Edge protector and method of making an edge protector

Abstract

A plastic edge protector for protecting corner regions of objects during shipping or transport includes a pair of generally perpendicularly oriented legs or walls, and a reinforced corner region which prevents damage to the object and the protector. The edge protector is formed so as to include a solid interior wall or bead of plastic which extends along the entire longitudinal extent of the edge protector.

1 . An edge protector for protecting corner-shaped edge regions of an object, the edge protector being constructed entirely from a corrugated plastic sheet having a pair laterally-spaced outer panels which are joined to one another by a plurality of generally parallel ribs which extend transversely between said panels, said edge protector comprising a pair of generally planar legs which are generally transversely oriented relative to one another and are joined together at an elongate junction which extends along the entire longitudinal extent of said edge protector, said ribs of said edge protector extending transversely relative to said junction and therealong forming a solid wall of plastic which extends along the entire longitudinal extent of said edge protector.  
   
   
       2 . The edge protector of  claim 1 , further including at least one perforation which extends transversely along said legs to allow said edge protector to be separated lengthwise into a plurality of said edge protectors.  
   
   
       3 . A combination edge protector and object to be protected from damage, said combination comprising an object defining at least one corner-shaped region thereon, and an edge protector, said edge protector having a pair of generally planar legs which are generally perpendicular to one another and joined to one another along a junction, said edge protector being constructed entirely from a plastic sheet including a pair of outer and generally planar panels and a plurality of ribs which extend transversely therebetween, said ribs of said edge protector extending transversely relative to said junction and therealong defining a solid wall of plastic along said junction to reinforce same and allow said edge protector to withstand transverse loading.  
   
   
       4 . An arrangement for protecting a corner-shaped edge of an object, said arrangement comprising at least one edge protector for positioning over the corner-shaped object edge and being constructed of corrugated plastic so as to have a pair of outer sheets interconnected by a plurality of spaced apart and parallel ribs, said edge protector having a pair of transversely oriented and generally planar legs which are joined to one another at a junction defined by a solid bead of plastic which extends along said junction in a direction transverse to said ribs, said arrangement further including at least one elongate band configured for disposal in surrounding relation with said edge protector such that said band extends transversely across said bead and secures said edge protector exteriorly on the corner-shaped object edge.  
   
   
       5 . A method of forming an edge protector, said method comprising the steps of: 
 providing a planar sheet-shaped material constructed of corrugated plastic defined by a pair of planar outer sheets joined together by a plurality of spaced-apart and generally parallel ribs which extend transversely between the outer sheets;    heating the sheet-shaped material; and    thereafter folding the sheet-shaped material along a fold line defined transversely relative to the direction in which the ribs extend to form a solid reinforcing wall of plastic material along the fold line, wherein said step of folding forms an edge protector defined by a pair of transversely oriented panels which are joined to one another by said reinforcing wall.    
   
   
       6 . The method of  claim 5 , wherein said step of heating comprises applying localized heat to the sheet-shaped material along a predefined longitudinal section thereof which coincides with the fold line.  
   
   
       7 . The method of  claim 5 , wherein said step of folding comprises folding the sheet-shaped material into a zig-zag configuration along a plurality of laterally-spaced and generally parallel fold lines.  
   
   
       8 . The method of  claim 7 , further including forming a plurality of laterally-spaced and generally parallel longitudinal perforations in the sheet-shaped material which extend generally parallel to the respective fold lines to allow separation of the folded sheet-shaped material into a plurality of edge protectors.  
   
   
       9 . The method of  claim 5 , wherein said step of folding comprises folding the sheet-shaped material along a single fold line to form an elongate and generally corner-shaped profile, and said method further comprises separating the elongate corner-shaped profile lengthwise into a plurality of edge protectors each of a desired length.  
   
   
       10 . The method of  claim 9 , further including forming at least one perforation in the sheet-shaped material which extends transversely to the fold line to allow ready separation of the corner-shaped profile into the plurality of edge protectors.  
   
   
       11 . The method of  claim 5 , wherein said step of folding is carried out by roll-forming the sheet-shaped material.  
   
   
       12 . The method of  claim 5 , further including cooling the edge protector after said step of folding.  
   
   
       13 . An edge protector formed by the process of  claim 5 .  
   
   
       14 . A method of making an edge protector, said method comprising the steps of: 
 supplying a plastic sheet to a heating station, the plastic sheet being defined by a pair of outer panels interconnected by a plurality of ribs extending transversely therebetween;    heating the sheet at the heating station;    transporting the heated sheet to a working station;    deforming the sheet along a fold line which extends transversely relative to the ribs by roll-forming; and    forming a solid bead of plastic along the fold line.    
   
   
       15 . The method of  claim 14 , further including cutting the deformed sheet transversely relative to the fold line to form one or more edge protectors of selected lengths.  
   
   
       16 . The method of  claim 14 , further including cooling the deformed sheet after said step of deforming.  
   
   
       17 . The method of  claim 14 , wherein said step of deforming causes portions of the ribs located at the fold line to flow into one another and form said solid bead of plastic.  
   
   
       18 . The method of  claim 14 , wherein said step of deforming forms an edge protector defined by a pair of perpendicularly oriented and generally flat panels joined to one another by the solid bead of plastic.  
   
   
       19 . An edge protector formed by the method according to  claim 14 .  
   
   
       20 . The method of  claim 14 , further including perforating the plastic sheet transversely relative to the fold line to allow ready separation of the deformed sheet into a plurality of edge protectors.