Corner protector, corner protector assembly and sash assembly comprising corner protector assembly

Abstract

A corner protector, a corner protector assembly, and a sash assembly including the same are provided, the corner protector being provided with a body having a recess formed therein. The recess defines a first surface to receive and contact a sash surface of the sash in the recess. The recess defines a second surface that is angled relative to and intersects the first surface to receive and contact a first edge surface of the sash. The recess defines a third surface that is angled relative to the first and second surfaces and intersects the first surface to receive and contact a second edge surface of the sash. The body defines an aperture formed in the first surface and oriented at a convergence of the first surface, the second surface, and the third surface such that the second surface and the third surface do not intersect. The aperture is formed in the body as a blind depth.

Description

Cross-reference to related applications

[0001] This application claims priority to Chinese Patent Application No. 202411325355.8, filed on September 23, 2024, the disclosure of which is hereby incorporated herein by reference in its entirety. Technical Field

[0002] Various embodiments relate to corner protectors for packaging shower door frames. Background Technology

[0003] Lemnios et al., U.S. Patent No. 11,254,489B2, was granted to LibertyHardware Mfg.Corp. on February 22, 2022, for a shower door glass frame packaging assembly that includes corner protectors. Summary of the Invention

[0004] According to an embodiment, a corner protector is provided having a body having a recess formed therein, the recess defining a first surface to receive and contact a frame surface of a grid in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the grid, the recess defining a third surface angled relative to the first and second surfaces and intersecting the first surface to receive and contact a second edge surface of the grid, and the body defining an orifice formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect, wherein the orifice is formed in the body as a blind depth.

[0005] According to another embodiment, the recess defines a fourth surface that is spaced apart from and opposite to the first surface to contact another grid surface of the grid. A second aperture is formed in the fourth surface and is oriented at the convergence of the second, third, and fourth surfaces such that the second and third surfaces do not intersect.

[0006] According to another embodiment, the body defines a first outer surface spaced apart from the first recessed surface. The body defines a second outer surface spaced apart from the second recessed surface. The body defines a third outer surface spaced apart from the third recessed surface. An aperture is formed through the first outer surface.

[0007] According to yet another embodiment, a second aperture is formed through the first surface and the first outer surface. The second aperture is spaced apart from the first aperture.

[0008] According to another embodiment, the recess defines a fourth surface spaced apart from and opposite to the first surface, contacting another frame surface of the grid. A body defines a first outer surface spaced apart from the first recess surface. A body defines a second outer surface spaced apart from the second recess surface. A body defines a third outer surface spaced apart from the third recess surface. A body defines a fourth outer surface spaced apart from the fourth recess surface. An aperture is formed through the first outer surface.

[0009] According to yet another embodiment, the aperture does not penetrate the fourth outer surface.

[0010] According to another embodiment, the second orifice is formed as a blind depth through the surface of the fourth recess.

[0011] According to another embodiment, the second aperture is formed through the fourth recessed surface but not through the fourth outer surface.

[0012] According to another embodiment, the body is formed of polypropylene material.

[0013] According to another embodiment, the frame assembly is provided with a corner protector having a body having a recess formed therein, the recess defining a first surface to receive and contact the frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the frame, the recess defining a third surface angled relative to the first and second surfaces and intersecting the first surface to receive and contact a second edge surface of the frame, and the body defining an orifice formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect, wherein the orifice is formed in the body as a blind depth. The frame is received in the recess of the corner protector, the frame defines a first frame surface that contacts the surface of the first recess, the frame defines a first edge surface that contacts the surface of the second recess, and the frame defines a second edge surface that contacts the surface of the third recess, wherein the first frame surface, the first edge surface, and the second edge surface converge at the corner of the frame, such that an opening is defined near the corner of the frame, in the gap between the first frame surface and the first recess surface.

[0014] According to another embodiment, the retaining element is attached to the corner protector and the frame to retain the corner protector on the frame.

[0015] According to another embodiment, the recess defines a fourth surface that is spaced apart from and opposite to the first surface, contacting another frame surface of the grid. An aperture is formed in the fourth surface and oriented at the convergence of the second, third, and fourth surfaces such that the second and third surfaces do not intersect.

[0016] According to another embodiment, a frame assembly is provided, comprising: a frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first and second frame surfaces, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame. A plurality of corner protectors each have a body having a recess formed therein, the recess defining a first surface to receive and contact the frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact the first edge surface of the frame, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact the second edge surface of the frame, and the body defining an orifice formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect, wherein the orifice is formed in the body as a blind depth. Each corner protector receives one corner of the corner of the frame.

[0017] According to another embodiment, the frame is further defined as a glass shower door.

[0018] According to another embodiment, the packaged frame assembly is provided with a box. The frame assembly is received in the box. A frame assembly is provided having: a frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first and second frame surfaces, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame. A plurality of corner protectors each have a body having a recess formed in the body, the recess defining a first surface to receive and contact the frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact the first edge surface of the frame, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact the second edge surface of the frame, and the body defining an orifice formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect, wherein the orifice is formed in the body as a blind depth. Each corner protector accepts one corner of the frame.

[0019] According to another embodiment, the frame assembly is provided with a corner protector having a body having a recess formed therein, the recess defining a first surface to receive and contact a frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the frame, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact a second edge surface of the frame, and the body defining an aperture formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect, wherein the aperture is formed in the body as a blind depth. The recess defines a fourth surface spaced apart from and opposite to the first surface to contact another frame surface of the frame. The aperture is formed in the fourth surface and oriented at the convergence of the second, third, and fourth surfaces such that the second and third surfaces do not intersect. A frame is received in a recess of a corner protector. The frame defines a first frame surface that contacts a first recess surface, a second frame surface that contacts a fourth recess surface, a first edge surface that contacts the second recess surface, and a second edge surface that contacts a third recess surface. The first frame surface, the first edge surface, and the second edge surface converge at the corner of the frame, such that an opening is defined near the corner of the frame in the gap between the first frame surface and the first recess surface, and the opening also defines the gap between the second frame surface and the fourth recess surface.

[0020] According to another embodiment, a packaged frame assembly is provided, the packaged frame assembly having a box and a frame assembly received within the box. A frame assembly is provided having: a frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first and second frame surfaces, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame. Multiple corner protectors, each corner protector receiving one corner of a frame, wherein each corner protector is provided with a body having a recess formed therein, the recess defining a first surface to receive and contact a first frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the frame, the recess defining a third surface angled relative to the first and second surfaces and intersecting the first surface to receive and contact a second edge surface of the frame, and the body defining an opening formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect.

[0021] According to another embodiment, multiple foam components are oriented inside the box and surround the frame assembly.

[0022] According to another embodiment, a corner protector assembly is provided, the corner protector assembly having a corner protector sized to receive the corner of a frame. A retainer is attached to the corner protector to attach the corner protector to the frame.

[0023] According to another embodiment, the retaining member is provided with an adhesive label.

