US20080179216A1

US20080179216A1 - Sleeve for protecting a corner portion of a product

Info

Publication number: US20080179216A1
Application number: US11/970,710
Authority: US
Inventors: David F. Kari
Original assignee: Individual
Current assignee: International Paper Co; Fidelity Container Corp
Priority date: 2007-01-25
Filing date: 2008-01-08
Publication date: 2008-07-31

Abstract

Corner sleeves are used for protecting corner portions of products. Each sleeve has a pair of cushioning members formed in an L-shaped configuration that define a generally triangular space therebetween. Top and bottom panel members of the sleeve are positioned to cover a top and a bottom of the triangular space. Top and bottom fold-over panel members of the sleeve are folded relative to the top and bottom panel members to be positioned within the triangular space and are biased toward one another. In use, upon insertion of the corner portion of the product between the top and bottom fold-over panel members, the fold-over panel members hold the product in place therebetween and the cushioning members protect the corner portion of the product. L-shaped channels may be provided within the sleeves to further assist in holding the product in place.

Description

CROSS-REFERENCE AND INCORPORATION BY REFERENCE

This application claims the domestic priority of U.S. Provisional Application Ser. No. 60/886,546, filed on Jan. 25, 2007, and entitled “Corner Sleeve”. U.S. Provisional Application Ser. No. 60/886,546 is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to the packaging of products. More specifically, the invention relates to sleeve members used for packaging the corner portions of products, such as marker boards and dry erase boards.

BACKGROUND OF THE INVENTION

It has long been known that it is desirable to package products in order to protect them from damage during shipping and/or storage. It has further been found that the corners of the products are more likely to be damaged during shipping and/or storage than other parts of the products. Prior art packaging used for protecting the corners of the products, however, typically suffer from one or more of the following disadvantages, among others: (1) a lack of substantial stacking strength in the horizontal direction; (2) a lack of substantial stacking strength in the vertical direction; (3) formed of non-environmentally friendly (recyclable) materials; (4) do not provide an adequate crumple zone to protect the product during corner drop tests; (5) do not allow for the packaging to easily slide on the corner of the product and stay on the corner of the product; (6) do not accommodate varying sizes of products; (7) are not formed in a pre-assembled packaging component; (8) do not protect the entire corner area of all products; (9) have tabs that interfere with placement of the product into the packaging; (10) have air cells that are too wide because, over time, while a product is stored upright on its end like a book on a book shelf, the bottom edge of the packaging tends to collapse; (11) do not accommodate the attachment of inserts, such as a marker tray insert, thereto; (12) the corner packaging does not “grip” the product; (13) are not easily manufactured by a machine; and (14) are expensive and time-consuming to manufacture.
Therefore, there is a need in the packaging industry to provide for a corner packaging that overcomes as many of these disadvantages as possible. The present packaging used for protecting the corners of the products overcomes each of these disadvantages and, therefore, is a major advancement for use in the packaging industry.

SUMMARY OF THE INVENTION

Briefly, and in accordance with the foregoing, the invention provides corner sleeves used for protecting corner portions of products. Each sleeve has a pair of cushioning members formed in an L-shaped configuration that define a generally triangular space therebetween. Top and bottom panel members of the sleeve are positioned to cover a top and a bottom of the triangular space. Top and bottom fold-over panel members of the sleeve are folded relative to the top and bottom panel members to be positioned within the triangular space and are biased toward one another. In use, upon insertion of the corner portion of the product between the top and bottom fold-over panel members, the fold-over panel members hold the product in place therebetween and the cushioning members protect the corner portion of the product.
The corner sleeves are formed from a blank and a filler. The blank is formed of a corrugated cardboard material. The filler is formed from a corrugated cardboard material in certain embodiments and in other embodiments is formed from a polyethylene foam. In certain embodiments of the invention, L-shaped channels may be provided within the sleeves between the fold-over panel members and the cushioning members to further assist in holding the product in place. The corner sleeves may also be provided with cutouts for assisting in securement of an insert.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention which are believed to be novel are described in detail hereinbelow. The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings wherein like reference numerals identify like elements in which:

FIG. 1 is a top plan view of a blank used to form a corner sleeve of the invention in accordance with a first embodiment of the invention;

FIG. 1A is an enlarged portion of the blank taken from circle 1A of FIG. 1;

FIG. 1B is an enlarged portion of the blank taken from circle 1B of FIG. 1;

FIG. 1C is an enlarged portion of the blank taken from circle 1C of FIG. 1;

FIG. 1D is an enlarged portion of the blank taken from circle 1D of FIG. 1;

FIG. 1E is an enlarged portion of the blank taken from circle 1E of FIG. 1;

FIG. 1F is an enlarged portion of the blank taken from circle 1F of FIG. 1;

FIG. 2 is a perspective view of a filler used to form a corner sleeve of the invention accordance with first, second and third embodiments of the invention;

FIGS. 3-7 are perspective views of the assembly of the corner sleeve of the invention in accordance with the first embodiment of the invention;

FIG. 8 is a top view of the corner sleeve of the invention in accordance with the first embodiment of the invention;

FIG. 9 is a top plan view of a blank used to form a corner sleeve of the invention in accordance with second and third embodiments of the invention;

FIG. 10 is a top view of the corner sleeve of the invention in accordance with the second embodiment of the invention;

FIG. 11 is a top view of the corner sleeve of the invention in accordance with the third embodiment of the invention;

FIG. 12 is a top plan view of a blank used to form a corner sleeve of the invention in accordance with fourth and fifth embodiments of the invention;

FIG. 13 is a top plan view of a blank used to form a filler of the corner sleeve of the invention in accordance with fourth and fifth embodiments of the invention;

FIG. 14 is a perspective view of the filler of the corner sleeve of the invention in accordance with fourth and fifth embodiments of the invention;

FIGS. 15-19 are perspective views of the assembly of the corner sleeve of the invention in accordance with the fourth embodiment of the invention;

FIG. 20 is a top view of the corner sleeve of the invention in accordance with the fourth embodiment of the invention;

FIG. 21 is a top view of the corner sleeve of the invention in accordance with the fifth embodiment of the invention;

FIG. 22 is a bottom view of a product having corner portions which the corner sleeves of the invention are configured to protect and secure;

FIG. 23 is an enlargement of a corner portion of the product illustrated in FIG. 22 taken from Circle 23;

FIG. 24 is a side view of the corner portion of the product illustrated in FIG. 23;

FIG. 25 is a bottom view of the product illustrating the corner sleeves of the fourth embodiment of the invention protecting and securing the corner portions of the product;

FIG. 26 is an enlargement of a corner portion of the product illustrated in FIG. 25 having the corner sleeve of the fourth embodiment of the invention thereon taken from Circle 26;

FIG. 27 is a perspective view of an alternative embodiment of the corner sleeve of the first embodiment of the invention having a cut-out for assisting in the securement of an insert; and

FIG. 28 is a bottom view of the product illustrating the alternative corner sleeves of the first embodiment of the invention protecting and securing the corner portions of the product and having an insert positioned and secured within the cut-outs of the alternative corner sleeves.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

