WO1994029196A1

WO1994029196A1 - Edge protector element

Info

Publication number: WO1994029196A1
Application number: PCT/GB1994/001299
Authority: WO
Inventors: Peter Arthur Hugh Farrington; Michael John Blake
Original assignee: Corrugated Plastic Products Limited
Priority date: 1993-06-16
Filing date: 1994-06-16
Publication date: 1994-12-22
Also published as: AU6974394A

Abstract

A cover (1) for fitting to a corner at the intersection of a curved surface with a second surface, wherein said cover includes an array of tooth portions (6) arranged to be closed together for covering at least a portion of the second surface, when the cover is fitted to the corner and covers a portion of the curved surface.

Description

EDGE PROTECTOR ELEMENT DESCRIPTION

The present invention relates to a cover. In particular, the invention relates to a cover for fitting to a corner at the intersection of a curved surface with a second surface. The invention also relates to a method of covering or protecting an edge portion or corner of an article.

The corners" and adjacent edges of many articles are vulnerable to damage, particularly during transportation. In order to prevent such damage, most industrial products are protected by packaging material, arranged to fit over and protect their corners and edges.

Coils or rolls of sheet steel are covered in protective packaging, prior to being shipped from the steel mills, where they are produced. At present, the packaging process involves wrapping each roll of steel with two strips of a protective material, to form a pair of cuffs around the axially outer edges of the radially outer, cylindrically curved surface of the roll. The cuffs of protective material are located so as to extend axially short distances beyond the axial extremities of the roll and, after installation, are caused to fold down over the annular ends of the roll, by stretch-wrapping the assembly of roll and cuffs in a plastic resin sheet, in completion of the packaging process. The material used to form the cuffs is manufactured from strips of hardboard, sandwiched between layers of bitumen impregnated kraft paper, laminated with polyethylene. The material is available under the Trademark LAMIFLEX.

Unfortunately, however, because the corners between the radially outer, cylindrically curved surface of the roll and its annular end surfaces are circular, the protective material, which is relatively rigid, often does not fold down over the roll's end surfaces in a predictable fashion. The material can fold irregularly and, in some instances, can be pulled out of place during the stretch-wrapping procedure. Moreover, the entire process is relatively slow and results in a product having a generally poor appearance.

Also, the stretch-wrapping procedure requires the roll of steel to be supported upon a pair of spaced rollers which are driven in rotation to thereby rotate the roll of steel. As a result of the weight of steel and the rigidity of the LAMIFLEX material, the pressure exerted at the nip between each of the rollers and the LAMIFLEX is sufficient to cause the latter to leave an impression on the outer turns of steel in the roll. This problem is particularly acute for thin gauges of steel and can also be caused by other handling procedures which involve rolling the roll of steel on the LAMIFLEX cuffs.

According to a first aspect of the present invention, there is provided a cover for fitting to a corner at the intersection of a curved surface with a second surface, wherein said cover includes an array of relatively movable flap or tooth portions arranged for covering at least a portion of the second surface, when the cover is fitted to the corner and covers a portion of the curved surface. When the cover is fitted in or over a corner or junction between a curved surface and a second surface (which may be flat), lying radially inwardly of the curved surface, the flap or tooth portions can close together and neatly cover the second surface, without the cover becoming irregularly folded or displaced, or pulled out of place during a subsequent stretch-wrapping or like procedure. When the cover is fitted in or over a corner or junction between a curved surface and a second surface, lying radially outwardly of the curved surface, the flap or tooth portions will move apart to come into covering contact with the second surface. In embodiments, the cover can be fitted to a corner at the intersection of an undulating surface and a second surface, where the undulating surface includes both convex and concave portions, and the flap or tooth portions can move together and apart to come into covering contact with the second surface.

Preferably, the cover is formed from an impact absorbing, cushioning or resiliently crushable material and, in an embodiment, comprises a deformable zone, located between adjacent flap or tooth portions, for facilitating the relative movement of the latter. Such deformable zones can comprise weakened or stretchable zones which, preferably, are less resistant to being bent or distorted than the remainder of the cover. The deformable zones can comprise flutes or crease lines. An advantage of forming the cover from a cushioning or resiliently crushable material is that, when the cover is used to protect the outer edges of a roll of sheet steel, it will not form an imprint on the steel, when the latter is rotated upon supporting rollers during the stretch-wrapping procedure. The cover spreads the pressure exerted by the rollers over a larger area of steel in the roll than was the case with the relatively rigid LAMIFLEX.

