Corner protectors and related systems and methods

Abstract

A product packaging includes a box blank having panels, flaps, creases, and cuts. An intersection of multiple creases and a cut defines an unfolded corner of the box blank. The product packaging also includes a corner protector attachable to the box blank adjacent to the unfolded corner. The corner protector includes a primary panel, a first leg panel, and a second leg panel that are arranged in a non-linear configuration. A packaging system includes a conveyor system with a gap therein, a corner protector placement mechanism for placing corner protectors on the box blank, and a transfer mechanism for positioning to-be-packaged item on the box blank. The gap allows for the box blank and to-be-packaged item to pass at least partially therethrough and facilitates folding of the box blank at least partially around the to-be-packaged item.

We claim: 
     
         1 . A product packaging, comprising:
 a box blank comprising a plurality of panels, a plurality of flaps, a plurality of creases, and a plurality of cuts, with an intersection of multiple creases and a cut defining an unfolded corner; and   a corner protector attachable to the box blank adjacent to the unfolded corner, the corner protector comprising a primary panel, a first leg panel, and a second leg panel, the primary panel, the first leg panel, and the second leg panel being arranged in a non-linear configuration.   
     
     
         2 . The product packaging of  claim 1 , wherein the corner protector has an L-shape. 
     
     
         3 . The product packaging of  claim 1 , wherein the corner protector comprises a crease formed between the primary panel and the first leg panel. 
     
     
         4 . The product packaging of  claim 3 , wherein the corner protector comprises a crease formed between the primary panel and the second leg panel. 
     
     
         5 . The product packaging of  claim 4 , wherein the creases formed between the primary panel and the first and second leg panels are oriented at a right angle relative to one another. 
     
     
         6 . The product packaging of  claim 4 , wherein the creases formed between the primary panel and the first and second leg panels are offset from the plurality of creases. 
     
     
         7 . The product packaging of  claim 4 , wherein the creases formed between the primary panel and the first and second leg panels are parallel to the plurality of creases. 
     
     
         8 . The product packaging of  claim 1 , wherein the primary panel of the corner protector is attachable to a first panel of the plurality of panels of the box blank, with the first leg panel extending from the primary panel and onto a second panel of the plurality of panels. 
     
     
         9 . The product packaging of  claim 1 , wherein the primary panel of the corner protector is attachable to a first panel of the plurality of panels of the box blank, with the second leg panel extending from the primary panel and onto a first flaps of the plurality of flaps. 
     
     
         10 . A packaging system, comprising:
 a conveyor system configured to transport a box blank there along, the conveyor system having a gap formed therein;   a corner protector placement mechanism configured to place corner protectors on the box blank; and   a transfer mechanism configured to position a to-be-packaged item onto a portion of the box blank that is positioned over the gap in the conveyor system, such that the box blank and the to-be-packaged item pass at least partially through the gap and the box blank folds at least partially around the to-be-packaged item.   
     
     
         11 . The packaging system of  claim 10 , further comprising a second conveyor system, the second conveyor system having a portion positioned below the gap in the conveyor system. 
     
     
         12 . The packaging system of  claim 10 , wherein the transfer mechanism comprises a movable arm and a clamp, the clamp being configured to clamp onto the to-be-packaged item and the arm being configured to move the to-be-packaged item onto the box blank. 
     
     
         13 . The packaging system of  claim 10 , wherein the corner protector placement mechanism comprises a repository configured to hold a stock of corner protectors. 
     
     
         14 . The packaging system of  claim 13 , wherein the repository comprises a conveyor mechanism configured to advance the corner protectors therethrough. 
     
     
         15 . The packaging system of  claim 13 , wherein the corner protector placement mechanism comprises a gripper configured to retrieve a corner protector from the repository and place the corner protector on the box blank. 
     
     
         16 . The packaging system of  claim 15 , wherein the gripper is movable between a retrieval position and a placement position. 
     
     
         17 . The packaging system of  claim 15 , wherein the gripper comprises a securing mechanism for selectively securing to a corner protector. 
     
     
         18 . A corner protector, comprising:
 a primary panel;   a first leg panel separated from the primary panel by a first crease; and   a second leg panel separated from the primary panel by a second crease,   the first crease and the second crease being oriented non-parallel to one another such that the primary panel, the first leg panel, and the second leg panel are arranged in a non-linear configuration.   
     
     
         19 . The corner protector of  claim 18 , wherein the first leg panel comprises a first edge and the second leg panel comprises a second edge, the first and second edges defining an interior corner of the corner protector. 
     
     
         20 . The corner protector of  claim 19 , wherein the first edge is colinear or parallel to the second crease and the second edge is colinear or parallel to the first crease.