While this invention may be susceptible to embodiment in different forms, there is shown in the drawings and will be described herein in detail, specific embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated.
The invention provides sleeves 100, 400, 700, 1000, 1400 used for packaging and protecting corner portions of flat style products, such as dry erase boards and bulletin boards, methods for forming the sleeves 100, 400, 700, 1000, 1400, and methods for securing the sleeves 100, 400, 700, 1000, 1400 to corner portions of flat style products. Of course, while the protection of corner portions of flat style products is preferred, the sleeves 100, 400, 700, 1000, 14000 could also be used to protect corner portions of other types of products.
Five separate corner sleeves 100, 400, 700, 1000, 1400 are described and illustrated herein with the understanding that other variations of the corner sleeves 100, 400, 700, 1000, 1400 may be obtained by varying the dimensions and/or the materials used in forming the corner sleeves 100, 400, 700, 1000, 1400. It should be noted that while the invention has been described hereinbelow as having certain dimensions, that these dimensions should be understood to be only one preferred embodiment of the invention and are provided merely for reference purposes. It should further be noted that the drawings are not necessarily drawn to scale.
Attention is invited to FIGS. 1-8, illustrating corner sleeve 100 and the formation thereof. Corner sleeve 100 is formed from a blank 102, a filler 104 and, if desired, adhesives, such as glue. The blank 102 is preferably formed from a sheet of a corrugated cardboard material. The blank 102 is best illustrated in FIGS. 1-1F.
The blank 102 provides a plurality of panels, including a bottom panel 106, a first fold-over panel 108, a side panel 110, a top panel 112, a second fold-over panel 114, a first air cell panel 116, a second air cell panel 118, a third air cell panel 120, a fourth air cell panel 122, a fifth air cell panel 124, and a sixth air cell panel 126. The blank 106 has a top surface 128, as shown in FIG. 1, and a bottom surface 130.
Bottom panel 106 is described with reference to points P1-P6 in FIGS. 1 and 1A. From point P1, fold line 132 extends upwardly to perforated line 134. From the connection with fold line 132, perforated line 134 extends upwardly to point P2. From point P2, edge 136 extends to the right to point P3. From point P3, fold line 138 extends angularly downwardly and to the right to point P4. From point P4, edge 140 extends downwardly to point P5. From point P5, perforated line 142 extends to the left to fold line 144. From the connection with perforated line 142, fold line 144 extends to the left to point P6. From point P6, edge 146 extends to the left to point P1. Fold line 132 and perforated line 134 are continuous with one another between points P1 and P2 and perforated line 142, fold line 144 and edge 146 are continues with one another between points P5 and P1.
First fold-over panel 108 is described with reference to points P3, P4 and P7 in FIG. 1, and includes fold line 138. From point P3, edge 148 extends to the right to point P7. From point P7, edge 150 extends angularly downwardly and to the right, to point P4.
Side panel 110 is described with reference to points P1, P2, P8 and P9 in FIG. 1, and includes fold line 132 and perforated line 134. From point P1, edge 152 extends to the left to point P8. From point P8, fold line 154 extends upwardly to perforated line 156. From the connection with fold line 154, perforated line 156 extends upwardly to point P9. From point P9, edge 158 extends to the right to point P2. Fold line 154 and perforated line 156 are continuous with one another between points P8 and P9.
Top panel 112 is described with reference to points P8-P14, in FIGS. 1 and 1B, and includes fold line 154 and perforated line 156. From point P8, edge 160 extends to the left to point P10. From point P10, edge 162 extends downwardly to edge 164. From the connection to edge 162, edge 164 curves downwardly and to the left to edge 166. From the connection to edge 164, edge 166 extends to the left to edge 168. From the connection to edge 166, edge 168 curves upwardly and to the left to edge 170. From the connection to edge 168, edge 170 extends upwardly to point P11. From point P11, edge 172 extends to the left to point P12. From point P12, edge 174 extends upwardly to point P13. From point P13, fold line 176 extends angularly upwardly and to the right, to point P14. From point P14, edge 178 extends to the right to point P9.
Second fold-over panel 114 is described with reference to points P13-P15, in FIG. 1, and includes fold line 176. From point P13, edge 180 extends angularly upwardly and to the right, to point P15. From point P15, edge 182 extends to the right to point P14.
First air cell panel 116 is described with reference to points P5, P6 and P16-P21, in FIGS. 1, 1A, 1C and 1E, and includes perforated line 142 and fold line 144. From point P6, edge 184 extends downwardly to point P16. From point P16, edge 186 extends angularly downwardly and to the right to point P17. From point P17, edge 188 extends downwardly to point P18. From point P18, fold line 190 extends to the right to perforated line 192. From the connection with fold line 190, perforated line 192 extends to the right to point P19. From point P19, cut line 194 curves downwardly and to the right to cut line 196. From the connection with cut line 194, cut line 196 extends to the right to cut line 197. From the connection with cut line 196, cut line 197 curves upwardly and to the right to point P20. From point P20, perforated line 198 extends to the right to point P21. From point P21, edge 200 extends upwardly to point P5. Fold line 190 and perforated line 192 are continuous with one another between points P18 and P19. Perforated lines 192, 198 are co-planar.
Second air cell panel 118 is described with reference to points P18-P29, in FIGS. 1, 1C and 1E, and includes fold line 190, perforated lines 192, 198 and cut lines 194, 196, 198. From point P18, edge 202 extends downwardly to point P22. From point P22, perforated line 206 extends downwardly to point P24. From point P24, edge 210 extends downwardly to point P26. From point P26, fold line 212 extends to the right to point P27. From point P27, cut line 214 extends to the right to point P28. From point P28, fold line 216 extends to the right to point P29. From point P29, edge 218 extends upwardly to point P21. Fold lines 212, 216 and cut line 214 are continuous with one another between points P26, P29. Edges 188, 202 are continuous with one another between points P17, P22.
Third air cell panel 120 is described with reference to points P26-P35, in FIGS. 1 and 1E, and includes fold lines 212, 216 and cut line 214. From point P26, edge 220 extends downwardly to point P30. From point P30, edge 222 extends angularly downwardly and to the left, to point P31. From point P31, edge 224 extends downwardly to point P32. From point P32, fold line 226 extends to the right to point P33. From point P33, cut line 228 extends to the right to point P34. From point P34, fold line 230 extends to the right to point P35. From point P35, edge 232 extends upwardly to point P29. The third air cell panel 120 has an aperture 234 provided therethrough such that first and second portions 236, 238 of the third air cell panel 120 are provided on either side of the aperture 234. The aperture 234 is defined by cut lines 214, 228 in combination with a cut line 240 extending downwardly from point P27 to point P33 and a cut line 242 extending downwardly from point P28 to point P34.
Fourth air cell panel 122 is described with reference to points P32-P40, in FIGS. 1 and 1D, and includes fold lines 226, 230 and cut line 228. From point P32, edge 244 extends downwardly to point P36. From point P36, edge 246 extends to the right to point P37. From point P37, perforated line 248 extends to the right to point P38. From point P38, cut line 250 extends to the right to point P39. From point P39, perforated line 252 extends to the right to point P40. From point P40, edge 254 extends upwardly to point P35.
Fifth air cell panel 124 is described with reference to points P37-P46, in FIGS. 1 and 1D, and includes perforated lines 248, 252 and cut line 250. From point P37, edge 256 extends downwardly to point P41. From point P41, perforated line 258 extends to the right to point P42. From point P42, cut line 260 extends downwardly to point P43. From point P43, cut line 262 extends to the right to point P44. From point P44, cut line 264 extends upwardly to point P45. From point P45, perforated line 266 extends to the right to point P46. From point P46, edge 268 extends upwardly to point P40. The fifth air cell panel 124 has an aperture 270 provided therethrough such that first and second portions 272, 274 of the fifth air cell panel 124 are provided on either side of the aperture 270. The aperture 270 is defined by cut lines 250, 262 in combination with a cut line 276 extending downwardly from point P38 to point P43 and a cut line 278 extending downwardly from point P39 to point P44.
Sixth air cell panel 126 is described with reference to points P41-P48, in FIGS. 1 and 1D, and includes perforated lines 258, 266 and cut lines 260, 262, 264. From point P41, edge 280 extends downwardly to point P47. From point P47, edge 282 extends to the right to point P48. From point P48, edge 284 extends upwardly to point P46.
The blank 102 has a first tab 286 as best illustrated in FIGS. 1 and 1C. The first tab 286 is formed as a portion of the first air cell panel 116 and is defined by cut lines 194, 196, 197.
The blank 102 has a second tab 288 as best illustrated in FIGS. 1 and 1E. The second tab 288 extends outwardly from the second air cell panel 118. The second tab 288 is described with reference to points P22, P24, in FIGS. 1 and 1E, and includes perforated line 206. From point P22, edge 290 extends to the left to edge 292. From the connection with edge 290, edge 292 curves downwardly and to the left to edge 294. From the connection with edge 292, edge 294 extends downwardly to edge 296. From the connection with edge 294, edge 296 curves downwardly and to the right to edge 298. From the connection with edge 296, edge 298 extends to the right to point P24.
The blank 102 has a third tab 300 as best illustrated in FIGS. 1 and 1B. The third tab 300 is formed as a portion of the top panel 112 and is partially defined by edges 162, 164, 166, 168, 170. The third tab 300 is further described with reference to points P10, P11, P49, P50 in FIGS. 1 and 1B. The third tab 300 includes cut line 302 which extends upwardly from point P10 to point P49. The third tab 300 includes cut line 304 which extends upwardly from point P11 to point P50. The third tab 300 includes fold line 306 which extends to the left from point P49 to point P50.
The blank 102 has a fourth tab 308 which is provided in the bottom panel 106 as illustrated in FIGS. 1 and 1F. The fourth tab 308 is defined by points P51-P58. From point P51, cut line 310 extends upwardly to point P52. From point P52, cut line 312 extends to the left to cut line 314. From the connection with cut line 312, cut line 314 curves upwardly and to the left to cut line 316. From the connection with cut line 314, cut line 316 extends upwardly to cut line 318. From the connection with cut line 316, cut line 318 curves upwardly and to the right to cut line 320. From the connection with cut line 318, cut line 320 extends to the right to point P53. From point P53, cut line 322 extends to the right to point P54. From point P54, cut line 324 extends to the right to point P55. Point P55 is provided on fold line 138. From point P55, cut line 326 extends angularly downwardly and to the right to point P56. Point P56 is provided on fold line 138. Cut line 326 is provided in place of fold line 138 between points P55, P56. From point P56, cut line 328 extends downwardly to cut line 330. From the connection with cut line 328, cut line 330 curves downwardly and to the left to cut line 332. From the connection with cut line 330, cut line 332 extends to the left to point P57. From point P57, cut line 334 extends downwardly to point P58. From point P58, fold line 336 extends to the left to point P51. From point P52, fold line 338 extends upwardly to point P53, thus defining a flap portion 340 of the fourth tab 308 between fold line 338 and cut lines 312, 314, 316, 318, 320. From point P57, fold line 342 extends upwardly to point P58, thus defining a flap portion 344 of the fourth tab 308 between fold line 342 and cut lines 324, 326, 328, 330, 332.