[0024] The embodiment may include one or more of the following features: A corner protector, wherein a recess defines a fourth surface spaced apart from and opposite to a first surface to contact another frame surface of a grid; and wherein a second aperture is formed in the fourth surface and oriented at the convergence of the second, third, and fourth surfaces such that the second and third surfaces do not intersect. A body defines a first outer surface spaced apart from the first recess surface; wherein the body defines a second outer surface spaced apart from the second recess surface; wherein the body defines a third outer surface spaced apart from the third recess surface; and wherein an aperture is formed through the first outer surface. A second aperture is formed through the first surface and the first outer surface; and wherein the second aperture is spaced apart from the first aperture. A recess defines a fourth surface, spaced apart from and opposite to the first surface, to contact another frame surface of the grid; wherein a body defines a first outer surface spaced apart from the first recess surface; wherein a body defines a second outer surface spaced apart from the second recess surface; wherein a body defines a third outer surface spaced apart from the third recess surface; wherein a body defines a fourth outer surface spaced apart from the fourth recess surface; and wherein an orifice is formed through the first outer surface. An orifice is formed without passing through the fourth outer surface. A second orifice is formed through the fourth recess surface as a blind depth. A second orifice is formed through the fourth recess surface without passing through the fourth outer surface. The body is formed of polypropylene material. The first frame surface, the first edge surface, and the second edge surface converge at the corner of the grid such that an orifice defines a gap located near the corner of the grid between the first frame surface and the first recess surface. The grid assembly may include a retainer attached to the corner protector and the grid to retain the corner protector on the grid. Each intersection of a pair of adjacent edge surfaces defines a corner of the frame; and a plurality of corner protectors, each corner protector receiving one corner of the frame. The frame may further include a glass shower door. A packaged frame assembly may include: a box, and a frame assembly received within the box. A recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the frame; and wherein an opening is formed in the fourth surface and oriented at the convergence of the second, third, and fourth surfaces such that the second and third surfaces do not intersect. The first frame surface, the first edge surface, and the second edge surface converge at the corner of the frame such that the opening defines a gap disposed near the corner of the frame between the first frame surface and the first recess surface, and the opening defines a gap between the second frame surface and the fourth recess surface.

[0025] One general embodiment includes a packaged frame assembly, which further includes a box. The component also includes a frame assembly received within the box, the frame assembly including: a frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first and second frame surfaces, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame, and a plurality of corner protectors, each corner protector receiving one corner of the corner of the frame, wherein each corner protector includes a body having a recess formed therein, the recess defining a first surface to receive and contact the first frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact the first edge surface of the frame, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact the second edge surface of the frame, and the body defining an opening formed in the first surface and oriented at the convergence of the first, second, and third surfaces such that the second and third surfaces do not intersect.

[0026] Embodiments may include one or more of the following features. The packaged frame assembly may include a plurality of foam members oriented within the box and surrounding the frame assembly. Another general embodiment includes a corner protector assembly that further includes corner protectors sized to receive corners of the frame. The assembly also includes a retainer attached to the corner protector to attach the corner protector to the frame.

[0027] According to another embodiment, a corner protector is provided, the corner protector comprising a body having a recess formed therein, the recess defining a first surface to receive and contact a frame surface of a grid within the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the grid, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact a second edge surface of the grid, and the body defining an aperture formed in the first surface and oriented at the convergence of the first surface, the second surface, and the third surface such that the second surface and the third surface do not intersect, wherein the body is formed of a polypropylene material. According to another embodiment, the aperture is formed through the body. According to another embodiment, the recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another grid surface of the frame; and wherein a second orifice is formed in the fourth surface and oriented at the convergence of the second surface, the third surface, and the fourth surface, such that the second surface and the third surface do not intersect. According to another embodiment, the body is formed of a polymer material. According to another embodiment, the corner protector further includes at least one structural rib disposed on the body to enhance the structural integrity of the body. According to another embodiment, the body defines a first outer surface spaced apart from the first surface of the recess; wherein the body defines a second outer surface spaced apart from the second surface of the recess; wherein the body defines a third outer surface spaced apart from the third surface of the recess; and wherein the orifice is formed through the first outer surface. According to another embodiment, the recess defines a fourth surface spaced apart from and opposite to the first surface to contact another frame surface of the grid; wherein the body defines a first outer surface spaced apart from the first surface of the recess; wherein the body defines a second outer surface spaced apart from the second surface of the recess; wherein the body defines a third outer surface spaced apart from the third surface of the recess; wherein the body defines a fourth outer surface spaced apart from the fourth surface of the recess; wherein the aperture is formed through the first outer surface; and wherein a second aperture is formed through the fourth outer surface.According to another embodiment, a frame assembly is provided, including a corner protector; and a frame received in a recess of the corner protector, the frame defining a first frame surface contacting a first surface of the recess, the frame defining a first edge surface contacting a second surface of the recess, and the frame defining a second edge surface contacting a third surface of the recess, wherein the first frame surface, the first edge surface, and the second edge surface converge at a corner of the frame such that an opening defines a gap disposed near the corner of the frame between the first surface and the first frame surface of the recess. According to another embodiment, the frame assembly further includes a retaining member attached to the corner protector and the frame to retain the corner protector on the frame. According to another embodiment, a frame assembly is provided, comprising: a frame defining a first frame surface and a second frame surface spaced apart from the first frame surface; and a plurality of edge surfaces intersecting the first frame surface and the second frame surface, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame; and a plurality of corner protectors, each corner protector according to claim 21, and each corner protector receiving one corner of the corner of the frame. According to another embodiment, the frame further includes a glass shower door. According to another embodiment, a packaged frame assembly is provided, comprising: a box; and a frame assembly received within the box. According to another embodiment, a corner protector has a recess defining a fourth surface spaced apart from and opposite to the first surface to contact another frame surface of the frame; and wherein an opening is formed in the fourth surface and oriented at the convergence of the second surface, the third surface, and the fourth surface such that the second surface and the third surface do not intersect. According to another embodiment, a frame assembly is provided, including: a corner protector; and a frame received in a recess of the corner protector, the frame defining a first frame surface contacting a first surface of the recess, the frame defining a second frame surface contacting a fourth surface of the recess, the frame defining a first edge surface contacting the second surface of the recess, and the frame defining a second edge surface contacting a third surface of the recess, wherein the first frame surface, the first edge surface, and the second edge surface converge at a corner of the frame such that an opening is defined near the corner of the frame, in a gap between the first surface and the first frame surface of the recess, and the opening defines a gap between the second frame surface and the fourth surface of the recess. Attached Figure Description

[0028] Figure 1 This is a front elevation view of a frame assembly according to an embodiment, illustrating a corner protector assembled onto the frame;

[0029] Figure 2 yes Figure 1 A side-view perspective of the corner protector;

[0030] Figure 3 yes Figure 1 A frontal stereoscopic view of the corner protector;

[0031] Figure 4 yes Figure 1 Side elevation view of the corner protector;

[0032] Figure 5 This is a front perspective view of a frame assembly according to another embodiment, illustrating a corner protector assembly assembled onto the frame;

[0033] Figure 6 yes Figure 5 A side-view perspective of the frame component;

[0034] Figure 7 This is a front elevation view of a frame assembly according to another embodiment, illustrating a corner protector assembled onto the frame;

[0035] Figure 8 This is a front elevation view of a frame assembly according to another embodiment, illustrating a corner protector assembled onto the frame;

[0036] Figure 9 This is a front-view 3D view of the packaging components;

[0037] Figure 10 yes Figure 9 Another partial 3D view of the bottom of the packaging components; and

[0038] Figure 11 This is a front perspective view of a corner protector according to another embodiment;

[0039] Figure 12 yes Figure 11 An enlarged side view of the corner protector; and

[0040] Figure 13 It is along Figure 12 The three-dimensional cross-sectional view taken by section line 13-13 in the figure. Detailed Implementation

[0041] Detailed embodiments of the invention are disclosed herein as needed; however, it should be understood that the disclosed embodiments are merely examples of the invention and may be implemented in different and alternative forms. The drawings are not necessarily drawn to scale; some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as a representative basis for teaching those skilled in the art to employ the invention in different ways.

[0042] It will be understood that although the terms "first," "second," etc., may be used herein to describe various elements in some instances, these elements should not be limited by these terms. These terms are used only to distinguish one element from another and are presented in the order of description of a particular embodiment, and may vary in the description of various embodiments. For example, a first surface may be referred to as a second surface without departing from the scope of the various embodiments described, and similarly, a second surface may be referred to as a first surface. Both the first and second surfaces are surfaces, but in the context of a particular embodiment, they are not the same surface.

