Moulded fibre packaging reinforcement system

Abstract

A packaging reinforcement system 100 comprising a moulded fibre first 105 and second 106 reinforcement parts. The first reinforcement part comprises at least one first engaging projection 120 and at l

Description

When items are transported within exterior packaging, such as cardboard boxes, it is common to include interior reinforcing elements mounted to the item within the exterior packaging. The reinforcement parts separate the item from the exterior packaging, thereby separating the item from, and absorbing, any impacts or other damage to the exterior packaging. Moulded fibre material or pulp has been found to be particularly suitable for forming interior reinforcement parts. Moulded fibre typically comprises a cellulose-based fibrous mass which can be formed from recycled paper, cardboard or wood, for example, and is typically biodegradable. As a result, it is relatively sustainable (such as compared to plastic). Furthermore, moulded fibre material has an excellent strength to weight ratio. However, by virtue of the relatively rigid nature of moulded fibre, the moulded fibre interior reinforcement parts have to be specifically designed and sized to carry specific items. Therefore, it is necessary to have different sizes of reinforcement parts for each size of a product range (paint tins with different diameters or different sized bottles, for example). Yet furthermore, moulded fibre interior reinforcement parts are not secured to each other within the exterior packaging and the interior reinforcement parts are instead held in place by the exterior packaging and item itself. Whilst this arrangement works well in many applications, it again relies upon the exterior packaging having a specific size to ensure a tight fit with the moulded fibre interior reinforcement parts and requires the exterior packaging to be sufficiently rigid to hold them in place. This can make moulded fibre interior reinforcement parts less suitable for carrying large items, such as shower trays, which often have a relatively more flexible exterior packaging due to the size of the cardboard sheets required. Summary An object of the present invention is to provide an improved packaging reinforcement system comprising moulded fibre reinforcement parts configured to be mounted to an item and in particular to relatively large items. A particular object is to provide moulded fibre reinforcement parts capable of being mounted to an item without requiring substantial support from exterior packaging. A further object is to provide moulded fibre reinforcement parts capable of being mounted to items of different sizes. The present invention therefore provides a packaging reinforcement system and kit in accordance with the claims. The packaging reinforcement system comprises moulded fibre first and second reinforcement parts configured to be mounted to an item. The first reinforcement part comprises at least one first engaging projection and at least one first support element. The second reinforcement part comprises at least one second through hole therethrough and at least one second support element. The first and second reinforcement parts are mountable to one another in an engaged configuration, in which the at least one first engaging projection extends through the at least one second through hole so as to extend through the second reinforcement part in an interference fit therewith. The first and second support elements are configured to, in the engaged configuration, at least partially contact the item such that the first and second reinforcement parts at least partially cover the item. By virtue of the interference fit resulting from the engagement of the projection and through hole, the reinforcement parts may be substantially joined together around an item such that they do not separate from each other. Hence, when inside exterior packaging, the reinforcement parts are held together by the interference fit rather than by the exterior packaging or the specific shape of the item to which they mounted. As a result, the reinforcement parts can be used in larger exterior packaging in which they may not receive as much exterior support as in smaller exterior packaging. Multiple reinforcement systems, each with the pair of reinforcement parts, can also be mounted around particularly large items and separated from one another within the exterior packaging. This is achievable by virtue of each pair of reinforcement parts being selfsecuring, without needing additional support from the exterior packaging or other reinforcement parts. In the present disclosure, the term “through hole” refers to an aperture or hole that passes through the entire reinforcement part such that it is present on both opposing surfaces or sides of the reinforcement part. In the present disclosure, the term “moulded fibre” refers to a dried or solidified, fibrous material and may be pulp. The material may comprise (recycled preferably) paper, cardboard, paperboard or similar products, plant fibres, wood, any cellulose fibrous product and the like. The moulded fibre may be formed by any suitable method, such as by grinding, refining, digesting and / or bleaching, as is known in the art. The reinforcement parts are preferably formed from moulded fibre sheet material or thin walled moulded fibre. The terms “sheet” and “thin walled” refer to the thickness of the first and second reinforcement parts being significantly smaller than the width, depth or height of the reinforcement parts. The thickness may be in the range of between about 0.3 mm and about 8 mm. The moulded fibre is preferably waterproof, for example with AKD (Alkyl Ketene Dimer), although different waterproofing agents can be