In a preferred embodiment, the blank 102 is formed from a sheet of corrugated cardboard material that is 17.5625 inches by 16.625 inches and has the following dimensions: a straight distance from edges 136, 148 to edge 282 is 17.5625 inches; a distance from point P5 to point P12 is 16.625 inches; a distance from point P1 to point P5 is 7.5625 inches; a distance from point P1 to point P8 is 1.5 inches; a distance from point P8 to point P12 is 7.5625 inches; a distance from point P1 to point P2 is 7.5625 inches; a distance from point P5 to point P21 is 1.375 inches; a distance from point P21 to point P29 is 2.1875; a distance from point P29 to point P35 is 1.25 inches; a distance from point P35 to point P40 is 2.0625 inches; a distance from point P40 to point P46 is 1.125 inches; a distance from point P46 to point P48 is 2.0 inches; a distance from point P40 to point P39 is 1.5 inches; a distance from point P2 to point P3 is 0.8125 inches; a distance from point P1 to perforated line 134 is 2.0 inches; a distance from point P6 to perforated line 142 is 2.0 inches; a distance from point P6 to point P5 is 7.5 inches; a straight distance from perforated line 206 to edge 294 is 1.25 inches; a distance from point P18 to point P21 is 7.4375 inches; a distance from point P32 to point P35 is 7.5 inches; a distance from point P37 to point P40 is 7.3125 inches; a distance from point P24 to point P26 is 0.0625 inches; a distance from point P26 to pint P30 is 0.0625 inches; a distance from point P19 to point P20 is 2.0 inches; a distance from point P20 to point P21 is 1.5 inches; a distance from point P27 to point P28 is 1.5 inches; a distance from point P28 to point P29 is 1.75 inches; a distance from point P38 to point P39 is 2.0 inches; a distance from point P39 to point P40 is 1.5 inches; a distance from point P42 to point P43 is 0.125 inches; a straight distance from cut line 196 to cut line 214 is 2.0 inches; a distance from point P10 to point P11 is 2.0 inches; a distance from point P11 to point P12 is 1.5 inches; a straight distance from edge 166 to fold line 306 is 1.0 inch; a distance from point P10 to point P49 is 0.125 inches; a distance from point P51 to point P58 is 1.5 inches; a straight distance from cut line 328 to fold line 342 is 0.5 inches; a straight distance from fold line 336 to perforated line 142 is 2.25 inches; a distance from point P51 to point P52 is 0.25 inches; and a distance from point P52 to point P53 is 0.875 inches.
Filler 104 is best illustrated in FIG. 2. Filler 104 is preferably formed of polyethylene foam and is preferably formed in the shape of a rectangular block such that filler 104 has an upper surface 346, a lower surface 348, a first end surface 350, a second end surface 352, a first side surface 354, and a second side surface 356.
In a preferred embodiment of the corner sleeve 100, the filler 104 has a height, defined as the distance between the upper and lower surfaces 346, 348, of 1.375 inches; a width, defined as the distance between the first and second side surfaces 354, 356, of 0.75 inches; and a length, defined as the distance between the first and second end surfaces 350, 352, of 5.3125 inches.
Attention is now invited to FIGS. 3-7 which will illustrate the formation of the corner sleeve 100. The sixth air cell panel 126 is folded upwardly along perforated lines 258, 266 such that it is generally perpendicular to the fifth air cell panel 124. The fifth air cell panel 124 is then folded upwardly along perforated lines 248, 252 such that it is generally perpendicular to the fourth air cell panel 122, which is also now parallel to the sixth air cell panel 126. The fourth air cell panel 122 is then folded upwardly along fold lines 226, 230 such that it is generally perpendicular to the third air cell panel 120, which is also now parallel to the fifth air cell panel 124, such that a generally rectangular tube is defined by the third, fourth, fifth and sixth air cell panels 120, 122, 124, 126. The third air cell panel 120 is then folded upwardly along fold lines 212, 216 such that it is generally perpendicular to the second and sixth air cell panels 118, 126, with the bottom surface 130 of the sixth air cell panel 126 facing, and preferably being in contact with, the top surface 128 of the second air cell panel 118. The second air cell panel 118 is then folded upwardly along fold line 190 and perforation lines 192, 198 such that it is generally perpendicular to the first and fifth air cell panels 116, 124, with the bottom surface 130 of the fifth air cell panel 124 facing, and preferably being in contact with, the top surface 128 of the first air cell panel 116. When the second air cell panel 118 is folded upwardly, the first tab 286 defined in the first air cell panel 116 extends outwardly beyond the bottom surface 130 of the second air cell panel 118 such that an aperture 358 is formed between the second air cell panel 118 and the first tab 286, with the aperture 358 being in line with the aperture 270 formed through the fifth air cell panel 124. The first air cell panel 116 is then folded upwardly along fold line 144 and perforation line 142 such that it is generally perpendicular to the fourth air cell panel 122 and the bottom panel 106, with the bottom surface 130 of the fourth air cell panel 122 facing, and preferably being in contact with, the top surface 128 of the bottom panel 106. The tab member 288 is then folded downwardly along perforated line 206 in order to close off the opening into the rectangular tube 360 formed by the folding of the air cell panels 116-126.
The fourth tab member 308 is then folded upwardly along fold line 336 and is moved through the aperture 234 provided through the third air cell panel 120 such that the bottom surfaces 130 of the first and second flap portions 340, 344 face the top surface 128 of the first and second portions 236, 238 of the third air cell panel 120. The bottom surfaces 130 of the first and second flap portions 340, 344 and/or the edges of the first and second flap portions 340, 344 defined by the cut line 312, 332 preferably contact the top surface 128 of the first and second portions 236, 238 of the third air cell panel 120. The securement of the fourth tab member 308 in this manner assists in retaining the air cell panels 116-126 in the configuration of the rectangular hollow tube 360 and further assists in maintaining the positioning of the air cell panels 116-126 over the bottom panel 106. In a preferred embodiment, although not necessary, adhesive 138 may be provided to secure the top surface 128 of the bottom panel 106 to the bottom surface 130 of the fourth air cell panel 122, to further assist in maintaining the positioning of the air cell panels 116-126 over the bottom panel 106.
The first side surface 354 of the filler 104 is positioned on the top surface 128 of the bottom panel 106 such that: (1) the first end surface 350 of the filler 104 is generally planar with the edge 136 of the bottom panel 106; (2) the second end surface 352 of the filler 104 is generally abutting against and/or facing the third air cell panel 120; (3) the lower surface 348 is generally planar to the fold line 132 and the perforated line 134; and (4) the second side surface 356 of the filler 104 is generally planar with the second air cell panel 118. In a preferred embodiment, although not necessary, the filler 104 is secured to the bottom panel 106 by an adhesive 361, such as glue applied to one or both of the first surface 354 of the filler 104 and the top surface 128 of the bottom panel 106.
With the air cell panels 116-126 formed in the rectangular tube 360 and the filler 104 in place as described hereinabove, the remainder of the panels are folded into place in order to form the corner sleeve 100 of the first embodiment of the invention. In a preferred embodiment, although not necessary, in order to assist in keeping the panels of the corner sleeve 100 held into position, an adhesive 362 is preferably applied to the bottom surface 130 of the second air cell panel 118 and an adhesive 364 is preferably applied to the second side surface 356 of the filler 104.
Fold-over panel 108 is folded upwardly and then downwardly along fold line 138 until the top surface 128 of the fold-over panel 108 abuts against or faces the top surface 128 of the bottom panel 106. Edge 148 of the fold-over panel 108 generally faces the top surface 346 of the filler 104, although it is angled relative thereto, and the edge 150 of the fold-over panel 108 generally faces and may abut the bottom surface 130 of the third air cell panel 120 of the rectangular tube 360.
Fold-over panel 114 is folded upwardly and then downwardly along fold line 176 until the top surface 128 of the fold-over panel 114 abuts against or faces the top surface 128 of the top panel 112. Edge 180 of the fold-over panel 114 is thus generally parallel to the edges 160, 172 of the top panel 112. Edge 182 of the fold-over panel 114 generally faces the top surface 346 of the filler 104, although it is angled relative thereto, and the edge 180 of the fold-over panel 114 generally faces and may abut the bottom surface 130 of the third air cell panel 120 of the rectangular tube 360.
Side panel 110 is folded upwardly along fold line 132 and perforated line 134 until it (and the top panel 112) is generally perpendicular to the bottom panel 106. The top surface 128 of the side panel 110 generally faces and abuts against the bottom surface 130 of the tab member 288 closing off the opening of the rectangular tube 360, and also generally faces and abuts against the bottom surface 348 of the filler 104.
Top panel 112 is then folded downwardly along fold line 154 and perforated line 156 until it is generally perpendicular with side panel 110 and generally parallel to bottom panel 106. Upon folding top panel 112 downwardly, tab member 300 is folded downwardly along fold line 306 until it is generally perpendicular to top panel 112. Tab member 300 is then inserted into the aperture 358 formed between the tab member 286 and the second air cell panel 118, and then into the aperture 270 provided through the fifth air cell panel 124 in order to hold the top panel 112 securely in position, thus forming the corner sleeve 100. If the adhesives 362, 364 are used, they would further assist in securing the top panel 112 in position.
As best illustrated in FIGS. 7 and 8, with the top panel 112 securely in position: the top surface 128 of the top panel 112 generally faces and abuts against the bottom surface 130 of the second air cell panel 118 of the rectangular tube 360 and against the second side surface 356 of the filler 104; the edges 160, 172 of the top panel 112 are generally planar with the bottom surface 130 of the first air cell panel 116; the edge 174 of the top panel 112 is generally planar with the edges 218, 284, 254, 140 of the rectangular tube 360; the bottom surface 130 of the fold-over panel 114 proximate to point P15 is in contact with the bottom surface 130 of the fold-over panel 108 proximate to point P7; space is provided between the top surface 128 of the fold-over panel 114 and the top surface 128 of the top panel 112 as the fold-over panel 114 is biased away from the top panel 112 in view of the fold line 176; space is provided between the top surface 128 of the fold-over panel 108 and the top surface 128 of the bottom panel 106 as the fold-over panel 108 is biased away from the bottom panel 106 in view of the fold line 138; space is provided between the bottom surface 130 of the fold-over panel 108 and the bottom surface 130 of the fold-over panel 114 where they are not touching and this space can be increased by forcing the fold-over panel 108 toward the bottom panel 106, thereby minimizing the space therebetween, and/or by forcing the fold-over panel 114 toward the top panel 112, thereby minimizing the space therebetween; and the bottom surface 130 of the tab member 300 generally faces and abuts against the top surface 128 of the first air cell panel 116; and gaps may be provided between the flexible fold-over panels 108, 114 and the filler 104 and the rectangular tube 360. The flexible fold-over panels 108, 114 assist in the entrapment and securement of the corner portions of flat style products, including but not limited to, dry erase boards and bulletin boards. The gaps generally do not assist in the entrapment and securement of the corner portions of flat style products.
Attention is now invited to FIGS. 2, 9 and 10, illustrating corner sleeve 400 and the formation thereof. Corner sleeve 400 is formed from a blank 402, a filler 104 (the same filler used in connection with forming corner sleeve 100 and, therefore, the description of filler 104 will not be repeated herein) and, if desired, adhesives, such as glue. The blank 402 is preferably formed from a sheet of a corrugated cardboard material, with the sheet preferably being 16.25 inches by 16.625 inches. The blank 402 is best illustrated in FIG. 9.
The blank 402 is generally identical to blank 102 except where discussed hereinbelow. It is to be understood that any panels, tabs, apertures, fold lines, perforated lines, cut lines and/or edges of blank 402 that are not specifically described hereinbelow are considered to be identical to that as described hereinabove with respect to blank 102, with like reference numerals denoting like elements.
Bottom panel 406 and fold-over panel 408 of the blank 402 are configured slightly differently than bottom panel 106 and fold-over panel 108 of the blank 102. Edge 148 is replaced with edges 447, 449 and 451 and fold line 138 is replaced with fold line 439.
From point P3, edge 447 extends angularly downwardly and to the right to point P59. From point P59, edge 449 extends angularly upwardly and to the right to point P60. From point P60, edge 451 extends to the right to point P7. Edge 451 is generally planar with edge 136. From point P59, fold line 439 extends angularly downwardly and to the right to point P4. Fold line 439 is generally planar and continuous with edge 447. Thus, bottom panel 406 is defined by fold line 132, perforated line 134, edges 136, 447, fold line 439, edge 140, perforated line 142, fold line 144 and edge 146. Likewise, fold-over panel 408 is thus defined by edges 449, 451, 150 and fold line 439.