[0043] Shower door assemblies are used in conjunction with shower enclosures and are designed to contain water within the enclosure and prevent water from spilling onto the bathroom floor. Shower doors are typically made of glass, although some may be made of acrylic, plastic, or any suitable frame. Glass doors can be clear, frosted, or patterned to provide different levels of privacy and style.

[0044] Shower door assemblies offer a variety of options and styles. For example, sliding shower door assemblies consist of two or more panels that slide along a track. Sliding shower door assemblies are compact and space-saving because they don't require additional space to swing open. Hinged or swing shower door assemblies open outwards at hinges. Swing shower door assemblies require sufficient space to swing open but offer a traditional look and ease of access. Bi-folding shower door assemblies fold in on themselves and are best suited for very tight spaces. Frameless shower door assemblies are made of tempered glass with a minimal metal frame for a sleek, modern look that is easier to clean. Framed shower door assemblies include a metal frame surrounding the glass, providing additional support and sometimes additional features (like built-in hardware).

[0045] Shower door assemblies offer additional features and hardware. Handles are mounted through the door's frame. In framed designs, handles can be mounted to the frame along the door's edge. Handles come in a variety of styles and finishes, from smooth chrome to brushed nickel. Rubber or silicone seals can be installed along the shower door's edge to help prevent leaks and maintain water retention. For sliding doors, the track subassembly may include a top track and sometimes a bottom track to guide the door's movement. Some doors have built-in towel bars or hooks for added convenience, which can also function as handles.

[0046] Shower door designs can range from minimalist to glamorous, depending on the overall décor of the bathroom. Clear glass doors can make a space feel larger and more open, while frosted or patterned glass can provide additional privacy. The chosen shower door components combine functionality with aesthetics, helping to define the look and usability of the shower enclosure.

[0047] Shower door assemblies are typically manufactured at one or more facilities and then shipped to retail locations for retail distribution. Alternatively, shower door assemblies may be shipped directly to the end customer. Shower door assemblies are packaged for transport to retail and end-user locations. Shower door assemblies may be packaged together with shower door frames that are packaged separately from other components. Alternatively, shower door assemblies may be packaged together with other features and hardware, such as handles, seals, track subassemblies, towel bars, etc.

[0048] refer to Figure 1 The corners of the shower door frame 20 are illustrated as partially wrapped with corner protectors 22. The shower door frame 20 has a first frame surface 24 and a second frame surface 26, the second frame surface being spaced apart from the first frame surface 24 by a certain thickness. The first frame surface 24 and the second frame surface 26 are generally parallel within normal manufacturing tolerances. The shower door frame 20 can be implemented in a typical shower door frame shape (e.g., a rectangular shape), whereby each of the frame surfaces 24, 26 is generally rectangular. The shower door frame 20 also includes a plurality of edge surfaces 28, 30, 32, 34 formed around the perimeter of the frame 20. Figure 1 The illustration shows two edge surfaces 28 and 30, which can be described as a first edge surface 28 and a second edge surface 30, or as a left edge surface 28 and a bottom edge surface 30. Each of the edge surfaces 28, 30, 32, and 34 may be generally planar within manufacturing tolerances and may converge at an edge, which may be rounded, chamfered, or otherwise shaped to reduce stress along the edge.

[0049] like Figure 1As shown, the first frame surface 24, the first edge surface 28, and the second edge surface 30 converge at a corner 36. The corner 36 is rounded, having a chamfer for stress relief. The corner 36 may also provide a corner edge extending to the point of convergence or intersection with the second frame surface 26. The intersections of the frame surfaces 24, 26 with each of the pair of edge surfaces 28, 30, 32, 34 form the corner 36. The corner 36 of the frame 20 is typically the most fragile part of the product 20.

[0050] Shower door frames 20 are typically made of glass, which is particularly vulnerable to damage at the corners 36 of the frame 20. Although glass shower door frames 20 have been described, other suitable materials, such as transparent materials, acrylic, or polymer materials, may also be considered.

[0051] Existing technology has employed corner protectors to protect corner 36 from direct edge contact or impact, and to distribute the load along the surfaces 24, 26, 28, 30, 32, 34 of the frame 20, away from corner 36. Corner protector 22 suspends corner 36 within itself to further isolate corner 36 from contact, and distributes the load away from corner 36, and away from the frame surfaces 24, 26 and edge surfaces 28, 30, 32, 34 of the frame 20.

[0052] Corner protector 22 Figures 1 to 4 Further detailed illustrations are provided. The corner protector 22 has a body 38, which can be formed from a polymeric material (such as polypropylene) or any suitable structural material. Polypropylene is useful in its balance of strength, flexibility, and chemical resistance, making it a versatile material in both industrial and consumer products. Polypropylene provides elasticity and reduced stiffness to absorb loads while resisting breakage or failure. Other suitable materials may include polycarbonate compounds, which are highly functional engineering plastics with physical properties enhanced by reinforcement with fillers and alloying with styrene resins (such as acrylonitrile butadiene styrene). The corner protector 22 can be molded, extruded, machined, or manufactured using additive manufacturing processes or other suitable manufacturing processes.

[0053] The corner protector 22 includes a recess 40 or groove formed in the body 38. The recess 40 is sized to receive the corner 36 of the frame 20. The recess 40 divides the body 38 into a pair of spaced-apart walls 42, 44, which are interconnected by a pair of webs 46, 48. The recess 40 provides passage to a pair of wall surfaces 50, 52 disposed within the recess 40 and on one of the walls 42, 44. The wall surfaces 50, 52 are spaced apart and sized to receive and contact the frame surfaces 24, 26 of the frame 20 therebetween, respectively. The wall surfaces 50, 52 may each be substantially flat and substantially parallel within manufacturing tolerances.

[0054] The recess 40 is formed as a blind depth, thereby making the webs 46, 48 angled relative to each other and interconnecting the walls 42, 44. For example, the webs 46, 48 are generally perpendicular to each other within manufacturing tolerances. Each of the webs 46, 48 provides a web surface 54, 56 within the recess 40. The web surfaces 54, 56 are also generally perpendicular to each other within manufacturing tolerances. The wall surfaces 50, 52 each intersect with the first web surface 54 and the second web surface 56. Within manufacturing tolerances, the wall surfaces 50, 52 are generally perpendicular to each of the first web surface 54 and the second web surface 56. The dimensions of the web surfaces 54, 56 are determined to receive two adjacent edge surfaces 28, 30 of the frame 20. Four corner protectors 22 can be assembled onto the four corners 36 of the rectangular frame 20 as frame assemblies 58.

[0055] In the body 38, an opening 60 is formed at the convergence of the first wall surface 50, the first web surface 54, and the second web surface 56, thereby preventing these three surfaces 50, 54, and 56 from intersecting at the corners. The opening 60 is formed through the body 38 and thus also extends through the second wall surface 52 at the convergence with the first web surface 54 and the second web surface 56. The opening 60 thus prevents the second wall surface 52, the first web surface 54, and the second web surface 56 from intersecting at the corners. The opening 60 is partially separated by a recess 40, thereby defining two separate openings 60 through the walls 42 and 44. Although the opening 60 is illustrated as being formed through both walls 42 and 44, the opening 60 may be formed through only one wall (e.g., wall 42).

