gardens, London Road, Shipston on Stour, Warwickshire, CV36 4ER, United Kingdom (54) Title of the Invention: Improved corner protector

Abstract Title: Corner Protector with Inspection Openings (57) A substantially rigid corner protector 10 suitable for protecting a frame comprising perpendicular first and second walls, 12 and 14, connected at a wall joint 20. The corner protector 10 also comprises first and second connecting walls or webs, 22 and 24, connected to both walls and each having an inspection opening 46. The opening 46 may be a window or an open-ended slot located at the centreline of the connecting wall, which permits inspection of a mitre weld of a uPVC window frame (40, figure 5) without removal of the corner protector 10. The walls 12, 14 may have a further inspection opening and/or a fastener hole. The corner protector 10 may comprise outwardly projecting protective ribs 52 that comprise local deformations of the wall material. The ribs 52 may comprise a further protective rib (154, figure 6). The interior surfaces of the corner protector 10 may be substantially flat. The connecting walls 22, 24 may be triangular in shape. The corner protector 10 may be made of a recyclable plastic material, such as HDPE, possibly 2mm thick.

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IMPROVED CORNER PROTECTOR

FIELD OF THE INVENTION

This invention relates to an improved corner protector, and in particular a corner protector designed to fit to the corner of a fabricated frame of a window or the like to protect the corner of the frame during manufacture, storage and/or transportation.

BACKGROUND TO THE INVENTION

Many window frames are known to be made of extruded plastics materials such as uPVC. The plastic extrusion, having a chosen profile, is cut and mitred and adjacent lengths are secured together so as to form a corner of the frame. The corners of the frame are particularly vulnerable to damage during subsequent manufacturing procedures, and also during storage and/or transportation to a customer. It is known to fit a corner protector to the frame as part of the manufacturing process, the protector being designed to cover the corner and to protect the corner of the frame from damage.

The mitred corners of adjacent profile lengths are typically welded at the corner, usually by melting the mitred ends. It is typically necessary to inspect all (or at least a proportion of) the mitre welds as part of the routine quality control procedures.

It is necessary to remove a corner protector in order to inspect the mitre welds, and the removal and subsequent replacement of the corner protector adds time and therefore cost to the quality control procedure. In particular, the corner protector is typically secured to the frame by a screw and it is necessary to remove the screw to permit removal of the corner protector, and subsequently to replace the screw to re-secure the corner protector after the inspection has been carried out.

The interior surfaces of the corner protector are typically a close sliding fit upon the exterior surface of the frame. The exterior surface will be visible in the fitted frame and it is necessary that no dirt or debris is located between the sliding surfaces of the corner protector and the frame since that could scratch or otherwise mark the exterior surface of the frame. The likelihood of dirt and debris being introduced between the corner protector and the frame is increased each time the corner protector is removed and replaced and it is therefore desirable to reduce the number of times the corner protector is removed. In addition, the insertion and removal of the screw securing the corner protector to the frame can cause small pieces of plastic to be released, which pieces of plastic might become located between the corner protector and the exterior surface of the frame, making it yet more desirable to reduce the number of times the corner protector is removed.

SUMMARY OF THE INVENTION

The inventor has conceived an improved corner protector which seeks to reduce or avoid the above-stated problems with the known corner protectors.

According to the invention there is provided a corner protector comprising a first wall and a second wall, the first wall being substantially perpendicular to the second wall, the first wall and the second wall being connected at a wall joint, the corner protector having a first connecting wall and a second connecting wall, each connecting wall being connected to both of the first wall and the second wall, the corner protector being a substantially rigid structure which in use surrounds the corner of a chosen frame with the first and second walls covering respective parts of the corner, in which each of the connecting walls has an inspection opening, the inspection opening in use overlying the mitre joint at the corner of the frame.

Preferably, the first wall and the second wall each have a number of protective ribs. The ribs may comprise local deformations of the wall material, or local thickening of the wall material. Desirably, the protective ribs project outwardly. The outward projection of the protective ribs permits the interior surfaces of the first and second walls of the corner protector (which will engage the frame in use) to be substantially flat. The interior surfaces of the connecting walls are also preferably substantially flat. Substantially flat interior surfaces are preferred since they provide the minimum of locations to trap dirt and debris which might scratch or otherwise mark the surface of the frame in use.

Preferably also, the or each protective rib of the first wall is joined to a protective rib of the second wall so that the protective ribs extend around the wall joint. It will be understood that the protective ribs provide additional impact protection and since the junction between the adjacent profile lengths is likely to be the part of the frame which is most vulnerable to damage, it is highly desirable to maximise the protection at the wall joint which will overlie the junction during use.

Desirably, the connecting walls are substantially triangular in shape, ideally substantially right-angled isosceles triangles. The term “substantially” is used since it is preferable to provide some rounding at the wall joint to match the slight rounding at the corner of the frame. Also, it is not necessary that the connecting walls are precisely right-angled and the shape can have a few degrees of tolerance.