Top panel 412 and fold-under panel 414 of the blank 402 are configured slightly differently than top panel 112 and fold-under panel 114 of the blank 102. Edge 182 is replaced with edges 481, 483 and 485 and fold line 176 is replaced with fold line 477.
From point P14, edge 481 extends angularly downwardly and to the left to point P61. From point P61, edge 483 extends angularly upwardly and to the left to point P62. From point P61, edge 485 extends to the left to point P15. Edge 485 is generally planar with edge 178. From point P61, fold line 477 extends angularly downwardly and to the left to point P13. Fold line 477 is generally planar and continuous with edge 481. Thus, top panel 406 is defined by fold line 154, perforated line 156, edges 178, 481, fold line 477 and edges 174, 172, 170, 168, 166, 164, 162, 160. Likewise, fold-under panel 414 is thus defined by edges 483, 485, 180 and fold line 477.
In a preferred embodiment, the blank 402 is formed from a sheet of corrugated cardboard material that is 16.25 inches by 16.625 inches and has the following dimensions: a straight distance from edge 136 to edge 282 is 16.25 inches; a distance from point P5 to point P12 is 16.625 inches; a distance from point P1 to point P5 is 7.5625 inches; a distance from point P1 to point P8 is 1.5 inches; a distance from point P8 to point P12 is 7.5625 inches; a distance from point P1 to point P2 is 7.5625 inches; a distance from point P5 to point P21 is 1.375 inches; a distance from point P21 to point P29 is 1.75 inches; a distance from point P29 to point P35 is 1.25 inches; a distance from point P35 to point P40 is 1.625 inches; a distance from point P40 to point P46 is 1.125 inches; a distance from point P46 to point P48 is 1.5625 inches; a distance from point P40 to point P39 is 1.5 inches; a distance from point P2 to point P3 is 0.8125 inches; a distance from point P6 to point P5 is 7.5 inches; a straight distance from perforated line 206 to edge 294 is 1.25 inches; a distance from point P18 to point P21 is 7.4375 inches; a distance from point P32 to point P35 is 7.5 inches; a distance from point P37 to point P40 is 7.3125 inches; a distance from point P24 to point P26 is 0.0625 inches; a distance from point P26 to pint P30 is 0.0625 inches; a distance from point P19 to point P20 is 2.0 inches; a distance from point P20 to point P21 is 1.5 inches; a distance from point P27 to point P28 is 1.5 inches; a distance from point P28 to point P29 is 1.75 inches; a distance from point P38 to point P39 is 2.0 inches; a distance from point P39 to point P40 is 1.5 inches; a distance from point P42 to point P43 is 0.125 inches; a straight distance from cut line 196 to cut line 214 is 1.5625 inches; a distance from point P10 to point P11 is 2.0 inches; a distance from point P11 to point P12 is 1.5 inches; a straight distance from edge 166 to fold line 306 is 1.0 inch; a distance from point P10 to point P49 is 0.125 inches; a distance from point P51 to point P58 is 1.5 inches; a straight distance from cut line 328 to fold line 342 is 0.5 inches; a straight distance from fold line 336 to perforated line 142 is 1.8125 inches; a distance from point P51 to point P52 is 0.25 inches; a distance from point P52 to point P53 is 0.875 inches; and a straight distance from point P59 to perforated line 134 is 1.5625.
The formation of the corner sleeve 400 begins with the formation of the rectangular tube 660 over the bottom panel 406 which is identical to the formation of the rectangular tube 360 of the corner sleeve 100 over the bottom panel 106 and, therefore, the description of the formation of the rectangular tube 660 will not be repeated herein for brevity purposes.
The first side surface 354 of the filler 104 is positioned on the top surface 128 of the bottom panel 406 such that: (1) the first end surface 350 of the filler 104 is generally spaced from and parallel with the edge 136 of the bottom panel 406; (2) the second end surface 352 of the filler 104 is generally abutting against and facing the third air cell panel 120; (3) the lower surface 348 of the filler 104 is generally planar to the fold line 132 and the perforated line 134; and (4) the second side surface 356 of the filler 104 is generally planar with the second air cell panel 118. In a preferred embodiment, although not necessary, the filler 104 is secured to the bottom panel 406 by an adhesive 361, such as glue applied to one or both of the first surface 354 of the filler 104 and the top surface 128 of the bottom panel 406.
With the air cell panels 116-126 formed in the rectangular tube 660 and the filler 104 in place as described hereinabove, the remainder of the panels are folded into place in order to form the corner sleeve 400 of the second embodiment of the invention. In a preferred embodiment, although not necessary, in order to assist in keeping the panels of the corner sleeve 400 held into position, an adhesive 362 is preferably applied to the bottom surface 130 of the second air cell panel 118 and an adhesive 364 is preferably applied to the second side surface 356 of the filler 104.
Fold-over panel 408 is folded upwardly and then downwardly along fold line 439 until the top surface 128 of the fold-over panel 408 abuts against or faces the top surface 128 of the bottom panel 406. Edge 449 of the fold-over panel 408 generally faces the top surface 346 of the filler 104 and the edge 150 of the fold-over panel 408 generally faces and may abut the bottom surface 130 of the third air cell panel 120 of the rectangular tube 660.
Fold-over panel 414 is folded upwardly and then downwardly along fold line 477 until the top surface 128 of the fold-over panel 414 abuts against or faces the top surface 128 of the top panel 412. Edge 483 of the fold-over panel 414 is generally parallel with edge 449 of the fold-over panel 408 and generally faces the top surface 346 of the filler 104. Edge 180 of the fold-over panel 414 is generally planar with edge 150 of the fold-over panel 408.
Side panel 110 is folded upwardly along fold line 132 and perforated line 134 until it (and the top panel 412) is generally perpendicular to the bottom panel 406. The top surface 128 of the side panel 110 generally faces and abuts against the bottom surface 130 of the tab member 288 closing off the opening of the rectangular tube 660, and also generally faces and abuts against the bottom surface 348 of the filler 104.
Top panel 412 is then folded downwardly along fold line 154 and perforated line 156 until it is generally perpendicular with side panel 110 and generally parallel to bottom panel 406. Upon folding top panel 412 downwardly, tab member 300 is folded downwardly along fold line 306 until it is generally perpendicular to top panel 412. Tab member 300 is then inserted into the aperture 358 formed between the tab member 286 and the second air cell panel 118, and then into the aperture 270 provided through the fifth air cell panel 124 in order to hold the top panel 412 securely in position, thus forming the corner sleeve 400. If the adhesives 362, 364 are used, they would further assist in securing the top panel 412 in position.
As best illustrated in FIG. 10, with the top panel 412 securely in position: the top surface 128 of the top panel 412 generally faces and abuts against the bottom surface 130 of the second air cell panel 118 of the rectangular tube 660 and against the second side surface 356 of the filler 104; the edges 160, 172 of the top panel 412 are generally planar with the bottom surface 130 of the first air cell panel 116; the edge 174 of the top panel 412 is generally planar with the edges 218, 284, 254, 140 of the rectangular tube 660; the bottom surface 130 of the fold-over panel 414 proximate to points P15, P62 is in contact with the bottom surface 130 of the fold-over panel 408 proximate to points P7, P60; space is provided between the top surface 128 of the fold-over panel 414 and the top surface 128 of the top panel 412 as the fold-over panel 414 is biased away from the top panel 412 in view of the fold line 477; space is provided between the top surface 128 of the fold-over panel 408 and the top surface 128 of the bottom panel 406 as the fold-over panel 408 is biased away from the bottom panel 406 in view of the fold line 439; space is provided between the bottom surface 130 of the fold-over panel 408 and the bottom surface 130 of the fold-over panel 414 where they are not touching and this space can be increased in size by forcing the fold-over panel 408 toward the bottom panel 406, thereby minimizing the space therebetween, and/or by forcing the fold-over panel 414 toward the top panel 412, thereby minimizing the space therebetween; the bottom surface 130 of the tab member 300 generally faces and abuts against the top surface 128 of the first air cell panel 116; and gaps may be provided between the flexible fold-over panels 408, 414 and the filler 104 and the rectangular tube 660. The flexible fold-over panels 408, 414 assist in the entrapment and securement of the corner portions of flat style products, including but not limited to, dry erase boards and bulletin boards. The gaps generally do not assist in the entrapment and securement of the corner portions of flat style products.
Attention is now invited to FIGS. 2, 9 and 11, illustrating corner sleeve 700 and the formation thereof. Corner sleeve 700 is formed from blank 402 (the same blank used in connection with forming corner sleeve 400 and, therefore, the description of blank 402 will not be repeated herein), a filler 704 and, if desired, adhesives, such as glue. The filler 704 is generally identical to the filler 104 used in forming the corner sleeves 100, 400, except in that the filler 704, in a preferred embodiment, has a width of 1.375 inches and a length of 5.75 inches.
The formation of the corner sleeve 700 is identical to the formation of the corner sleeve 400, except as it relates to the filler 704 being used instead of the filler 104, as will be discussed herein. The remainder of the description of the formation of the corner sleeve 700 therefore will not be discussed.
The first side surface 954 of the filler 704 is positioned on the top surface 128 of the bottom panel 406 such that: (1) the first end surface 950 of the filler 704 is generally planar with the edge 136 of the bottom panel 406; (2) the second end surface 952 of the filler 704 is generally facing and abutting against the third air cell panel 120; (3) the lower surface 948 is generally planar to the fold line 132 and the perforated line 134; (4) the second side surface 956 of the filler 704 is generally planar with the second air cell panel 118; (5) a generally triangular portion of the first side surface 954 of the filler 704 extends beyond the edge 447 of the bottom panel 406; and (6) a generally triangular portion of the second side surface 956 of the filler 704 extends beyond the edge 481 of the top panel 412. In a preferred embodiment, although not necessary, the filler 704 is secured to the bottom panel 406 by an adhesive 361, such as glue applied to one or both of the first surface 954 of the filler 704 and the top surface 128 of the bottom panel 406.
With the air cell panels 116-126 formed in the rectangular tube 660 and the filler 704 in place as described hereinabove, the remainder of the panels are folded into place in order to form the corner sleeve 700 of the third embodiment of the invention. In a preferred embodiment, although not necessary, in order to assist in keeping the panels of the corner sleeve 700 held into position, an adhesive 362 is preferably applied to the bottom surface 130 of the second air cell panel 118 and an adhesive 364 is preferably applied to the second side surface 956 of the filler 704.
Fold-over panel 408 is folded upwardly and then downwardly along fold line 439 until the top surface 128 of the fold-over panel 408 abuts against or faces the top surface 128 of the bottom panel 406. Edge 449 of the fold-over panel 408 generally faces and preferably at least partially abuts against the top surface 346 of the filler 704 and the edge 150 of the fold-over panel 408 generally faces and may abut the bottom surface 130 of the third air cell panel 120 of the rectangular tube 660.
Fold-over panel 414 is folded upwardly and then downwardly along fold line 477 until the top surface 128 of the fold-over panel 414 abuts against or faces the top surface 128 of the top panel 412. Edge 483 of the fold-over panel 414 is generally planar with edge 449 of the fold-over panel 408 and generally faces and preferably at least partially abuts against the top surface 346 of the filler 704. Edge 180 of the fold-over panel 414 is generally planar with edge 150 of the fold-over panel 408 and generally faces and may abut the bottom surface 130 of the air cell panel 120 of the rectangular tube 660.
Side panel 110 is folded upwardly along fold line 132 and perforated line 134 until it (and the top panel 412) is generally perpendicular to the bottom panel 406. The top surface 128 of the side panel 110 generally faces and abuts against the bottom surface 130 of the tab member 288 closing off the opening of the rectangular tube 660, and also generally faces and abuts against the bottom surface 348 of the filler 704.