[0056] An aperture 60 defines a cavity 62 within the body 38, which provides a gap between the wall surfaces 50, 52 of the body 38 and the frame surfaces 24, 26 of the frame 20 near the corner 36 of the frame 20. The gap can be a suitable size for suspending the corner 36 within the body 38, for example, 3.5 mm. The aperture 60 is formed through walls 42, 44 at the intersection of the wall surfaces 50, 52 and the web surfaces 54, 56. Therefore, the cavity 62 also provides a gap between the first web surface 54 and the first edge surface 28 of the frame 20. The gap between the first web surface 54 and the first edge surface 28 of the frame 20 can be a suitable size for suspending the corner 36 within the body 38, for example, 3.5 mm. The cavity 62 also provides a gap between the second web surface 56 and the second edge surface 30 of the frame 20. The gap between the second web surface 56 and the second edge surface 30 of the frame 20 can be a suitable size for suspending the corner portion 36 within the body 38, for example, 3.5 mm. Generally, the corner portion 36 is suspended from the body 38 along the four surfaces 24, 26, 28, 30 of the frame 20.

[0057] By suspending the corner 36, the load applied to the corner protector 22 is distributed along the frame surfaces 24, 26 and the edge surfaces 28, 30 to the frame 20, away from the corner 36, to avoid direct impact or stress on the corner 36 or along the edge formed by the corner 36. Therefore, the load is distributed to the less fragile surfaces 24, 26, 28, 30 of the frame 20 than the corner 36.

[0058] Corner protectors 22 optimize structural integrity to support and protect the corners 36 of the frame 20. Walls 42 and 44 have outer surfaces 64 and 66 to protect the areas of the frame surfaces 24 and 26 extending beyond the corners 36. Similarly, webs 46 and 48 also have outer surfaces 68 and 70 to protect the areas of the edge surfaces 28 and 30 extending beyond the corners 36. Structural ribs 72 are provided on the outer wall surfaces 64 and 66 to increase the structural reinforcement and additional stiffness of the walls 42 and 44.

[0059] An aperture 60 is formed through the outer wall surfaces 64, 66 to provide a window 60 for observing the corner 36. According to an embodiment, when the aperture 60 is formed through only one wall surface 64, the aperture 60 provides a window 60 for observing the corner 36 through one side 64 of the corner protector 22. During the unpacking of the frame 20, the end user can use the window 60 to visually inspect the corner 36 to determine if the frame 20 has been transported undamaged. If so, the end user can proceed with the unpacking and installation of the frame 20. If the corner 36 of the frame 20 is damaged, the end user can repackage the frame 20 without removing the corner protector 22. According to another embodiment, the aperture 60 is formed as a blind depth without a window to provide additional protection against accidental contact with the corner 36.

[0060] The corner protector 22 is designed to optimize protection of the frame 20 while being compact enough to minimize packaging for transport. Similarly, the corner protector 22 is compact enough to protect the corners 36 during the installation of the frame 20. The corner protector 22 can be removed after the frame 20 has been installed.

[0061] See now Figure 5 and Figure 6 A retaining element 74 is used to secure the corner protector 22 to the corner 36 of the frame 20. The retaining element 74 is illustrated as an adhesive label 74, which adheres to both the corner protector 22 and the frame 20 to secure the corner protector 22 in its installed position. Once installation is complete, the end user can peel the label 74 off the frame 20 and then remove the corner protector 22 and the label 74. The corner protector 22 and the label 74 together provide a corner protector assembly 76 according to an embodiment. The label 74 may include an information mark with instructions on how to remove the label 74 after the frame 20 has been installed.

[0062] Corner protectors 22 allow manufacturers to ship the shower door assembly frame 20 to retailers or directly to end users via a package shipping distribution chain. The robustness of corner protectors 22 can be manifested in various shapes, thicknesses, materials, etc., as appropriate for specific applications.

[0063] The corner protector 22 has generally square walls 42, 44. However, other shapes are possible. The corner protector 22 may have recesses 40 of varying width to receive frames 20 of varying thickness or material. The corner protector 22 suspends the corners 36 of the frame 20 so that the corners 36 do not come into contact with the corner protector 22, other objects or surfaces, or other packaging. The thickness of the walls 42, 44 and the webs 46, 48 may vary depending on the size, weight, fragility, intended transport, or intended use of the particular frame 20. The corner protector 22 provides a streamlined appearance without the need for additional buffers associated with prior art corner protectors. The corner protector 22 may be embossed with a company logo, text, etc.

[0064] The corner protector 22 has a cavity 62 of a specific shape formed inside its body 38. This internal geometry is designed to work with the required material type and thickness such that when the corner protector 22 is placed on the frame 20, it stops at a specific point to create a certain amount of space between the corner 36 of the product 20 and the end of the corner protector 22. The corner protector 22 can be used with mirrors, glass frames, wood, metal, or any suitable material, and at any suitable thickness.

[0065] The cavity 62 of the corner protector 22 may or may not have a window 60 to view the corner 36 of the product for observation of the condition of the product 20 and whether the corner protector 22 is correctly installed. The thickness and material of the corner protector 22 may vary depending on the fragility of the product and its use, with embossed design standards used for added strength and / or branding. The area surrounding the cavity 62 is solid to "frame" the cavity 62 and help protect the product 20 and the corner protector 22. This "frame" may be removed at the inward corners of the corner protector 22 to further expose the product 20, but still provides protection by transferring stress to the edge surfaces 28, 30, 32, 34. The corner protector 22 may be implemented in a range of shapes depending on cost, level of protection, brand adhesion, etc. Adhesives (tape, label 74, etc.) may be used to hold the corner protector 22 attached to the product 20 for installation (if required).

[0066] Figure 7 The illustration shows a corner protector 90 according to another embodiment. The corner protector 90 has a body 92, which can be formed from a polymeric material (such as polypropylene, polycarbonate compounds), or any suitable structural material. The corner protector 90 can be molded, extruded, machined, or manufactured using additive manufacturing processes or other suitable manufacturing processes.

[0067] The corner protector 90 includes a recess 94 or groove formed in the body 92. The recess 94 is sized to receive the corner 36 of the frame 20. The recess 94 divides the body 92 into a pair of spaced-apart walls 96 interconnected by a pair of webs 98, 100. The recess 94 provides passage to a pair of wall surfaces 102 disposed within the recess 94, each on one of the walls 96. The wall surfaces 102 are spaced apart and sized to receive and contact the frame surfaces 24, 26 of the frame 20 therebetween. The wall surfaces 102 may each be substantially flat and substantially parallel within manufacturing tolerances.

[0068] The recess 94 is formed to a certain depth, thereby making the webs 98 and 100 angled relative to each other and interconnecting the walls 96. For example, the webs 98 and 100 are generally perpendicular to each other within manufacturing tolerances. Each of the webs 98 and 100 provides a web surface 104, 106 within the recess 94. The web surfaces 104 and 106 are also generally perpendicular to each other within manufacturing tolerances. Wall surfaces 102 each intersect the first web surface 104 and the second web surface 106. Within manufacturing tolerances, the wall surfaces 102 are generally perpendicular to each of the first web surface 104 and the second web surface 106. The dimensions of the web surfaces 104 and 106 are determined to receive two adjacent edge surfaces 28 and 30 of the frame 20. Four corner protectors 90 can be assembled onto the four corners 36 of the rectangular frame 20 as frame assemblies 108.

[0069] In the body 92, an opening 110 is formed at the convergence of the first wall surface 102, the first web surface 104, and the second web surface 106, thereby preventing these three surfaces 102, 104, and 106 from intersecting at the corners. The opening 110 is formed through the body 92 and thus also extends through the second wall surface 102 at the convergence with the first web surface 104 and the second web surface 106. The opening 110 thus prevents the second wall surface 102, the first web surface 104, and the second web surface 106 from intersecting at the corners. The opening 110 is partially separated by a recess 94, thereby defining two separate openings 110 through the wall 96. Although the opening 110 is illustrated as being formed through both walls 96, the opening 110 may be formed through only one wall 96.