Ideally the corner protector is injection moulded in plastics material, but an alternative fabricated construction can be provided.

Preferably, the inspection opening is a slot aligned with the wall joint, the slot ideally being located at the middle of the connecting wall. Desirably the slot is open-ended, i.e. extending to the free edge of the connecting wall.

It will be understood that the inspection opening is located and sized to overlie the mitre weld of a corner of a frame to which the corner protector is fitted. The mitre weld can therefore be visually inspected without having to remove the corner protector. As above indicated, this avoids the requirement for the inspector to remove and replace the corner protector. This also avoids the possibility that a less diligent inspector will not replace (or will not correctly replace) the corner protector. This also reduces the likelihood that dirt and debris might become located between the corner protector and the frame.

Desirably, the corner protector is secured to the frame by a fastener such as a screw. Preferably the corner protector is secured by two screws. Corner protectors are typically secured by a single screw to minimise the time taken to remove the corner protector during the inspection procedure. Since the improved corner protector does not need to be removed for inspection it is desirable to use two screws so as to more securely fix the corner protector to the frame. The provision of two screws also provides a level of redundancy in the event that one of the screws is overtightened and strips the plastic, that screw alone being insufficient to retain the corner protector.

Preferably, each of the first and second walls has a hole for a fastener formed therethrough, ideally a countersunk hole.

The corner protector is not intended to be re-usable, i.e. it is intended that it is fitted as early as possible in the frame manufacturing process and then remains upon the frame during the subsequent manufacturing stages and during subsequent storage and transportation to the customer. The corner protector can therefore be removed (only once) by the customer immediately prior to installation of the window, thereby providing the maximum protection to the corner of the frame. Re-use of the corner protector is possible, but is not preferred as the likelihood of dirt and debris engaging the corner protector and being retained thereby is significantly increased by re-use. It is therefore preferred that the corner protector is discarded after use, and is preferably made of a material which can be recycled.

Desirably, the first wall and the second wall also have at least one inspection opening enabling the inspection of other chosen parts of the corner of the frame to which the protector is fitted.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention will now be described in more detail, by way of example, with reference to the accompanying drawings, in which:

Fig. 1 shows a perspective view of the improved corner protector;

io Fig.2 shows a side view of the improved corner protector;

Fig.3 shows an end view of the improved corner protector;

Fig.4 shows an underside view of the improved corner protector;

Fig.5 shows a representative corner of part of a frame to which the corner protector can be fitted; and

Fig.6 shows a cross-section through a part of an alternative improved corner protector

DETAILED DESCRIPTION

Figs 1 -4 show an improved corner protector 10 having a first wall 12 and a second wall 14. In this embodiment both of the first and second walls 12, 14 are rectangular with two long edges 16 and two short edges 18. The first wall 12 is in this embodiment exactly perpendicular to the second wall 14 (although it will be understood that a few degrees away from perpendicular will have little or no adverse effect upon the invention).

One long edge 16 of the first wall 12 is connected to one of the long edges 16 of the second wall 14 at a wall joint 20. The wall joint 20 is linear and provides a right-angled corner of the protector (although in this embodiment the wall joint is slightly rounded). It will be observed from Fig.2 in particular that the wall joint 20 steps down adjacent to the ends of the wall joint 20, which steps are due to the greater rounding of the wall joint at those locations.

A first connecting wall or web 22 is connected to one of the short edges 18 of each of the first and second walls 12, 14 and a second connecting wall or web 24 is connected to the other of the short edges 18 of each of the first and second walls. The first and second walls 12, 14 are therefore interconnected by the wall io joint 20 and by the first and second connecting webs 22, 24.

The corner protector 10 is injection moulded from plastics material and is sufficiently thick to provide a substantially rigid structure. In an alternative but less preferred embodiment the corner protector is fabricated from separate panels which are welded or otherwise adhered together.

The corner protector 20 is designed to surround a corner 30 of a chosen frame 32 (a part of which is shown in Fig.5). In known fashion, the frame 32 is manufactured from lengths 34, 36 of (identical) plastics profile, the lengths being mitred and welded together at the junction 40, in known fashion. Whilst Fig.5 shows the profile as solid for simplicity, the profile will in practice be largely hollow, made up of webs of plastic material in a pattern providing some standard features (such as the Euro-groove in which locking componentry may be located), as well as other channels and features which may be unique to a particular frame manufacturer. It will be understood that the corner 30 is particularly vulnerable to damage as the frame is moved around the manufacturing location during subsequent manufacturing stages, as well as during storage and transportation. Fitting the corner protector 10 to the corner 30 will minimise the likelihood of damage to the frame 32.

The corner protector 10 is therefore sufficiently thick to absorb impacts which might occur during manufacturing, storage and transportation. In a preferred embodiment the corner protector is manufactured from high density polyethylene (HDPE) with a thickness of around 2 mm. HDPE has the advantage of being a recyclable material so that the corner protector 10 can be recycled after use.