Top panel 412 is then folded downwardly along fold line 154 and perforated line 156 until it is generally perpendicular with side panel 110 and generally parallel to bottom panel 406. Upon folding top panel 412 downwardly, tab member 300 is folded downwardly along fold line 306 until it is generally perpendicular to top panel 412. Tab member 300 is then inserted into the aperture 358 formed between the tab member 286 and the second air cell panel 118, and then into the aperture 270 provided through the fifth air cell panel 124 in order to hold the top panel 412 securely in position, thus forming the corner sleeve 700. If the adhesives 362, 364 are used, they would further assist in securing the top panel 412 in position.
As best illustrated in FIG. 11, with the top panel 412 securely in position: the top surface 128 of the top panel 412 generally faces and abuts against the bottom surface 130 of the second air cell panel 118 of the rectangular tube 660 and against the second side surface 356 of the filler 704; the edges 160, 172 of the top panel 412 are generally planar with the bottom surface 130 of the first air cell panel 116; the edge 174 of the top panel 412 is generally planar with the edges 218, 284, 254, 140 of the rectangular tube 660; the bottom surface 130 of the fold-over panel 414 proximate to points P15, P62 is in contact with the bottom surface 130 of the fold-over panel 408 proximate to points P7, P60; space is provided between the top surface 128 of the fold-over panel 414 and the top surface 128 of the top panel 412 as the fold-over panel 414 is biased away from the top panel 412 in view of the fold line 477; space is provided between the top surface 128 of the fold-over panel 408 and the top surface 128 of the bottom panel 406 as the fold-over panel 408 is biased away from the bottom panel 406 in view of the fold line 439; space is provided between the bottom surface 130 of the fold-over panel 408 and the bottom surface 130 of the fold-over panel 414 where they are not touching and this space can be increased in size by forcing the fold-over panel 408 toward the bottom panel 406, thereby minimizing the space therebetween, and/or by forcing the fold-over panel 414 toward the top panel 412, thereby minimizing the space therebetween; the bottom surface 130 of the tab member 300 generally faces and abuts against the top surface 128 of the first air cell panel 116; and gaps may be provided between the flexible fold-over panels 408, 414 and the filler 704 and the rectangular tube 660. The flexible fold-over panels 408, 414 assist in the entrapment and securement of the corner portions of flat style products, including but not limited to, dry erase boards and bulletin boards. The gaps generally do not assist in the entrapment and securement of the corner portions of flat style products.
Attention is now invited to FIGS. 12-20, illustrating the corner sleeve 1000 and the formation thereof. Corner sleeve 1000 is formed from blank 1002, a filler 1004 and, if desired, adhesives, such as glue. The blank 1002 is preferably formed from a sheet of a corrugated cardboard material, with the sheet preferably being 21.125 inches by 24.875 inches. The blank 1002 is best illustrated in FIG. 12.
The blank 1002 is generally identical to blank 402 except where discussed hereinbelow. It is to be understood that any panels, tabs, apertures, fold lines, perforated lines, cut lines and/or edges of blank 1002 that are not specifically described hereinbelow are considered to be identical to that as described hereinabove with respect to blank 402, with like reference numerals denoting like elements.
Bottom panel 1006 and fold-over panel 1008 of the blank 1002 are configured slightly differently than bottom panel 406 and fold-over panel 408 of the blank 402. Edge 449, 451, 150 are replaced with edges 1053, 1055, 1057, 1059 and fold line 439 is replaced with fold line 1041.
From point P59, edge 1053 extends to the right to point P63. From point P63, edge 1055 angles downwardly and to the right to point P64. From point P64, edge 1057 extends downwardly to point P65. From point P65, edge 1059 extends angularly downwardly and to the right to point P4. Edge 1059 is generally planar with edge 447. From point P59, fold line 1041 extends angularly downwardly and to the right to point P65. Fold line 439 is generally planar and continuous with edges 447, 1059. Thus, bottom panel 1006 is defined by fold line 132, perforated line 134, edges 136, 447, fold line 1041, edges 1059, 140, perforated line 142, fold line 144 and edge 146. Likewise, fold-over panel 1008 is thus defined by edges 1053, 1055, 1057 and fold line 1041.
Top panel 1012 and fold-under panel 1014 of the blank 1002 are configured slightly differently than bottom panel 406 and fold-over panel 408 of the blank 402. Edge 483, 485, 180 are replaced with edges 1087, 1089, 1091, 1093 and fold line 477 is replaced with fold line 1079.
From point P61, edge 1087 extends to the left to point P66. From point P66, edge 1089 angles downwardly and to the left to point P67. From point P67, edge 1091 extends downwardly to point P68. From point P68, edge 1093 extends angularly downwardly and to the left to point P13. Edge 1093 is generally planar with edge 481. From point P61, fold line 1079 extends angularly downwardly and to the left to point P68. Fold line 1079 is generally planar and continuous with edges 481, 1093. Thus, bottom panel 1012 is defined by fold line 154, perforated line 156, edges 178, 481, fold line 1079 and edges 1093, 174, 172, 170, 168, 166, 164, 162, 160. Likewise, fold-under panel 1014 is thus defined by edges 1087, 1089, 1091 and fold line 1079.
Tab member 1208 of the blank 1002 is configured slightly differently than tab member 308 of the blank 402. Cut lines 324, 326, 328 are replaced with cut line 1225. From point P54, cut line 1225 extends angularly downwardly and to the right to connect with cut line 330. Unlike angled cut line 326, which is provided along fold lines 138, 439, cut line 1225 is not provided along fold line 1041, but rather is spaced from and parallel to fold line 1041. The second flap portion 1244 of the tab member 1208 is thus defined by fold line 342 and cut lines 325, 330, 332.
In a preferred embodiment, the blank 1002 is formed from a sheet of corrugated cardboard material that is 21.125 inches by 24.875 inches and has the following dimensions: a straight distance from edge 136 to edge 282 is 21.125 inches; a distance from point P5 to point P12 is 24.875 inches; a distance from point P1 to point P5 is 11.6875 inches; a distance from point P1 to point P8 is 1.5 inches; a distance from point P8 to point P12 is 11.6875 inches; a distance from point P1 to point P2 is 11.6875 inches; a distance from point P5 to point P21 is 1.375 inches; a distance from point P21 to point P29 is 2.0 inches; a distance from point P29 to point P35 is 1.25 inches; a distance from point P35 to point P40 is 1.875 inches; a distance from point P40 to point P46 is 1.125 inches; a distance from point P46 to point P48 is 1.8125 inches; a distance from point P40 to point P39 is 2.0 inches; a distance from point P2 to point P3 is 2.0625 inches; a distance from point P1 to perforated line 134 is 3.0 inches; a distance from point P6 to perforated line 142 is 3.0 inches; a distance from point P6 to point P5 is 11.625 inches; a straight distance from perforated line 206 to edge 294 is 1.25 inches; a distance from point P18 to point P21 is 11.5625 inches; a distance from point P32 to point P35 is 11.625 inches; a distance from point P37 to point P40 is 11.4375 inches; a distance from point P24 to point P26 is 0.0625 inches; a distance from point P26 to pint P30 is 0.0625 inches; a distance from point P19 to point P20 is 2.0 inches; a distance from point P20 to point P21 is 2.0 inches; a distance from point P27 to point P28 is 1.75 inches; a distance from point P28 to point P29 is 2.25 inches; a distance from point P38 to point P39 is 2.0 inches; a distance from point P39 to point P40 is 2.0 inches; a distance from point P42 to point P43 is 0.125 inches; a straight distance from cut line 196 to cut line 214 is 1.8125 inches; a distance from point P10 to point P11 is 2.0 inches; a distance from point P11 to point P12 is 2.0 inches; a straight distance from edge 166 to fold line 306 is 1.0 inch; a distance from point P10 to point P49 is 0.125 inches; a distance from point P51 to point P58 is 1.5 inches; a straight distance from cut line 316 to fold line 338 is 0.5 inches; a straight distance from fold line 336 to perforated line 142 is 2.0625 inches; a distance from point P51 to point P52 is 0.25 inches; a distance from point P52 to point P53 is 0.875 inches; a distance from point P63 to perforated line 142 is 10.5625; and a distance from point P64 to perforated line 134 is 11.0625 inches.
The filler 1004 is best illustrated in FIG. 14. Filler 1004 is formed from a blank 1305 which is preferably formed of a corrugated cardboard material, with the sheet preferably being 8.9375 inches by 9.625 inches. The blank 1305 is best illustrated in FIG. 13.
The blank 1305 provides a plurality of panels, including a first panel 1307, a second panel 1309, a third panel 1311, a fourth panel 1313 and a fifth panel 1315. The blank 1305 has a top surface 1317, as shown in FIG. 13, and a bottom surface 1319.
First panel 1307 is described with reference to points P70-P77. From point P70, edge 1321 extends upwardly to point P71. From point P71, fold line 1323 extends to the right to point P72. From point P72, cut line 1325 extends downwardly to point P73. From point P73, cut line 1327 extends to the right to point P74. From point P74, cut line 1329 extends upwardly to point P75. From point P75, fold line 1331 extends to the right to point P76. From point P76, edge 1333 extends downwardly to point P77. From point P77, edge 1335 extends to the left to point P70.
Second panel 1309 is described with references to points P71-P76, P78 and P79, and includes fold lines 1323, 1331 and cut lines 1325, 1327, 1329. From point P71 edge 1337 extends upwardly to point P78. From point P78, fold line 1339 extends to the right to point P79. From point P79, edge 1341 extends downwardly to point P76.
Third panel 1311 is described with reference to points P78-P81, and includes fold line 1339. From point P78, edge 1343 extends upwardly to point P80. From point P80, fold line 1345 extends to the right to point P81. From point P81, edge 1347 extends downwardly to point P79.
Fourth panel 1313 is described with reference to points P80-P83, and includes fold line 1345. From point P80, edge 1349 extends upwardly to point P82. From point P82, fold line 1351 extends to the right to point P83. From point P83, edge 1353 extends downwardly to point P81.
Fifth panel 1315 is described with reference to points P82-P87, and includes fold line 1351. From point P82, edge 1355 extends upwardly to point P84. From point P84, edge 1357 extends to the right to point P85. From point P85, edge 1359 extends upwardly to edge 1361. From the connection with edge 1359, edge 1361 curves upwardly and to the right to edge 1363. From the connection with edge 1361, edge 1363 extends to the right to edge 1365. From the connection with edge 1363, edge 1365 curves downwardly and to the right to edge 1367. From the connection with edge 1365, edge 1367 extends downwardly to point P86. From point P86, edge 1369 extends to the right to point P87. From point P87, edge 1371 extends downwardly to point P83.
The blank 1305 also defines first and second tab members 1373, 1375. Tab member 1373 is defined as a part of the second panel 1309 by cut lines 1325, 1327, 1329. Tab member 1375 is defined as a part of the fifth panel 1315 by edges 1359, 1361, 1363, 1365, 1367 and cut line 1377, fold line 1379 and cut line 1381. From point P85, cut line 1377 extends downwardly to point P88. From point P88, fold line 1379 extends to the right to point P89. From point P89, cut line extends upwardly to point P86.
In a preferred embodiment, the blank 1305 is formed from a sheet of corrugated cardboard material that is 8.9375 inches by 9.625 inches and has the following dimensions: a straight distance from edge 1335 to edge 1363 is 8.9375 inches; a distance from point P70 to point P77 is 9.625 inches; a distance from point P70 to point P71 is 1.8125 inches; a distance from point P71 to point P78 is 1.125 inches; a distance from point P78 to point P80 is 1.875 inches; a distance from point P80 to point P82 is 1.25 inches; a distance from point P82 to point P84 is 1.9375 inches; a straight distance from fold line 1351 to point P88 is 1.75 inches; a straight distance from fold line 1379 to edge 1363 is 1.125 inches; a distance from point P85 to point P88 is 0.1875 inches; a distance from point P84 to point P85 is 3.625 inches; a distance from point P85 to point P86 is 2.375 inches; a distance from point P71 to point P72 is 3.625 inches; a distance from point P72 to point P75 is 2.375 inches; and a distance from point P72 to point P73 is 0.1875 inches.