Preferably, the cover includes an array of deformable zones with each said zone located between adjacent flap or tooth portions. In an embodiment, adjacent flap or tooth portions are also separated by one of an array of, preferably, substantially "V" shaped notches. In an alternative embodiment, adjacent flap or tooth members are linked by intervening deformable zones and are otherwise not separated. In this embodiment the deformable zones, preferably, are in the form of flutes or crease lines which can be arranged to cause each deformable zone to fold in a predictable manner when the cover is used.

In a preferred embodiment, deformable zones and, preferably, notches are located between all the adjacent flap or tooth portions. Thus, the flap or tooth portions and the deformable zones, can cover the second surface, while the remainder of the cover covers the adjacent portion of the curved surface, to thereby fully cover and provide full protection to the corner, defined between the curved and second surfaces.

Preferably, the cover comprises two portions disposed either side of a crease line, with the flap or tooth portions projecting away from the crease line and located in the same cover portion as the deformable zones. The purpose of including a crease line is to facilitate the positioning of the cover over or into a corner.

Preferably, the cover is elongated and the array of flap or tooth portions and, if present, the arrays of deformable zones and notches and the crease line, extend along the cover in the direction of its elongation. In a preferred embodiment the array of flap or tooth members, deformable zones and, if present, notches extend along substantially the entire length of the cover's elongation, together with the crease line, if present.

In a further embodiment, the cover comprises first and second intersecting and elongate flanges, the first flange comprising the flap or tooth portions, deformable zones and, if present, the notches. An advantage of this embodiment is that the cover can be fitted over or into a corner with the flap or tooth portions and deformable zones covering at least a portion of the second surface, without the latter having to be forced into place by other means, such as by stretch-wrapping.

Preferably, the cover is formed from a corrugated material, preferably a corrugated plastic resin material, such as polypropylene or an ethylene/polypropylene co-polymer. In embodiments where the cover is formed from a corrugated material it is supplied, preferably, in elongate strips with the corrugations extending along the length thereof. When supplied in this way, sections of cover can be cut to the length required to fit into or over the corner, which it is wished to cover. Where the cover is formed from a corrugated material, it is preferred that the deformable zones are formed by compressing, crimping or stretching the corrugated material, between the flap or tooth portions, beyond its resilient capacity.

Corrugated plastic resin material is manufactured in continuous lengths, with the corrugations running length wise; the manufacturing process makes it difficult or impossible to produce long strips of the material, with the corrugations running crossways. Thus, until the present invention, this material's resistance to being folded, across its corrugations, made it impossible to use it to form covers, of the type to which the invention relates, in sufficient lengths to be of practical use, for instance, to protect the edges of rolls of sheet steel. Covers in accordance with the invention do not suffer from this difficulty because they include flap or tooth portions, which can close together or move apart without difficulty and, in embodiments, deformable zones, which can be easily and predictably deformed or folded.

In another embodiment, the cover comprises a second array of flap or tooth portions and, preferably, deformable zones and, more preferably, notches. In a further embodiment, where the cover is formed from a plastic resin material and comprises first and second intersecting and elongate flanges, both flanges can be formed from a single and originally flat length of material. Preferably, such an embodiment is formed by a heat forming process, such as by ultrasonic welding or by a heated nose and platen arrangement.

In a second aspect, the invention relates to a method of protecting an edge portion or corner of an article, comprising fitting a cover in accordance with the first aspect of the invention to a corner of the article, at the intersection of a curved surface with a second surface of the article, such that the flap or tooth portions cover the second surface and a portion of the curved surface, also, is covered by the cover.

In an embodiment of this second aspect, the cover is provided in an elongate strip, preferably supplied in the form of a coil, and is cut to length, prior to being fitted into or over a corner. More preferably, the article being covered is a coil or roll of sheet steel and at least two lengths of cover, in accordance with the first aspect of the invention, are fitted over the substantially circular outer edges of the radially outer cylindrically curved surface thereof, with the flap or tooth portions at least partially covering the flat annular end surfaces of the roll. Likewise, a further two lengths of cover, optionally, can be fitted over the substantially circular edges of the radially inner cylindrically curved surface of the roll, which defines a bore therethrough, with the flap or tooth portions thereof at least partially covering the flat annular end surfaces of .the roll. Preferably, once the covers are so installed, the assembly is then shrink-wrapped with polyethylene sheeting.

Embodiments of the present invention will now be described by way of example only and with reference to the following drawings:- Figure 1, which is a perspective view of a first cover in accordance with the present invention; and

Figure 2, which is a perspective view of a second cover in accordance with the invention.