[0070] An aperture 110 defines a cavity 112 within the body 92, which provides a gap between the wall surface 102 of the body 92 and the frame surfaces 24, 26 of the frame 20 near the corner 36 of the frame 20. The gap can be a suitable size for suspending the corner 36 within the body 92. The aperture 110 is formed through the wall 96 at the intersection of the wall surface 102 and the web surfaces 104, 106. Therefore, the cavity 112 also provides a gap between the first web surface 104 and the first edge surface 28 of the frame 20. The gap between the first web surface 104 and the first edge surface 28 of the frame 20 can be a suitable size for suspending the corner 36 within the body 92. The cavity 112 also provides a gap between the second web surface 106 and the second edge surface 30 of the frame 20. The gap between the second web surface 106 and the second edge surface 30 of the frame 20 can be a suitable size for suspending the corner 36 within the body 92. Overall, the corner 36 is suspended from the body 92 along the four surfaces 24, 26, 28, and 30 of the frame 20.

[0071] By suspending the corner 36, the load applied to the corner protector 90 is distributed along the frame surfaces 24, 26 and the edge surfaces 28, 30 to the frame 20, away from the corner 36, to avoid direct impact or stress on the corner 36 or along the edge formed by the corner 36. Therefore, the load is distributed to the less fragile surfaces 24, 26, 28, 30 of the frame 20 than the corner 36.

[0072] Corner protectors 90 optimize structural integrity to support and protect the corners 36 of the frame 20. Wall 96 has an outer surface 114 to protect the areas of the frame surfaces 24, 26 extending beyond the corners 36. Similarly, webs 98, 100 also have outer surfaces 116, 118 to protect the areas of the edge surfaces 28, 30 extending beyond the corners 36. Structural ribs 120 are provided on the outer wall surface 114 to increase the structural reinforcement and additional stiffness of the wall 96.

[0073] An opening 110 is formed through the outer wall surface 96 to provide a window 110 for observing the corner 36. According to an embodiment, when the opening 110 is formed through only one wall surface 96, the opening 110 provides a window 110 for observing the corner 36 through one side 96 of the corner protector 90. During the unpacking of the frame 20, the end user can use the window 110 to visually inspect the corner 36 to determine if the frame 20 has been transported undamaged. If so, the end user can proceed with the unpacking and installation of the frame 20. If the corner 36 of the frame 20 is damaged, the end user can repackage the frame 20 without removing the corner protector 90.

[0074] The corner protector 90 is designed to optimize protection of the frame 20 while being compact enough to minimize packaging for transport. Similarly, the corner protector 90 is compact enough to protect the corners 36 during the installation of the frame 20. The corner protector 90 can be removed after the frame 20 has been installed.

[0075] Corner protectors 90 allow manufacturers to ship shower door assembly frames 20 to retailers or directly to end users via a package shipping distribution chain. The robustness of corner protectors 90 can be manifested in various shapes, thicknesses, materials, etc., depending on the specific application.

[0076] The corner protector 90 has a generally square wall 96. A cavity 112 of a specific shape is created within the body 92 of the corner protector 90. This internal geometry is designed to work with the required material type and thickness such that when the corner protector 90 is placed on the frame 20, it stops at a specific point to create a certain amount of space between the corner 36 of the product 20 and the end of the corner protector 90. The corner protector 90 can be used with glass frames, wood, metal, or any suitable material, and at any suitable thickness.

[0077] The cavity 112 of the corner protector 90 may or may not have a window 110 to view the corner 36 of the product to observe the condition of the product 20 and whether the corner protector 90 is correctly installed. The thickness and material of the corner protector 90 may vary depending on the fragility of the product and its use, with embossed design standards used for added strength and / or branding. An opening 122 is formed through the webs 98, 100 to enter the cavity 112, further suspending the corner 36 of the frame 20 within the corner protector 90. The opening 122 further exposes the product 20 but still protects the frame 20 by transferring stress to the edge surfaces 28, 30, 32, 34, which are stronger than the corner 36. The corner protector 90 can be implemented in a range of shapes depending on cost, level of protection, brand adhesion, etc.

[0078] Figure 8 The illustration shows a corner protector 130 according to another embodiment. The corner protector 130 has a body 132, which may be formed from a polymeric material (such as polypropylene, polycarbonate compounds), or any suitable structural material. The corner protector 130 may be molded, extruded, machined, or manufactured using additive manufacturing processes or other suitable manufacturing processes.

[0079] The corner protector 130 includes a recess 134 formed in the body 132. The recess 134 is sized to receive the corner 36 of the frame 20. The recess 134 divides the body 132 into a pair of spaced-apart walls 136 interconnected by a pair of webs 138, 140. The recess 134 provides access to a pair of wall surfaces 142 disposed within the recess 134, each on one of the walls 136. The wall surfaces 142 are spaced apart and sized to receive and contact the frame surfaces 24, 26 of the frame 20 therebetween. The wall surfaces 142 may each be substantially flat and substantially parallel within manufacturing tolerances.

[0080] The recess 134 is formed to a depth such that the webs 138, 140 are angled relative to each other and the walls 136 are interconnected. For example, the webs 138, 140 are generally perpendicular to each other within manufacturing tolerances. The webs 138, 140 each provide web surfaces 144, 146 within the recess 134. The web surfaces 144, 146 are also generally perpendicular to each other within manufacturing tolerances. The wall surfaces 142 each intersect the first web surface 144 and the second web surface 146. Within manufacturing tolerances, the wall surfaces 142 are generally perpendicular to each of the first web surface 144 and the second web surface 146. The dimensions of the web surfaces 144, 146 are determined to receive two adjacent edge surfaces 28, 30 of the frame 20. Four corner protectors 130 can be assembled onto the four corners 36 of the rectangular frame 20 as frame assemblies 148.

[0081] In the body 132, an opening 150 is formed at the convergence of the first wall surface 142, the first web surface 144, and the second web surface 146, thereby preventing these three surfaces 142, 144, and 146 from intersecting at the corners. The opening 150 is formed through the body 132 and thus also extends through the second wall surface 142 at the convergence with the first web surface 144 and the second web surface 146. The opening 150 thus prevents the second wall surface 142, the first web surface 144, and the second web surface 146 from intersecting at the corners. The opening 150 is partially separated by a recess 134, thereby defining two separate openings 150 through the wall 136. Although the opening 150 is illustrated as being formed through both walls 136, the opening 150 may be formed through only one wall 136.

[0082] An aperture 150 defines a cavity 152 within the body 132, which provides a gap between the wall surface 142 of the body 132 and the frame surfaces 24, 26 of the frame 20 near the corner 36 of the frame 20. The gap can be a suitable size for suspending the corner 36 within the body 132. The aperture 150 is formed through the wall 136 at the intersection of the wall surface 142 and the web surfaces 144, 146. Therefore, the cavity 152 also provides a gap between the first web surface 144 and the first edge surface 28 of the frame 20. The gap between the first web surface 144 and the first edge surface 28 of the frame 20 can be a suitable size for suspending the corner 36 within the body 132. The cavity 152 also provides a gap between the second web surface 146 and the second edge surface 30 of the frame 20. The gap between the second web surface 146 and the second edge surface 30 of the frame 20 can be a suitable size for suspending the corner 36 within the body 132. Overall, the corner 36 is suspended from the body 132 along the four surfaces 24, 26, 28, 30 of the frame 20.

[0083] By suspending the corner 36, the load applied to the corner protector 130 is distributed along the frame surfaces 24, 26 and the edge surfaces 28, 30 to the frame 20, away from the corner 36, to avoid direct impact or stress on the corner 36 or the edge formed along the corner 36. Therefore, the load is distributed to the less fragile surfaces 24, 26, 28, 30 of the frame 20 than the corner 36.

