Edge protector

Abstract

Articles being transported are susceptible to damage upon impact. In order to prevent damage to articles during handling or transport, edge protectors are provided that are preferably made from molded pulp fiber and are formed into a base of protrusions. The protrusions on the base are arranged, e.g., in a grid pattern to help prevent stacked flat articles from slipping between rows of protrusions. The edge protector may have a foldable flap containing protrusions that add protection of the edges of the articles, as well as rib protrusions. The edge protector alternatively may include an elongated edge rigidly attached to the base, which includes protrusions or chair-shaped protrusions to add protection of the edges of the articles, as well as rib protrusion. The edge protectors described may be used inside a container (e.g., a corrugated box), and articles may be transported while protected by the edge protectors.

I claim: 
     
         1 . A protector comprising:
 a base having a plurality of base protrusions; and   an elongated edge having a flexible connection to the base   wherein the elongated edge has a plurality of rib protrusions.   
     
     
         2 . The protector of  claim 1 , wherein the plurality of base protrusions is arranged in a pattern that is free of horizontal protrusion-free channels and vertical protrusion-free channels. 
     
     
         3 . The protector of  claim 1  wherein the plurality of base protrusions is arranged in a diagonal grid pattern. 
     
     
         4 . The protector of  claim 3 , wherein the protector is constructed from thin-walled molded pulp fiber. 
     
     
         5 . The protector of  claim 4 , wherein the elongated edge has one or more edge protrusions so arranged as to be adjacent to the base protrusions when the elongated edge is folded about the flexible connection. 
     
     
         6 . A protector comprising:
 a base having a plurality of base protrusions; and   an elongated edge, wherein the elongated edge has a rigid connection to the base.   
     
     
         7 . The protector of  claim 6 , wherein the plurality of base protrusions has an arrangement that is free of horizontal protrusion-free channels and vertical protrusion-free channels. 
     
     
         8 . The protector of  claim 6  wherein the base has a plurality of base protrusions arranged in a diagonal grid pattern. 
     
     
         9 . The protector of  claim 8 , wherein the protector is constructed from thin-walled molded pulp fiber. 
     
     
         10 . The protector of  claim 9 , wherein the elongated edge has rib protrusions. 
     
     
         11 . The protector of  claim 8 , wherein the rigid connection contains one or more chair-shaped protrusions, the chair-shaped protrusions being comprised of a seat and a back,
 wherein the seat extends the same distance from the base as the height of the base protrusions,   wherein the back extends substantially the height of the elongated edge, and   wherein the seat and the back meet at a juncture.   
     
     
         12 . The protector of  claim 11 , wherein
 the base protrusions are at a height of about one inch above the base and have a draft angle of about seven degrees;   the elongated edge extends to a height of about two inches above the base;   the seat of each of the chair-shaped protrusions is at a height of about one inch above the base;   the seat of each of the chair-shaped protrusions has a length of about 0.5 inch measured from the juncture and extending into the base;   the back of each of the chair-shaped protrusions extends one inch above the seat of the chair-shaped protrusions;   the chair-shaped protrusions are spaced at a distance of about 0.63 inch, measured from center to center;   each of the chair-shaped protrusions has a width and a top, wherein the width is about 0.22 inches measured at the top of the chair-shaped protrusions;   the juncture is about 0.39 inch from the elongated edge; and   each of the chair-shaped protrusions has a draft angle of seven degrees.   
     
     
         13 . The protector of  claim 11 , further comprising a second elongated edge, wherein the second elongated edge has a second rigid connection to the base. 
     
     
         14 . The protector of  claim 13 , wherein the second rigid connection contains one or more second chair-shaped protrusions, the second chair-shaped protrusions being comprised of a second seat and a second back,
 wherein the second seat extends the same distance from the base as the height of the base protrusions,   wherein the second back extends substantially the height of the second elongated edge, and   wherein the second seat and the second back meet at a second juncture.   
     
     
         15 . The protector of  claim 14  wherein the elongated edge is parallel to the second elongated edge, and wherein the elongated edge and the second elongated edge are connected to the base on opposite sides of the base. 
     
     
         16 . The protector of  claim 15  having a vertical protrusion-free channel between and parallel to the elongated edge and the second elongated edge. 
     
     
         17 . The protector of  claim 16  wherein
 the base protrusions are at a height of one inch above the base and have a draft angle of about seven degrees; 
 the elongated edge and the second elongated edge extend to a height of about two inches above the base; 
 the seats and the second seats have a height of about one inch above the base; 
 each of the seats has a length of about 0.5 inch measured from each seat's juncture and extending into the base; 
 each of the second seats has a length of about 0.5 inch measured from each second seat's second juncture and extending into the base; 
 the backs of the chair-shaped protrusions extend about one inch above the seats of the chair-shaped protrusions; 
 the second backs of the second chair-shaped protrusions extend about one inch above the second seats of the second chair-shaped protrusions; 
 the distance between the chair-shaped protrusions, measured from center to center, is about 0.63 inches; 
 the distance between the second chair-shaped protrusions, measured from center to center, is about 0.63 inches; 
 the chair-shaped protrusions have a width and a top, wherein the width is about 0.22 inches measured at the top of the chair-shaped protrusions; 
 the second chair-shaped protrusions have a second width and a second top, wherein the second width is about 0.22 inches measured at the second top of the second chair-shaped protrusions; 
 the juncture is about 0.39 inch from the elongated edge; 
 the second juncture is about 0.39 inch from the second elongated edge; and 
 each of the chair-shaped protrusions and each of the second chair-shaped protrusions has a draft angle of about seven degrees. 
 
     
     
         18 . A method of protecting flat, stacked articles comprising:
 placing a plurality of articles having edges into a container having an inside surface; and   arranging one or more edge protectors between edges of the articles and the inside surface of the container.   
     
     
         19 . The method of protecting flat, stacked articles of  claim 18 , wherein the one or more edge protectors are edge protectors as described in the claims consisting of  claim 2 ,  claim 5 ,  claim 7 ,  claim 11 ,  claim 12 , and  claim 16 . 
     
     
         20 . The method of protecting flat, stacked articles of  claim 19  wherein the stacked flat articles are particleboard having a thickness of about 0.5 inch to about 0.625 inch. 
     
     
         21 . A method of transporting flat, stacked articles comprising:
 placing a plurality of articles having edges into a container having an inside surface;   arranging one or more edge protectors between edges of the articles and the inside surface of the container; and   transporting the container.   
     
     
         22 . The method of transporting flat stacked articles of  claim 21 , wherein the one or more edge protectors are edge protectors as described in the claims consisting of  claim 2 ,  claim 5 ,  claim 7 ,  claim 11 ,  claim 12 , and  claim 16 . 
     
     
         23 . The method of transporting flat stacked articles of  claim 22  wherein the stacked flat articles are particleboard having a thickness of about 0.5 inch to about 0.625 inch. 
     
     
         24 . A container comprising:
 a plurality of flat stacked articles; and   one or more edge protectors as described in the claims consisting of  claim 2 ,  claim 5 ,  claim 7 ,  claim 11 ,  claim 12 , and  claim 16 ;   wherein the container has an inside surface, and wherein the one or more edge protectors are positioned between the inside surface of the container and the stacked flat articles.   
     
     
         25 . The container of  claim 24  wherein the stacked flat articles have shortest edges and are arranged such that the shortest edges of the articles are aligned, further comprising four edge protectors, wherein the edge protectors are arranged about the aligned shortest edges of the stacked flat articles. 
     
     
         26 . The container of  claim 25  wherein the stacked flat articles are particleboard having a thickness of about 0.5 inch to about 0.625 inch.