Attention is now invited to FIGS. 15-19 which will illustrate the formation of the corner sleeve 1000. The formation of the corner sleeve 1000 preferably begins with the formation of the filler 1004. In order to form the filler 1004, the blank 1305 is folded and preferably secured to itself in the following manner. The first panel 1307 is folded upwardly along fold line 1323, 1331 until it is generally perpendicular to the second panel 1309. The folding of the first panel 1307 relative to the second panel 1309 forms an aperture (not shown) through the blank 1305 between the tab 1373 and cut lines 1325, 1327, 1329. The second panel 1309 is folded upwardly along fold line 1339 until it is generally perpendicular to the third panel 1311, such that the first panel 1307 is generally spaced from, but parallel to, the third panel 1311. The third panel 1311 is folded upwardly along fold line 1345 until it is generally perpendicular to the fourth panel 1313, such that the second panel 1309 is generally spaced from, but parallel to, the fourth panel 1313. The edge 1335 of the blank 1305 contacts the top surface 1317 of the fourth panel 1313 proximate the fold line 1351, such that a generally rectangular tube is formed by the first, second, third and fourth panels 1307, 1309, 1311, 1313. The fourth panel 1313 is folded upwardly along fold line 1351 until it is generally perpendicular to the fifth panel 1315 such that the top surface 1317 of the fifth panel 1315 is facing and abutting against the bottom surface 1319 of the first panel 1307. The tab member 1375 is folded along fold line 1379 and is inserted into the aperture formed by folding the first panel 1307 relative to the second panel 1309 such that the panels 1307, 1309, 1311, 1313, 1315 are held in place in the configuration of the hollow rectangular tube forming the filler 1004.
With the filler 1004 formed, the rectangular tube 1260 over the bottom panel 1006 is formed, which is identical to the formation of the rectangular tube 360 of the corner sleeve 100 over the bottom panel 106 and, therefore, the description of the formation of the rectangular tube 1260 will not be repeated herein for brevity purposes.
The bottom surface 1319 of the third panel 1311 of the filler 1004 is positioned on the top surface 128 of the bottom panel 1006 such that: (1) the edges 1321, 1337, 1343, 1349, 1355 of the filler 1004 are generally planar with the edge 136 of the bottom panel 1006; (2) the edges 1333, 1341, 1347, 1353, 1371 of the filler 1004 are generally positioned to face and preferably abut the third air cell panel 120; (3) the bottom surface 1319 of the second panel 1309 is generally planar to the fold line 132 and the perforated line 134; and (4) the bottom surface 1319 of the fifth panel 1315 is generally planar with the second air cell panel 118. In a preferred embodiment, although not necessary, the filler 1004 is secured to the bottom panel 1006 by an adhesive 361, such as glue applied to one or both of the bottom surface 1319 of the third panel 1311 of the filler 1004 and the top surface 128 of the bottom panel 1006.
With the air cell panels 116-126 formed in the rectangular tube 1260 and the filler 1004 in place as described hereinabove, the remainder of the panels are folded into place in order to form the corner sleeve 1000 of the fourth embodiment of the invention. In a preferred embodiment, although not necessary, in order to assist in keeping the panels of the corner sleeve 1000 held into position, an adhesive 362 is preferably applied to the bottom surface 130 of the second air cell panel 118 and an adhesive 364 is preferably applied to the bottom surface 1319 of the fifth panel 1315 of the filler 1004.
Fold-over panel 1008 is folded upwardly and then downwardly along fold line 1041 until the top surface 128 of the fold-over panel 1008 abuts against or faces the top surface 128 of the bottom panel 1006. Edge 1053 of the fold-over panel 1008 is spaced from, and generally faces in parallel alignment, the bottom surface 1319 of the fourth panel 1313 of the filler 1004. Edge 1057 of the fold-over panel 1008 is spaced from, and generally faces in parallel alignment, the bottom surface 130 of the third air cell panel 120 of the rectangular tube 1260.
Fold-over panel 1014 is folded upwardly and then downwardly along fold line 1079 until the top surface 128 of the fold-over panel 1014 abuts against or faces the top surface 128 of the top panel 1012. Edge 1087 of the fold-over panel 1014 is generally parallel with edge 1053 of the fold-over panel 1008 and generally faces the bottom surface 1319 of the second panel 1309 of the filler 1004. Edge 1091 of the fold-over panel 1014 is generally planar with edge 1057 of the fold-over panel 1008.
Side panel 110 is folded upwardly along fold line 132 and perforated line 134 until it (and the top panel 1012) is generally perpendicular to the bottom panel 1006. The top surface 128 of the side panel 110 generally faces and abuts against the bottom surface 130 of the tab member 288 closing off the opening of the rectangular tube 1260, and also generally faces and abuts against the bottom surface 1319 of the second panel 1309 of the filler 1004 and the edges 1357, 1369 of the filler 1004.
Top panel 1012 is then folded downwardly along fold line 154 and perforated line 156 until it is generally perpendicular with side panel 110 and generally parallel to bottom panel 1006. Upon folding top panel 1012 downwardly, tab member 300 is folded downwardly along fold line 306 until it is generally perpendicular to top panel 1012. Tab member 300 is then inserted into the aperture 1258 formed between the tab member 286 and the second air cell panel 118, and then into the aperture 270 provided through the fifth air cell panel 124 in order to hold the top panel 1012 securely in position, thus forming the corner sleeve 1000. If the adhesives 362, 364 are used, they would further assist in securing the top panel 1012 in position.
As best illustrated in FIGS. 19 and 20, with the top panel 1012 securely in position: the top surface 128 of the top panel 1012 generally faces and abuts against the bottom surface 130 of the second air cell panel 118 of the rectangular tube 1260 and against the bottom surface 1319 of the fifth panel 1315 of the filler 1004; the edges 160, 172 of the top panel 1012 are generally planar with the bottom surface 130 of the first air cell panel 116; the edge 174 of the top panel 1012 is generally planar with the edges 218, 284, 254, 140 of the rectangular tube 1260; the bottom surface 130 of the fold-over panel 1014 proximate to points P66, P67 is in contact with the bottom surface 130 of the fold-over panel 1008 proximate to points P63, P64; space is provided between the top surface 128 of the fold-over panel 1014 and the top surface 128 of the top panel 1012 as the fold-over panel 1014 is biased away from the top panel 1012 in view of the fold line 1079; space is provided between the top surface 128 of the fold-over panel 1008 and the top surface 128 of the bottom panel 1006 as the fold-over panel 1008 is biased away from the bottom panel 1006 in view of the fold line 1041; space is provided between the bottom surface 130 of the fold-over panel 1008 and the bottom surface 130 of the fold-over panel 1014 where they are not touching and this space can be increased in size by forcing the fold-over panel 1008 toward the bottom panel 1006, thereby minimizing the space therebetween, and/or by forcing the fold-over panel 1014 toward the top panel 1012, thereby minimizing the space therebetween; the bottom surface 130 of the tab member 300 generally faces and abuts against the top surface 128 of the first air cell panel 116; and a continuous generally L-shaped channel 1385 is defined between: (1) the bottom surface 1319 of the fourth panel 1313 of the filler 1004; (2) the bottom surface 130 of the third air cell panel 120 of the rectangular tube 1260; (3) the edges 1059, 1093 of the top and bottom panels 1006, 1012, respectively; (4) the edges 1057, 1091 of the fold-over panels 1008, 1014, respectively; (5) the edges 1055, 1089 of the fold-over panels 1008, 1014, respectively; (6) the edges 1053, 1087 of the fold-over panels 1008, 1014, respectively; and (7) the edges 447, 481 of the top and bottom panels 1006, 1012, respectively. The flexible fold-over panels 1008, 1014 and the L-shaped channel 1385 assist in the entrapment and securement of the corner portions of flat style products, including but not limited to, dry erase boards and bulletin boards.
Attention is now invited to FIGS. 12-14 and 21, illustrating the corner sleeve 1400 and the formation thereof. Corner sleeve 1400 is formed from blank 1002 (the same blank used in connection with forming corner sleeve 1000 and, therefore, the description of blank 1002 will not be repeated herein), a filler 1404 and, if desired, adhesives, such as glue. The filler 1404 is generally identical to the filler 1004 used in forming the corner sleeve 1000 except in that the blank 1705 used to form the filler 1404, in a preferred embodiment, is larger than the blank 1305 used to form the filler 1004 and, as such, the filler 1404 is larger than the filler 1004. The blank 1705 is folded to form the filler 1404 in the same manner as the blank 1305 is folded in order to form the filler 1004.
In a preferred embodiment, the blank 1705 is formed from a sheet of corrugated cardboard material that is 10.25 inches by 9.625 inches and has dimensions which are identical to those in the preferred embodiment of the blank 1305, except for the following dimensions: a straight distance from edge 1335 to edge 1363 is 10.25 inches; a distance from point P70 to point P77 is 9.625 inches; a distance from point P70 to point P71 is 2.25 inches; a distance from point P78 to point P80 is 2.3125 inches; a distance from point P82 to point P84 is 2.375 inches; and a straight distance from fold line 1351 to point P88 is 2.1875 inches.
The only difference between the formation of the corner sleeve 1400 and the corner sleeve 1000 relates to the larger filler 1404 being used instead of the smaller filler 1004. As best illustrated in FIG. 21, the bottom surface 1319 of the third panel 1311 of the filler 1404 is positioned on the top surface 128 of the bottom panel 1006 such that: (1) the edges 1321, 1337, 1343, 1349, 1355 of the filler 1404 are generally planar with the edge 136 of the bottom panel 1006; (2) the edges 1333, 1341, 1347, 1353, 1371 of the filler 1404 are generally positioned to face and preferably abut the third air cell panel 120; (3) the bottom surface 1319 of the second panel 1309 is generally planar to the fold line 132 and the perforated line 134; (4) the bottom surface 1319 of the fifth panel 1315 is generally planar with the second air cell panel 118; (5) a generally triangular portion of the third panel 1311 extends beyond the edge 447 of the bottom panel 1006; and (6) a generally triangular portion of the fifth panel 1315 extends beyond the edge 481 of the top panel 1012. In a preferred embodiment, although not necessary, the filler 1404 is secured to the bottom panel 1006 by an adhesive 361, such as glue applied to one or both of the third panel 1311 of the filler 1404 and the top surface 128 of the bottom panel 1006.
Upon completion of the folding process with the top panel 1012 securely in position, a continuous generally L-shaped channel 1785 is defined between: (1) the bottom surface 1319 of the fourth panel 1313 of the filler 1404; (2) the bottom surface 130 of the third air cell panel 120 of the rectangular tube 1260; (3) the edges 1059, 1093 of the top and bottom panels 1006, 1012, respectively; (4) the edges 1057, 1091 of the fold-over panels 1008, 1014, respectively; (5) the edges 1055, 1089 of the fold-over panels 1008, 1014, respectively; (6) the edges 1053, 1087 of the fold-over panels 1008, 1014, respectively; and (7) the edges 447, 481 of the top and bottom panels 1006, 1012, respectively. The L-shaped channel 1785 formed in the corner sleeve 1400 is generally identical to the L-shaped channel 1385 formed in the corner sleeve 1000, with the exception that the width of the L-shaped channel 1785 provided between the filler 1404 and the fold-over panels 1008, 1014 is smaller than the width of the L-shaped channel 1385 provided between the filler 1004 and the fold-over panels 1008, 1014. The flexible fold-over panels 1008, 1014 and the L-shaped channel 1785 assist in the entrapment and securement of the corner portions of flat style products, including but not limited to, dry erase boards and bulletin boards.
Each of the corner sleeves 100, 400, 700, 1000, 1400 are typically used to protect the corner portions of flat style products, including but not limited to, dry erase boards and bulletin boards. An example of such a flat style product 20 is illustrated in FIGS. 22-24. The product 20 includes a rectangular board 22 and a frame 24 that surrounds the edges of the board 22. From the edges, the frame 24 has a first raised portion 26 that is distanced from a backside of the board 22 and a second lowered portion 28 that is preferably positioned against the backside of the board 22. In larger products 20, the frame 24 is generally provided around all four edges of the board 22, but with smaller products 20, the frame 24 may only be provided around the two shorter edges of the board 22.