[0084] Corner protectors 130 optimize structural integrity to support and protect the corners 36 of the frame 20. Wall 136 has an outer surface 154 to protect the areas of the frame surfaces 24, 26 extending beyond the corners 36. Similarly, webs 138, 140 also have outer surfaces 156, 158 to protect the areas of the edge surfaces 28, 30 extending beyond the corners 36. Structural ribs 160 are provided on the outer wall surface 154 to increase the structural reinforcement and additional stiffness of the wall 136.

[0085] An opening 150 is formed through the outer wall surface 142 to provide a window 150 for observing the corner 36. According to an embodiment, when the opening 150 is formed through only one wall surface 142, the opening 150 provides a window 150 for observing the corner 36 through one side 142 of the corner protector 130. During the unpacking of the frame 20, the end user can use the window 150 to visually inspect the corner 36 to determine if the frame 20 has been transported undamaged. If so, the end user can proceed with the unpacking and installation of the frame 20. If the corner 36 of the frame 20 is damaged, the end user can repackage the frame 20 without removing the corner protector 130.

[0086] The corner protector 130 is designed to optimize protection of the frame 20 while being compact enough to minimize packaging for transport. Similarly, the corner protector 130 is compact enough to protect the corners 36 during the installation of the frame 20. The corner protector 130 can be removed after the frame 20 has been installed.

[0087] Corner protector 130 allows manufacturers to ship the shower door assembly frame 20 to retailers or directly to end users via a package shipping distribution chain. The robustness of corner protector 130 can be manifested in various shapes, thicknesses, materials, etc., as appropriate for specific applications.

[0088] The corner protector 130 is provided with generally triangular walls 136. By utilizing the triangular walls 136, the corner protector 130 provides a triangular shape, thereby reducing material usage compared to previous embodiments. The corner protector 130 creates a cavity 152 of a specific shape within its body 132. This internal geometry is designed to work with the required material type and thickness such that when the corner protector 130 is placed on the frame 20, it stops at a specific point to create a certain amount of spacing between the corner 36 of the product 20 and the end of the corner protector 130. The corner protector 130 can be used with glass frames, wood, metal, or any suitable material, and at any suitable thickness.

[0089] The cavity 152 of the corner protector 130 may or may not have a window 150 to view the corner 36 of the product to observe the condition of the product 20 and whether the corner protector 130 is correctly installed. The thickness and material of the corner protector 130 may vary depending on the fragility of the product and its intended use, wherein embossed design standards are used for added strength and / or branding. The corner protector 130 may be implemented in a range of shapes depending on cost, level of protection, brand adhesion, etc.

[0090] Figure 10 The illustration shows a corner protector 170 according to another embodiment. The corner protector 170 has a body that can be formed from a polymeric material (such as polypropylene, polycarbonate compounds), or any suitable structural material. The corner protector 170 can be molded, extruded, machined, or manufactured using additive manufacturing processes or other suitable manufacturing processes.

[0091] The four corner protectors 170 can be assembled onto the four corners 36 of the rectangular frame 20 as frame components 192.

[0092] By suspending the corner 36, the load applied to the corner protector 170 is distributed along the frame surfaces 24, 26 and the edge surfaces 32, 34 to the frame 20, away from the corner 36, to avoid direct impact or stress on the corner 36 or the edges formed along the corner 36. Therefore, the load is distributed to the less fragile surfaces 24, 26, 28, 30 of the frame 20 than the corner 36.

[0093] Corner protectors 170 optimize structural integrity to support and protect the corners 36 of the frame 20. The walls have outer surfaces to protect the areas of the frame surfaces 24, 26 extending beyond the corners 36. Similarly, the web also has an outer surface 202 to protect the areas of the edge surfaces 32, 34 extending beyond the corners 36.

[0094] The corner protector 170 is designed to optimize protection of the frame 20 while being compact enough to minimize packaging for transport. Similarly, the corner protector 170 is compact enough to protect the corners 36 during the installation of the frame 20. The corner protector 170 can be removed after the frame 20 has been installed.

[0095] Corner protector 170 allows manufacturers to ship shower door assembly frames 20 to retailers or directly to end users via a package shipping distribution chain. The robustness of corner protector 170 can be manifested in various shapes, thicknesses, materials, etc., as appropriate for specific applications.

[0096] The thickness and material of the corner protector 170 can vary depending on the product's fragility and intended use, with embossed design standards used for added strength and / or branding. The corner protector 170 can be implemented in a range of shapes to suit different needs, such as cost, level of protection, and brand adhesion.

[0097] Figures 9 to 10 The illustration shows the packaged frame assembly 208 used for frame assembly 192. (See diagram for example.) Figure 9 As shown, the packaged frame assembly 208 includes a carton or box 210, which can be formed from cardboard or any suitable packaging material. The box 210 holds a pair of frame assemblies 192 for use with a shower door assembly employing two frames 20. The packaged frame assembly 192 can use any number of frames 20 for suitable shower door enclosures. Figure 9 and Figure 10 As shown, the frame components 208 are stacked such that the corner protectors 170 are directly stacked on top of each other, wherein each corner protector 170 engages with the structural ribs 206 of the adjacent corner protector 170.

[0098] like Figure 9 and Figure 10 As shown, the packaged frame assembly 208 includes a plurality of foam side members 212 and a plurality of foam transverse members 214. The foam members 212, 214 provide additional protection and damping to protect the frame assembly 192 during transport. According to an embodiment, the side members 212 may include recesses 216 for gaps in the corner protectors 170. The lower corner protectors 170 are suspended within the foam members 212, 214, such that the lower corner protectors 170 rest directly within the carton 210. Alternatively, the recesses 216 may be omitted; and due to the dimensions between the corner protectors 170 and the glass frame 20, space can be provided within the box 210. According to another embodiment, the space within the box 210 may be filled with padding material, such as corrugated cardboard or another packaging material.

[0099] Now for reference Figure 10Other shower door hardware can also be packaged in the pre-packaged frame assembly 208. Additional hardware may include tracks 218, seals 220, etc.

[0100] refer to Figures 11 to 13 The illustration shows a corner protector 322 according to another embodiment. Similar to the previous embodiment, the corner protector 322 is configured to suspend the corners 36 of the frame 20 within the corner protector 322 to further isolate the corners 36 from contact and to distribute the load away from the corners 36 and away from the frame surfaces 24, 26 and edge surfaces 28, 30, 32, 34 of the frame 20. The corner protector 322 has a body 338, which can be formed from a polymeric material (such as polypropylene) or any suitable structural material. The corner protector 322 can be molded, extruded, machined, or manufactured using additive manufacturing processes or other suitable manufacturing processes.

[0101] Corner protector 322 includes a recess 340 or groove formed in body 338, such as Figure 12 and Figure 13 As shown. The dimensions of the recess 340 are determined to be the corner 36 of the receiving frame 20. See again. Figures 11 to 13 The recess 340 divides the body 338 into a pair of spaced-apart walls 342, 344, which are interconnected by a pair of webs 346, 348. Figure 12 and Figure 13 As depicted, the recess 340 provides passageway to a pair of wall surfaces 350, 352 disposed within the recess 340, each on one of the walls 342, 344. The wall surfaces 350, 352 are spaced apart and sized to receive and contact the frame surfaces 24, 26 of the frame 20 therebetween, respectively. The wall surfaces 350, 352 may each be substantially flat and substantially parallel within manufacturing tolerances.