It will be understood that in use the first and second walls 12, 14 cover respective outer parts of the corner 30, and one of the first and second connecting webs 22, 24 covers the surface 42 of the corner 30 (and the other connecting web covers the corresponding unseen part behind the corner 30. The surface 42 is an exterior surface which will typically be visible when the frame 32 (which may be a window frame for example) is installed.

io

The corner protector 10 is sized to cooperate with the frame 32, in particular so that the connecting webs 22, 24 are separated by a distance equal to (or slightly larger than) the thickness T of the frame. When the corner protector 10 is fitted to the corner 30 therefore, the connecting webs 22, 24 cover the surface 42 of the frame. The corner protector is secured by a respective fastener (not shown - but ideally a screw) passing through each of the countersunk holes 44 in the first and second walls 12, 14. It will be understood that the screws form holes in parts of the frame profiles 34, 36 which will be hidden from view when the frame 32 is installed. The fasteners together secure the corner protector 10 to the corner 30 so that it remains in place during movement of the frame 32 around the manufacturing facility, and also during subsequent storage and transportation.

As above indicated, the respective parts 34, 36 of the frame 32 are typically joined at the junction 40 by a mitre weld, and it is necessary to check the weld of every frame, or a proportion of the frames, as part of the routine quality control procedures. The connecting webs 22, 24 each have an inspection opening 46 at their approximate centre, the inspection opening being aligned with the wall joint 20 so that in use it overlies the junction 40 and thereby the mitre weld. The inspection opening 46 permits a visual inspection of the mitre weld without removal of the corner protector 10 from the frame 32. A visual inspection is normally sufficient for most quality control procedures, but the inspection opening may be made sufficiently large to permit the introduction of an ultrasound probe or the like if more rigorous testing is required.

In this embodiment the inspection opening is an open-ended slot, but it will be understood that a round or elongate window (i.e. an opening surrounded by material of the connecting web) could alternatively be provided.

In addition, in this embodiment the first and second walls 12, 14 also have inspection openings or inspection windows 50 permitting the visual (and more rigorous, if required) inspection of selected areas of the profiles 34 and 36.

io In order to increase the rigidity of the corner protector 10, and furthermore to enhance the impact protection provided, first wall 12 and the second wall 14 each have a number of (in this embodiment four) protective ribs 52. The (four) protective ribs 52 of the first wall 12 are jointed to the (four) protective ribs of the second wall 14, so that the protective ribs extend around the wall joint 20. In this embodiment the protective ribs are formed mostly as deformations in the first and second walls 12, 14, and are therefore visible in the bottom view of Fig.4. In an alternative embodiment the protective ribs are formed from additional material so that the internal surfaces of the first and second walls 12, 14 are substantially flat.

A part of an alternative embodiment of corner protector is shown in Fig.6. This embodiment also has four protective ribs 152, only one of which is seen in Fig.6. A further rib 154 projects from each of the protective ribs 152 (along the full length of the protective rib). In use, the further ribs 154 lift the frame to which the corner protector is fitted further off the ground or other surface upon which the frame is supported during storage and/or transportation.

Claims

1. A corner protector comprising a first wall and a second wall, the first wall being substantially perpendicular to the second wall, the first wall and the

5 second wall being connected at a wall joint, the corner protector having a first connecting wall and a second connecting wall, each connecting wall being connected to both of the first wall and the second wall, the corner protector being a substantially rigid structure which in use surrounds a corner of a chosen frame with the first and second walls covering respective io parts of the corner, each of the connecting walls having an inspection opening.

2. A corner protector according to claim 1 in which the first wall and the second wall each have a number of protective ribs.

3. A corner protector according to claim 2 in which the protective ribs comprise local deformations of the wall material.

4. A corner protector according to claim 2 or claim 3 in which the protective ribs

20 project outwardly.

5. A corner protector according to any one of claims 2-4 in which the or each protective rib of the first wall is joined to a protective rib of the second wall, the protective ribs extending around the wall joint.

6. A corner protector according to any one of claims 1-5 in which the first and second walls each have a substantially flat interior surface.

7. A corner protector according to any one of claims 1-6 in which the

30 connecting walls each have a substantially flat interior surface.

8. A corner protector according to any one of claims 1-6 in which the connecting walls are substantially triangular in shape.

9. A corner protector according to any one of claims 1-8 made of plastics

5 material.

10. A corner protector according to claim 9 made of recyclable plastics material.

11. A corner protector according to claim 9 or claim 10 made of HDPE io approximately 2 mm thick.

12. A corner protector according to any one of claims 1-11 in which the inspection opening is a window or an open-ended slot.

15

13. A corner protector according to any one of claims 1-12 in which inspection window is located at the centreline of the connecting wall.

14. A corner protector according to any one of claims 1-13 in which each of the first and second walls has a fastener hole.

15. A corner protector according to any one of claims 1-14 in which one or both of the first and second walls has a further inspection opening.

Intellectual

Property

Office

Application No: GB1800487.9 Examiner: Dr Kathryn Willett