The cover 1, shown in Figure 1, is formed from a corrugated polyethylene/polypropylene co-polymer extrusion, with the corrugations 2 extending lengthwise along the cover 1 and in the direction of arrows A. The cover 1 comprises first and second flanges 3 and 4. The second flange 4 upstands from the first flange 3, along one of the latter's long edges, to form a substantially right-angled corner 5. The second flange 4 is castellated and consists of an array of tooth portions 6 upstanding from a continuous flange portion which joins with the first flange portion 3 at the corner 5. The tooth portions 6 are separated by substantially "V" shaped notches and the areas of the second flange 4, adjacent to the corner 5 and located between the tooth portions 6, have been subjected to crushing and/or stretching during manufacture, to provide weakened and/or stretched deformable zones 7.

The cover 1 is manufactured from a strip of corrugated polyethylene/polypropylene board, available from Corrugated Plastic Products Limited of Ringwood, Hampshire as Twin-Wall polypropylene board, which is cut and bent, while being heated, to the above described shape, using conventional processing techniques.

The cover 1, can be elongated in the direction of arrows A, with the array of tooth portions 6 and deformable zones 7 repeated, to extend along its entire length.

In use, the cover 1 can be bent in the direction of arrows B, to fit the first flange 3 around a curved surface. As the first flange 3 is caused to so bend, the tooth portions 6 will close together and the deformable zones 7 will bend sufficiently to allow the first flange 3 to curve evenly and smoothly, while allowing the tooth portions 6 to remain substantially in a common plane. In this manner, the cover 1 can be fitted to a corner between a cylindrically curved surface and a flat surface, with the first flange 3 in contact with the curved surface and the tooth portions 6 of the second flange 4 in contact with the flat surface.

In a preferred embodiment, the deformable zones 8 are formed by crushing the inner surface of the second flange 4, which faces the first flange 3, towards the outer surface of the second flange 4, thereby ensuring that, as the first flange 3 is caused to bend, the deformable zones 7 bend outwardly and away from the first portion 3.

Most preferably, the cover is sufficiently elongated that it can be fitted around the entire circumference of a cylindrically curved surface, such as that of a roll of sheet steel, with the first flange 3 in contact with said curved surface and the tooth portions 6 of the second flange 4 in contact with an adjacent flat and annular surface. When for use in protecting rolls of sheet steel, the cover 1 is formed from Twin-Wall polypropylene (polyethylene/polypropylene co-polymer) board, having a material grade of 2/1000gsm, and is supplied in 100m reels, ready to be cut to the required length. The cover 11, shown in Figure 2, is also formed from a corrugated polyethylene/polypropylene co-polymer extrusion, with the corrugations 12 extending lengthwise along the cover 11 and in the direction of arrows C. The cover 11 comprises first and second flanges 13 and 14. The second flange 14 upstands from the first flange 13, along one of the letter's long edges, to form a substantially right- angled corner 15.

An array of crease lines 17, orientated in pairs as the arms of a series of "V"s, rooted at the right-angled corner 15 are formed in the second flange 14, to define an array of tooth portions 16. The material for forming the cover 11 is available from Corrugated Plastic Products Limited of Ringwood, Hampshire as twin-wall polypropylene board and can be cut, bent and creased, while being heated, to the above described shape, using conventional processing techniques.

The cover 11 can be elongated in the direction of arrows C, with the array of tooth portions 16 and crease lines 17 repeated, to extend along its entire length.

The cover 11 is used in a similar fashion to the cover 1, shown in Figure 1, by being bent in the direction of arrows D, to fit the first flange 13 around a curved surface. As the first flange 13 is caused to so bend, the tooth portions 16 will close together and each pair of crease lines 17 will move in the direction of arrows E and F, sufficiently to allow the first flange 13 to curve evenly and smoothly. In this manner, the cover 11 can be fitted to a corner between a cylindrically curved surface and a flat surface, with the first flange 13 in contact with the curved surface and the tooth portions 16 of the second flange 14 in contact with the flat surface.

In a preferred embodiment, extra crease lines 18 (shown dotted) are provided between each pair of crease lines 17 and, when the first flange 13 is caused to bend, the tooth portions 16 will close together and the crease lines 17 and 18 will move in the direction of arrows G and H, sufficiently to allow the first flange 13 to curve evenly and smoothly, while allowing the tooth portions 16 to remain substantially in a common plane. An advantage of this last embodiment is that when a cover of this type is fitted around the circumference of a cylindrically curved surface, such as that of a roll of sheet steel, the first flange 13 will be in contact with said curved surface and, when the tooth portions 16 are in contact with an adjacent flat and annular surface, of the roll, the crease lines 18 will upstand therefrom and provide retaining means for a protective cover, such as one formed from stretch-wrapped polyethylene sheeting.