[0102] The recess 340 is formed as a blind depth, thereby making the webs 346, 348 angled relative to each other and interconnecting the walls 342, 344. For example, the webs 346, 348 are generally perpendicular to each other within manufacturing tolerances. The webs 346, 348 each provide web surfaces 354, 356 within the recess 340. The web surfaces 354, 356 are also generally perpendicular to each other within manufacturing tolerances. The wall surfaces 350, 352 each intersect with the first web surface 354 and the second web surface 356. Within manufacturing tolerances, the wall surfaces 350, 352 are generally perpendicular to each of the first web surface 354 and the second web surface 356. The dimensions of the web surfaces 354, 356 are determined to receive two adjacent edge surfaces 28, 30 of the frame 20. Four corner protectors 322 can be assembled onto the four corners 36 of the rectangular frame 20 as frame assemblies.

[0103] Refer again Figures 11 to 13 In the body 338, a first opening 360 is formed at the convergence of the first wall surface 350, the first web surface 354, and the second web surface 356, thereby preventing the three surfaces 350, 354, and 356 from intersecting at the corners. The opening 360 is formed through the first forward wall 342 of the body 338. The opening 360 extends into a blind depth 362 within the second wall surface 352 at the convergence of the first web surface 354 and the second web surface 356. The opening 360 is formed as a blind depth 362, having only one window to provide additional protection, thereby preventing unintentional contact with the corner 36. The first opening 360 prevents the second wall surface 352, the first web surface 354, and the second web surface 356 from intersecting at the corners. The first opening 360 is partially separated by a recess 340, thereby defining two separate openings 360 through the walls 342 and 344. Although the aperture 360 ​​is illustrated as being formed in two walls 342, 344, the aperture 360 ​​can be formed through one wall (such as wall 342).

[0104] An aperture 360 ​​defines a cavity 364 within the body 338, which provides a gap between the wall surfaces 350, 352 of the body 338 and the frame surfaces 24, 26 of the frame 20 near the corner 36 of the frame 20. The gap can be a suitable size for suspending the corner 36 within the body 338. The aperture 360 ​​is formed in the walls 342, 344 at the intersection of the wall surfaces 350, 352 and the web surfaces 354, 356. Therefore, the cavity 364 also provides a gap between the first web surface 354 and the first edge surface 28 of the frame 20. The gap between the first web surface 354 and the first edge surface 28 of the frame 20 can be a suitable size for suspending the corner 36 within the body 338. The cavity 364 also provides a gap between the second web surface 356 and the second edge surface 30 of the frame 20. The gap between the second web surface 356 and the second edge surface 30 of the frame 20 can be a suitable size for suspending the corner portion 36 within the body 338. Generally, the corner portion 36 is suspended from the body 338 along the four surfaces 24, 26, 28, 30 of the frame 20. The aperture 360 ​​is formed as a pair of intersecting slots, or as an 'L' shape, to align with the intersecting edge surfaces 28, 30 at the corner portion 36 of the frame 20.

[0105] By suspending the corner 36, the load applied to the corner protector 322 is distributed along the frame surfaces 24, 26 and the edge surfaces 28, 30 to the frame 20, away from the corner 36, to avoid direct impact or stress on the corner 36 or along the edge formed by the corner 36. Therefore, the load is distributed to the surfaces 24, 26, 28, 30 of the frame 20 that are less fragile than the corner 36.

[0106] Corner protectors 322 optimize structural integrity to support and protect the corners 36 of the frame 20. Walls 342 and 344 have outer surfaces 366 and 368 to protect the areas of the frame surfaces 24 and 26 extending beyond the corners 36. Similarly, webs 346 and 348 also have outer surfaces 370 and 372 to protect the areas of the edge surfaces 28 and 30 extending beyond the corners 36.

[0107] An opening 360 is formed through the outer wall surface 366 to provide a window 360 for observing the corner 36 through one side 366 of the corner protector 322. During the unpacking of the frame 20, the end user can use the window 360 to visually inspect the corner 36 to determine if the frame 20 has been transported undamaged. If so, the end user can proceed with the unpacking and installation of the frame 20. If the corner 36 of the frame 20 is damaged, the end user can repackage the frame 20 without removing the corner protector 322.

[0108] A second opening 374 is formed through the first wall 344 and enters the recess 340. The second opening 374 is spaced apart from the first opening 360 and provides a window 374 for observing the frame 20 during installation into the recess 340 of the corner protector 322. The window 374 also provides a secondary viewpoint for inspection. The window 374 can be configured as a slot, as shown, offset from the inner edge 376 of the corner protector 322. The second opening 374 can be provided by other shapes and geometries.

[0109] The corner protector 322 is designed to optimize protection of the frame 20 while being compact enough to minimize packaging for transport. Similarly, the corner protector 322 is compact enough to protect the corners 36 during the installation of the frame 20. The corner protector 322 can be removed after the frame 20 has been installed.

[0110] Corner protector 322 allows manufacturers to ship the shower door assembly frame 20 to retailers or directly to end users via a package shipping distribution chain. The robustness of corner protector 322 can be manifested in various shapes, thicknesses, materials, etc., as appropriate for specific applications.

[0111] The corner protector 322 is provided with an inner edge 376 that is angled relative to the webs 346, 348 to provide generally chamfered walls 342, 344. By utilizing the chamfered walls 342, 344, the corner protector 322 provides an overall chamfer or near-triangular shape, thereby reducing material usage compared to previous embodiments. The corner protector 322 may be provided with recesses 340 of varying width to receive frames 20 with varying thickness or material. The corner protector 322 suspends the corners 36 of the frame 20 such that the corners 36 do not come into contact with the corner protector 322, other objects or surfaces, or other packaging. The thickness of the walls 342, 344 and the webs 346, 348 can vary depending on the size, weight, brittleness, designed transport, or intended use of the particular frame 20. The corner protector 322 provides a streamlined appearance without the need for additional buffers associated with prior art corner protectors. The corner protector 322 can be embossed with the company logo, text, etc.

[0112] The corner protector 322 has a cavity 364 of a specific shape formed inside its body 338. This internal geometry is designed to work with the required material type and thickness, such that when the corner protector 322 is placed on the frame 20, it stops at a specific point to create a certain amount of gap between the corner 36 of the product 20 and the end of the corner protector 322. The corner protector 322 can be used with mirrors, glass frames, wood, metal, or any suitable material, and at any suitable thickness.

[0113] The cavity 364 of the corner protector 322 may or may not have a window 360 to view the corner 36 of the product to observe the condition of the product 20 and whether the corner protector 322 is correctly installed. The thickness and material of the corner protector 322 may vary depending on the fragility of the product and its use, with embossed design standards used for added strength and / or branding. The area surrounding the cavity 364 is solid to "frame" the cavity 364 and help protect the product 20 and the corner protector 322. This "frame" can be removed at the inner corner of the corner protector 322 to further expose the product 20, but still provides protection by transferring stress to the edge surfaces 28, 30, 32, 34. The corner protector 322 can be implemented in a range of shapes depending on cost, level of protection, brand adhesion, etc. Adhesives (tape, label 74, etc.) can be used to hold the corner protector 322 attached to the product 20 for installation (if required).

[0114] While various embodiments have been described above, this does not mean that these embodiments describe all possible forms of the invention. Rather, the terms used in this specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the invention. Furthermore, features from different implementations can be combined to form further embodiments of the invention.

Claims

1. A corner protector comprising a body having a recess formed therein, the recess defining a first surface to receive and contact a frame surface of a grid within the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the grid, the recess defining a third surface angled relative to the first and second surfaces and intersecting the first surface to receive and contact a second edge surface of the grid, and the body defining an aperture formed in the first surface and oriented at the convergence of the first surface, the second surface, and the third surface, such that the second surface and the third surface do not intersect, wherein... The orifice is formed as a blind depth in the body.

2. The corner protector as claimed in claim 1, wherein, The recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the grid. and The second orifice is formed in the fourth surface and is oriented at the convergence of the second surface, the third surface, and the fourth surface, such that the second surface and the third surface do not intersect.