In the packaging of larger products 20, one type of the corner sleeves 1000, 1400 is typically used in order to protect corner portions 30 thereof. The larger products 20 are typically packaged at two separate stations, the first where the corner sleeves 1000, 1400 are secured in place around the corner portions 30 of the larger products 20 and the second where a secondary packaging (not shown) is used to further protect the larger products 20 by securing material around the corner sleeves 1000, 1400 and the exposed frame 24 between adjacent corner sleeves 1000, 1400. Because the larger products 20 are moved to a second station after the securement of the corner sleeves 1000, 1400, the corner sleeves 1000, 1400 preferably are provided with the L-shaped channels 1385, 1785. The L-shaped channels 1385, 1785 provide for extra protection to the corner portions 30 of the larger products 20.
As best illustrated in FIGS. 25 and 26, when a corner portion 30 of the larger product 20 is inserted into the space between the fold-over panels 1008, 1014 of the corner sleeves 1000, 1400 (illustrated with reference to corner sleeve 1400), the fold-over panels 1008, 1014 are forced away from one another to enlarge the space therebetween in order to accommodate the corner portion 30 of the larger product 20. Upon the first raised portion 26 of the frame 24 being forced past the fold-over panels 1008, 1014 and into the L-shaped channels 1385, 1785, the fold-over panels 1008, 1014 spring back toward one another, thus locking the first raised portion 26 of the frame 24 within the L-shaped channels 1385, 1785 of the corner sleeves 1000, 1400. The corner portion 30 of the larger product 20 is further held in place between the fold-over panels 1008, 1014 due to the springing action of the fold-over panels 1008, 1014 causing the fold-over panels 1008, 1014 to be biased toward one another to decrease the space therebetween. Thus, the friction force between the corner portion 30 of the larger product 20 and the fold-over panels 1008, 1014 will hold the corner portion 30 of the larger product 20 in place within the corner sleeves 1000, 1400. The corner portion 30 of the larger product 20 thus cannot be removed from the corner sleeve 1000, 1400 unless and until the fold-over panels 1008, 1014 are forced away from one another, overcoming the bias, in order to allow the first raised portion 26 of the frame 24 to move over and past the fold-over panels 1008, 1014. This extra protection provided by the provision of the L-shaped channels 1385, 1785 in the corner sleeves 1000, 1400 allows for the larger products 20 with the corner sleeves 1000, 1400 thereon to be transferred from the first packaging station to the second packaging station without concern for possible damage of the corner portions 30 of the larger products 20 during this transferring process.
The rectangular tubes 1260 of the corner sleeves 1000, 1400 act as cushioning air cells along one edge of the corner portion 30 of the larger product 20 in order to provide protection to that edge of the corner portion 30 of the larger product 20. The fillers 1004, 1404 of the corner sleeves 1000, 1400 act as cushions along the other edge of the corner portion 30 of the larger product 20 in order to provide protection to that edge of the corner portion 30 of the larger product 20. The difference in the sizes of the fillers 1004, 1404 and thus the L-shaped channels 1385, 1785 of the corner sleeves 1000, 1400 allow for an appropriately sized corner sleeve 1000, 1400 to be used to protect the corner portions 30 of the varying larger products 20 to ensure that the corner sleeves 1000, 1400 are as snugly fit as possible around the corner portions 30 of the larger products 20. It should be noted that, if desired, corner sleeves of sizes other than corner sleeves 1000, 1400 could be formed using different sized/shaped blanks and different sized/shaped fillers. It should further be noted that, if desired, the material from which the fillers 1004, 1404 are formed could be changed to any other material that would protect the edge of the larger products 20, for instance polyethylene foam material like that from which the fillers 104, 704 are formed or other relatively lightweight materials.
In the packaging of smaller products 20, one type of the corner sleeves 100, 400, 700 is typically used in order to protect the corner portions 30 thereof. Unlike the packaging of the larger products 20, the smaller products 20 are typically packaged at a single station where the corner sleeves 100, 400, 700 are first secured in place around the corner portions 30 of the smaller products 20 and, thereafter, a secondary packaging (not shown) is used to further protect the smaller products 20 by securing material around the corner sleeves 100, 400, 700 and the exposed frame 24 between adjacent corner sleeves 100, 400, 700. Because the smaller products 20 are not typically moved to a second station after the securement of the corner sleeves 100, 400, 700, the corner sleeves 100, 400, 700 preferably are not provided with the L-shaped channels 1385, 1785 that are provided for in the corner sleeves 1000, 1400 (although gaps are provided, these gaps generally do not serve any purpose in corner sleeves 100, 400, 700) as there is not the need for the extra protection provided by the corner sleeves 1000, 1400 due to the provision of the L-shaped channels 1385, 1785.
As such, when a corner portion 30 of the smaller product 20 is inserted into the space between the fold-over panels 108, 114 of the corner sleeve 100 or the space between the fold-over panels 408, 414 of the corner sleeves 400, 700, the fold-over panels 108, 114; 408, 414 are moved away from one another to enlarge the space therebetween in order to accommodate the corner portion 30 of the smaller product 20. The corner portion 30 of the smaller product 20 is held in place between the fold-over panels 108, 114; 408, 414 due to the springing action of the fold-over panels 108, 114; 408, 414 causing the fold-over panels 108, 114; 408, 414 to be biased toward one another to decrease the space therebetween. Thus, the friction force between the corner portion 30 of the smaller product 20 and the fold-over panels 108, 114; 408, 414 will hold the corner portion 30 of the smaller product 20 in place within the corner sleeves 100, 400, 700.
The rectangular tubes 360, 660 of the corner sleeves 100, 400, 700 act as cushioning air cells along one edge of the corner portion 30 of the smaller product 20 in order to provide protection to that edge of the corner portion 30 of the smaller product 20. The fillers 104, 704 of the corner sleeves 100, 400, 700 act as cushions along the other edge of the corner portion 30 of the smaller product 20 in order to provide protection to that edge of the corner portion 30 of the smaller product 20. The difference in the sizes of the rectangular tubes 360, 660 and the fillers 104, 704 of the corner sleeves 100, 400, 700 allow for an appropriately sized corner sleeve 100, 400, 700 to be used to protect the corner portions 30 of the varying smaller products 20 to ensure that the corner sleeves 100, 400, 700 are as snugly fit as possible around the corner portions 30 of the smaller products 20. It should be noted that, if desired, corner sleeves of sizes other than corner sleeves 100, 400, 700 could be formed using different sized/shaped blanks and different sized/shaped fillers. It should further be noted that, if desired, the material from which the fillers 104, 704 are formed could be changed to any other material that would protect the edges of the smaller products 20, for instance corrugated cardboard material like that from which the fillers 1004, 1404 are formed or other relatively lightweight materials.
If desired, each of the corner sleeves 100, 400, 700, 1000, 1400 may also be provided with a cut-out (illustrated in FIGS. 27 and 28 as reference numeral 390 in connection with corner sleeve 100). The cut-out 390 may be provided in the bottom and fold-over panels 106, 108; 406, 408; 1006, 1008 along fold-lines 138; 439; 1041, respectively, and/or in the top and fold-over panels 112, 114; 412, 414; 1012, 1014 along fold lines 176; 477; 1079, respectively. The cut-out 390 may be provided in order to hold in position during shipping and storage an elongated corrugated insert 40 for holding, for example, a detached marker tray (not shown) associated with the product 20. The insert 40 is placed diagonally across the product 20 and is held into position at each end by the cut-out 390 of the corner sleeves 100, 400, 700, 1000, 1400.
In the drawings of the blanks 102, 402, 1002, 1305, 1705, fold lines are denoted by dashed lines, cut lines within the confines of the blanks 102, 402, 1002, 1305, 1705 are denoted by solid lines, and perforated lines are denoted by alternating dashed and solid lines. It is also to be understood that the drawings do not generally illustrate the thickness of the blanks 102, 402, 1002, 1305, 1705 for clarity purposes. In the preferred embodiment, the blanks 102, 402, 1002, 1305, 1705 have a thickness of one-eighth (0.125) inches, but may also have other thicknesses, such as three-sixteenths (0.1875) inches, for example.
The corner sleeves 100, 400, 700, 1000, 1400 provide a number of benefits when used in connection with protecting the corner portions 30 of a product 20, such as dry erase boards or bulletin boards, during shipping and storage. Each of the corner sleeve 100, 400, 700, 1000, 1400 provides a corrugated air cell roll- up 360, 660, 1260 on one side thereof, which are formed from the blanks 102, 402, 1002, in order to cushion and protect that side of the product 20 at the corner. On the other, second side of the corner sleeves 100, 400, 700, 1000, 1400, fillers 104, 704, 1004, 1404 are provided, which may be formed of either a foam material or corrugated cardboard material, in order to cushion and protect that side of the product 20 at the corner. Of course, it is to be understood that, if desired, the fillers 104, 704, 1004, 1404 may be formed of different materials than those that are shown and described. It is also to be understood that, if desired and/or sufficient in certain applications, the fillers 104, 704, 1004, 1404 may not be included in the formation of the corner sleeves 100, 400, 700, 1000, 1400 or may be inserted into the corner sleeves 100, 400, 700, 1000, 1400 at any other appropriate time during the folding of the blanks 102, 402, 1002 or after the completion of the folding of the blanks 102, 402, 1002 as the fillers 104, 704, 1004, 1404 need not be secured within the corner sleeves 100, 400, 700, 1000, 1400. The corner sleeves 100, 400, 700, 1000, 1400 also provide substantial stacking strength in both the horizontal and vertical orientations and provide adequate crumple zones which protect the product 20 during corner drop tests.
Each of the corner sleeves 100, 400, 700, 1000, 1400 also provide first and second gripping flaps 108, 114; 408, 414; 1008, 1014 which assist in receiving and positioning the products 20 within the corner sleeves 100, 400, 700, 1000, 1400. The gripping flaps 108, 114; 408, 414; 1008, 1014 are generally triangular shaped panels of the blanks 102, 702, 1002 which fold inwardly and push against each other to provide enough friction so that a corner portion 30 of a product 20 fitting between them is held in place and so that the corner sleeve 100, 400, 700, 1000, 1400 does not fall off or away from the product 20. Thus, the gripping action of the gripping flaps 108, 114; 408, 414; 1008, 1014 allows the corner sleeves 100, 400, 700, 1000, 1400 to easily slide onto the products 20 and to stay on the products 20.
The corner sleeves 1000, 1400 also provide for channels 1385, 1785 between the gripping flaps 1008, 1014 and the corrugated air cell roll-ups 1260 and the fillers 1004, 1404. The channels 1385, 1785 allow the gripping flaps 1008, 1014 to engage into the back side of the framed products 20 in order to provide a more positive hold on the product 20. The channels 1385, 1785 are formed in the corner sleeves 1000, 1400 because of the formation of the gripping flaps 1008, 1014 on the blanks 1002, 1402 where no portion of the edges of the gripping flaps 1008, 1014 are provided along the outer boundaries of the blanks 1002, 1402, whereas portions of the edges of the gripping flaps 108, 114; 408, 414 are provided along the outer boundaries of the blanks 102, 402. Such a configuration of the gripping flaps 1008, 1014 may be changed, if desired, to provide the channels 1385, 1785 in the corner sleeves 100, 400, 700, but it has been found that with the smaller blanks 102, 402 (the blank 1002 being larger than the blanks 102, 402) the provision of the channels would reduce the hold that the gripping flaps 108, 114; 408, 414 would have on the product 20.
Also as the corner sleeves 1000, 1400 are formed entirely of corrugated cardboard material, the corner sleeves 1000, 1400 are environmentally friendly and are recyclable. The blanks 102, 402 of the corner sleeves 100, 400, 700 are also formed of corrugated cardboard material and, therefore, are environmentally friendly and recyclable.
While preferred embodiments of the invention are shown and described, it is envisioned that those skilled in the art may devise various modifications without departing from the spirit and scope of the appended claims.