Claims

1. A cover for fitting to a corner at the intersection of a curved surface with a second surface, wherein said cover includes an array of relatively movable flap or tooth portions arranged for covering at least a portion of the second surface, when the cover is fitted to the corner and covers a portion of the curved surface.

2. A cover as claimed in claim 1 and formed from an impact absorbing or cushioning material.

3. A cover as claimed in claim 1 or claim 2, comprising a deformable zone, located between adjacent flap or tooth portions, for facilitating the relative movement of the latter.

4. A cover as claimed in claim 3, comprising an array of deformable zones, with each said zone located between adjacent flap or tooth portions.

5. A cover as claimed in any of the preceding claims, wherein adjacent flap or tooth portions are separated by one of an array of notches.

6. A cover as claimed in claim 5, wherein the notches are substantially "V" shaped.

7. A cover as claimed in any of claims 1-4, wherein adjacent flap or tooth portions are linked by intervening deformable zones.

8. A cover as claimed in any of claims 3-7 and arranged so that the flap or tooth portions and deformable zones can cover the second surface.

9. A cover as claimed in any of claims 3-8, comprising a pair of cover portions disposed about a crease line, with the flap or tooth portions extending away from the crease line and located in the same cover portion as the deformable zones.

10. A cover as claimed in any of the preceding claims, wherein the cover is elongated and the array of flap or tooth portions and, if present, the arrays of notches and deformable zones and the crease line, extend along the cover in the direction of its elongation.

11. A cover, as claimed in claim 10, wherein the array of flap or tooth members and, if present, the arrays of notches and deformable zones and the crease line extend along substantially the entire length of the cover's elongation.

12. A cover as claimed in any of the preceding claims, comprising first and second intersecting and elongate flanges, the first flange comprising the tooth portions and, if present, the deformable zone or array of deformable zones.

13. A cover, as claimed in any of the preceding claims and formed from a resiliently crushable or cushioning material which, preferably, is a corrugated material and, more preferably, a corrugated plastic resin material.

14. A cover as claimed in claim 13, wherein the material is corrugated polypropylene or a polyethylene/polypropylene co- polymer.

15. A cover as claimed in claim 13 or claim 14, wherein the cover is elongated and the corrugations extend in a direction of its elongation.

16. A cover as claimed in any of claims 13-15, wherein the deformable zones are formed by compressing the corrugated material, between the flap or tooth portions, beyond its resilient capacity.

17. A cover as claimed in any of claims 3-15, wherein the deformable zone or zones comprises a crease line and, preferably, at least two crease lines.

18. A cover as claimed in any of claims 3-17, wherein the deformable zone is arranged for becoming upstanding from adjacent flap or tooth members.

19. A cover as claimed in any of the preceding claims comprising a second array of flap or tooth portions and, preferably, intervening deformable zones.

20. A cover, as claimed in claim 15, and comprising first and second intersecting elongate flanges, wherein both flanges are formed from a single and originally flat length of material by a heat forming process.

21. A method of protecting an edge portion or corner of an article, comprising fitting a cover as claimed in any of claims 1-20 to a corner of the article, at the intersection of a curved surface with a second surface of the article, such that the flap or tooth portions cover the second surface and a portion of the curved surface, also, is covered by the cover.

22. A method as claimed in claim 14, wherein the cover comprises deformable zones and is fitted to the corner with the deformable zones and flap or tooth portions covering the second suface.

23. A method as claimed in claim 21 or claim 22, wherein the cover is provided in an elongate strip and is cut to length, prior to being fitted into or over a corner.

24. A method as claimed in either claim 21 or claim 22, wherein the article being covered is a coil or roll of sheet steel and, preferably, at least two covers, as claimed in any of claims 1-20, are fitted over the axially outer edges of the radially outer cylindrically curved surface thereof, with the tooth portions at least partially covering the flat annular end surfaces of the roll.

25. A method as claimed in claim 24, wherein the resulting assembly of roll and covers is stretch-wrapped with a plastic resin sheeting, preferably, with polyethylene sheeting.

26. A cover substantially as hereinbefore described with reference to the accompanying drawings.

27. A method substantially as hereinbefore described with reference to the accompanying drawings.