3. The corner protector as described in claim 1, wherein, The body defines a first outer surface that is spaced apart from the first surface of the recess; The body defines a second outer surface that is spaced apart from the second surface of the recess; The body defines a third outer surface spaced apart from the third surface of the recess; and The orifice is formed through the first outer surface.

4. The corner protector as described in claim 3, wherein, A second opening is formed by passing through the first surface and the first outer surface; and The second orifice is spaced apart from the first orifice.

5. The corner protector as claimed in claim 1, wherein, The recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the grid. The body defines a first outer surface spaced apart from the first surface of the recess; The body defines a second outer surface that is spaced apart from the second surface of the recess; The body defines a third outer surface that is spaced apart from the third surface of the recess; The body defines a fourth outer surface spaced apart from the fourth surface of the recess; and The orifice is formed through the first outer surface.

6. The corner protector as claimed in claim 5, wherein, The orifice is not formed through the fourth outer surface.

7. The corner protector as claimed in claim 5, wherein, The second opening passes through the fourth surface of the recess, forming a blind depth.

8. The corner protector as claimed in claim 5, wherein, The second opening is formed by passing through the fourth surface of the recess without passing through the fourth outer surface.

9. The corner protector as claimed in claim 1, wherein, The body is formed of polypropylene material.

10. A frame component, comprising: The corner protector as described in claim 1; as well as A frame is received in the recess of the corner protector, the frame defining a first frame surface that contacts a first frame surface that contacts a second surface that contacts a second surface that contacts a third ...

11. The frame assembly of claim 10, further comprising a retaining member attached to the corner protector and the frame to retain the corner protector on the frame.

12. A frame component, comprising: A frame, the frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first frame surface and the second frame surface, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame; and A plurality of corner protectors, each corner protector as described in claim 1, and each corner protector receiving one corner of the corner of the frame.

13. The frame assembly as claimed in claim 12, wherein, The frame further includes a glass shower door.

14. A packaged frame assembly, comprising: Box; as well as The frame assembly as claimed in claim 12, wherein the frame assembly is received within the box.

15. The corner protector as claimed in claim 1, wherein, The recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the grid. and The orifice is formed in the fourth surface and is oriented at the convergence of the second surface, the third surface, and the fourth surface, such that the second surface and the third surface do not intersect.

16. A frame component, comprising: The corner protector as described in claim 15; as well as A frame is received in the recess of the corner protector, the frame defining a first frame surface that contacts a first surface of the recess, the frame defining a second frame surface that contacts a fourth surface of the recess, the frame defining a first edge surface that contacts the second surface of the recess, and the frame defining a second edge surface that contacts a third surface of the recess, wherein the first frame surface, the first edge surface, and the second edge surface converge at the corner of the frame such that an opening is defined near the corner of the frame, in a gap between the first frame surface and the first surface of the recess, and the opening defines a gap between the second frame surface and the fourth surface of the recess.

17. A packaged frame assembly, comprising: Box; as well as A frame assembly, received within the box, the frame assembly comprising: A frame, the frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first frame surface and the second frame surface, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame, and A plurality of corner protectors, each corner protector receiving one corner of a frame, wherein each corner protector includes a body having a recess formed therein, the recess defining a first surface to receive and contact a first frame surface of the frame in the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the frame, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact a second edge surface of the frame, and the body defining an aperture formed in the first surface and oriented at the convergence of the first surface, the second surface, and the third surface such that the second surface and the third surface do not intersect.

18. The packaged frame assembly as claimed in claim 17, further comprising: Multiple foam components, which are oriented within the box and surround the frame assembly.

19. A corner protector assembly, comprising: Corner protector, the dimensions of which are determined to receive the corner of the frame; as well as A retainer is attached to the corner protector to attach the corner protector to the frame.

20. The corner protector as claimed in claim 19, wherein, The retaining element includes an adhesive label.

21. A corner protector comprising a body having a recess formed therein, the recess defining a first surface to receive and contact a frame surface of a grid within the recess, the recess defining a second surface angled relative to and intersecting the first surface to receive and contact a first edge surface of the grid, the recess defining a third surface angled relative to and intersecting the first surface to receive and contact a second edge surface of the grid, and the body defining an aperture formed in the first surface and oriented at the convergence of the first surface, the second surface, and the third surface, such that the second surface and the third surface do not intersect, wherein... The body is formed of polypropylene material.

22. The corner protector as claimed in claim 21, wherein, The opening is formed through the body.

23. The corner protector as claimed in claim 21, wherein, The recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the grid. and The second orifice is formed in the fourth surface and is oriented at the convergence of the second surface, the third surface, and the fourth surface, such that the second surface and the third surface do not intersect.

24. The corner protector as claimed in claim 21, wherein, The body is formed of a polymer material.

25. The corner protector of claim 21, further comprising at least one structural rib, the at least one structural rib being disposed on the body to enhance the structural integrity of the body.

26. The corner protector as claimed in claim 21, wherein, The body defines a first outer surface that is spaced apart from the first surface of the recess; The body defines a second outer surface that is spaced apart from the second surface of the recess; The body defines a third outer surface spaced apart from the third surface of the recess; and The orifice is formed through the first outer surface.

27. The corner protector as claimed in claim 21, wherein, The recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the grid. The body defines a first outer surface spaced apart from the first surface of the recess; The body defines a second outer surface that is spaced apart from the second surface of the recess; The body defines a third outer surface that is spaced apart from the third surface of the recess; The body defines a fourth outer surface that is spaced apart from the fourth surface of the recess; The orifice is formed through the first outer surface; and The second opening is formed by passing through the fourth outer surface.

28. A frame component, comprising: Corner protector as described in claim 21; as well as A frame is received in the recess of the corner protector, the frame defining a first frame surface that contacts a first surface of the recess, the frame defining a first edge surface that contacts a second surface of the recess, and the frame defining a second edge surface that contacts a third surface of the recess, wherein the first frame surface, the first edge surface, and the second edge surface converge at the corner of the frame such that the opening defines a gap disposed near the corner of the frame between the first surface and the first frame surface of the recess.

29. The frame assembly of claim 28, further comprising a retaining member attached to the corner protector and the frame to retain the corner protector on the frame.

30. A frame component, comprising: A frame, the frame defining a first frame surface and a second frame surface spaced apart from the first frame surface, and a plurality of edge surfaces intersecting the first frame surface and the second frame surface, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the frame; and A plurality of corner protectors, each corner protector as described in claim 21, and each corner protector receiving one corner of the corner of the frame.

31. The frame assembly as claimed in claim 30, wherein, The frame further includes a glass shower door.

32. A packaged frame assembly, comprising: Box; as well as The frame assembly as claimed in claim 30, wherein the frame assembly is received within the box.

33. The corner protector as claimed in claim 21, wherein, The recess defines a fourth surface, which is spaced apart from and opposite to the first surface to contact another frame surface of the grid. and The orifice is formed in the fourth surface and is oriented at the convergence of the second surface, the third surface, and the fourth surface, such that the second surface and the third surface do not intersect.

34. A frame component, comprising: Corner protector as described in claim 33; as well as A frame is received in the recess of the corner protector, the frame defining a first frame surface that contacts a first surface of the recess, the frame defining a second frame surface that contacts a fourth surface of the recess, the frame defining a first edge surface that contacts the second surface of the recess, and the frame defining a second edge surface that contacts a third surface of the recess, wherein the first frame surface, the first edge surface, and the second edge surface converge at the corner of the frame such that an opening is defined near the corner of the frame, in the gap between the first surface and the first frame surface of the recess, and the opening defines a gap between the second frame surface and the fourth surface of the recess.

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