Claims

1. A sleeve for protecting a corner portion of a product, said sleeve comprising:

first and second cushioning members formed in an L-shaped configuration such that said first cushioning member is generally perpendicular to said second cushioning member and such that said first and second cushioning members define a generally triangular space therebetween;

top and bottom panel members which are each secured to at least said first cushioning member, said top panel member being positioned to at least partially cover a top of said generally triangular space, said bottom panel member being positioned to at least partially cover a bottom of said generally triangular space; and

top and bottom fold-over panel members, said top fold-over panel member being folded downwardly relative to said top panel member and being positioned within said generally triangular space, said bottom fold-over panel member being folded upwardly relative to said bottom panel member and being positioned within said generally triangular space, said top and bottom fold-over panel members being biased toward one another;

whereby, upon insertion of the corner portion of the product between said top and bottom fold-over panel members, said fold-over panel members will hold the product in place therebetween and said first and second cushioning members will protect the corner portion of the product.

2. The sleeve as defined in claim 1, wherein said first cushioning member, said top and bottom panel members and said top and bottom fold-over panel members are formed from a corrugated cardboard material.

3. The sleeve as defined in claim 1, wherein said second cushioning member is formed from a corrugated cardboard material.

4. The sleeve as defined in claim 1, wherein said second cushioning member is formed from a polyethylene foam material.

5. The sleeve as defined in claim 1, wherein said first cushioning member, said top and bottom panel members and said top and bottom fold-over panel members are all formed from a single blank.

6. The sleeve as defined in claim 1, wherein said bottom panel member has a tab member extending therefrom, and wherein said first cushioning member has an aperture provided therethrough, said tab member configured to be inserted into said aperture in order to secure said bottom panel member to said first cushioning member.

7. The sleeve as defined in claim 1, wherein said top panel member has a tab member extending therefrom, and wherein said first cushioning member has an aperture provided therethrough, said tab member configured to be inserted into said aperture in order to secure said top panel member to said first cushioning member.

8. The sleeve as defined in claim 1, wherein said bottom panel member is secured to one or both of said first and second cushioning members by an adhesive.

9. The sleeve as defined in claim 1, wherein said top panel member is secured to one or both of said first and second cushioning members by an adhesive.

10. The sleeve as defined in claim 1, wherein said first cushioning member is generally formed in a shape of a rectangular tube.

11. The sleeve as defined in claim 1, wherein said second cushioning member is generally formed in a shape of a rectangular tube.

12. The sleeve as defined in claim 1, wherein said second cushioning member is generally formed in a shape of a rectangular block.

13. The sleeve as defined in claim 1, wherein an L-shaped channel is defined between said first and second cushioning members, said top and bottom panel members and said top and bottom fold-over panel members, said L-shaped channel configured to receive and trap edges of the corner portion of the product therein such that the corner portion of the product cannot be pulled out of the sleeve without separate manipulation of one or both of said top and bottom fold-over panel members.

14. The sleeve as defined in claim 1, further comprising a side panel member which connects said top panel member to said bottom panel member, said side panel member configured to abut against at least one of said first and second cushioning members.

15. The sleeve as defined in claim 1, wherein a cut-out is formed along said folded connection between said top panel member and said top fold-over panel member, said cut-out configured to receive at least a portion of an insert therein.

16. The sleeve as defined in claim 1, wherein a cut-out is formed along said folded connection between said bottom panel member and said bottom fold-over panel member, said cut-out configured to receive at least a portion of an insert therein.

17. The sleeve as defined in claim 1, wherein said top and bottom panel members are generally parallel to one another.

18. The sleeve as defined in claim 1, wherein said second cushioning member can be removed from between said top and bottom panel members.

19. A method of forming a sleeve used for protecting a corner portion of a product, said method comprising the steps of:

a) providing a blank having a plurality of air cell panels, top and bottom panels, a side panel, and top and bottom fold-over panels;

b) folding said plurality of air cell panels into a rectangular tube positioned on said bottom panel;

c) folding said bottom fold-over panel relative to said bottom panel such that a first edge of said bottom fold-over panel faces a first portion of said rectangular tube;

d) folding said side panel to a position generally perpendicular to said bottom panel such that said side panel faces a second portion of said rectangular tube;

e) folding said top panel to a position generally perpendicular to said side panel and generally parallel to said bottom panel such that said top panel faces a third portion of said rectangular tube;

f) folding said top fold-over panel relative to said top panel such that a first edge of said top fold-over panel faces said first portion of said rectangular tube and is generally parallel to said first edge of said bottom fold-over panel; and

g) securing said top panel to said rectangular tube.

20. The method as defined in claim 19, further comprising the step of:

securing said rectangular tube to said bottom panel.

21. The method as defined in claim 19, further comprising the step of:

providing a filler which upon completion of step (g) is positioned between second edges of said top and bottom fold-over panels, said rectangular tube, said side panel, and said top and bottom panels, said rectangular tube and said filler being generally L-shaped in configuration.

22. The method as defined in claim 21, further comprising the step of:

securing said filler to at least one of said top and bottom panels.

23. The method as defined in claim 21, wherein said folding of said top and bottom fold-over panels provides a generally L-shaped channel between said rectangular tube, said filler, said first and second edges of said top fold-over panel and said first and second edges of said bottom fold-over panel.

24. A method of securing a protective sleeve to a corner portion of a product, said method comprising the steps of:

a) providing a protective sleeve having first and second cushioning members provided in a generally L-shaped configuration such that a generally triangular space is provided therebetween, top and bottom panel members covering said generally triangular space, and top and bottom fold-over panels folded relative to said top and bottom panel members, respectively, that are positioned within said generally triangular space and which are biased toward one another;

b) inserting said corner portion of said product into said protective sleeve between said top and bottom fold-over panels until a first edge of said corner portion of said product is provided proximate to said first cushioning member and until a second edge of said corner portion of said product is provided proximate to said second cushioning member; and

c) allowing said top and bottom fold-over panels to be biased against said corner portion of said product in opposite directions in order to hold said corner portion of said product within said protective sleeve.

25. The method as defined in claim 24, further comprising the steps of:

providing said protective sleeve with an L-shaped channel defined between said first and second cushioning members and said top and bottom fold-over panels; and

inserting said corner portion of said product into said protective sleeve until said edges of said corner portion of said product are positioned within said L-shaped channel.