used. In the present disclosure, the term “interference fit” refers to the engaging projection(s) of one reinforcement part engaging with the through hole (i.e. so it contacts the perimeter of the through hole) of the other reinforcement part in a full contact, friction and / or pressed fit. The reinforcement parts are therefore substantially held together by the joint created by the friction of the interference fit. In particular, when the reinforcement parts are joined by the interference fit, they may not be separable by the force of gravity when held aloft. When the interference fit is formed, the at least one first engaging projection is preferably compressed and the at least one second through hole is preferably expanded. Thus the at least one first engaging projection, where it contacts the edge of the at least one second through hole, is larger when not in the engaged configuration and the at least one second through hole is smaller when not in the engaged configuration. Such compression and expansion provide a tighter interference fit. The engaged configuration may be a fully engaged configuration or an initially engaged configuration. In both the fully and initially engaged configurations the at least one first engaging projection is in the interference fit with the second reinforcement part at the at least one second through hole. However, in the fully engaged configuration, the at least one engaging projection extends further through the at least one second through hole than in the initially engaged configuration. Such different engaged configurations may be achievable by virtue of the compression and expansion of the at least one first engaging projection and at least one second through hole. Effectively, the interference fit can therefore provide different sizes of gaps between the reinforcement parts. As a result, the first and second reinforcement parts can fit different sized items therebetween. This is in contrast to prior art systems, which require entirely different elements in order to fit different sized items. The first reinforcement part generally extends across a thickness between a first part inner surface and a second part outer surface. In order to further enhance the lock between the reinforcement parts, the first part inner surface preferably has a higher surface roughness than the second part outer surface and the first part inner surface of the at least one first engaging projection is preferably configured to engage the second reinforcement part in the interference fit at the at least one second through hole. The differential in surface roughness may be created during the manufacturing process, which may, for example, comprise forming and drying, which produces products with a smooth surface on one side and a rougher surface on the other side. The forming process may comprise utilising a rotary machine as a forming tool thereon. Pulp may be drawn onto the forming tool, the machine rotates and a further 'wet press' compresses the pulp. The rotary machine may then rotate again and a transfer tool removes the pulp therefrom. In the drying process, the product removed by the transfer tool is dried in an oven before being stacked and palletised. The manufacturing process may not comprise after pressing or dry pressing, or thermo forming, which result in smooth surfaces on both sides of the product. The system may be configured to contact different parts of an item, depending on the shape of the item. In particular, the reinforcement parts may be configured to support items sides connected at angles to one another (for example a top and edge of a shower tray). Hence, the support elements may be configured to, in the engaged configuration, at least partially contact the item in at least two different directions, the different directions having an angle of at least 45 degrees to each other, and / or contact a face of the item and an edge of the item to which the face extends such that the reinforcement parts at least partially cover the face and the edge of the item. The reinforcement parts may also be able to support opposite faces of an item (for example a top and bottom of a shower tray) by being configured to contact, in the engaged configuration, opposing item faces of the item such that the first and second reinforcement parts at least partially cover both item faces and the item is located between the first and second reinforcement parts. As a result, the system of the present invention can be applied to reinforcement parts with different shapes for fitting different items or different parts of items. For example, the system may comprise elongate item corner or side reinforcement parts configured to enclose an item corner with two vertices or a side of an item, particularly an elongate item having a smaller thickness than width or length (for example a shower tray). In both the item corner and side configurations, the reinforcement parts are configured to support items sides connected at angles to one another and opposite sides of an item. Hence, for example, the top, bottom and edge of an elongate item are in contact with the reinforcement elements. Alternatively, the system may comprise large item reinforcement parts for mounting over a single vertex and configured to contact three sides of an item at right angles to one another (for example the corner of any box-shaped item, such as the corner of a fridge or the like). The reinforcement parts are configured to only support items sides connected at angles to one another. The first and second reinforcement parts may at least partially mirror each other and may be nestable with each other. In particular, the second reinforcement part preferably comprises at least one second engaging projection for forming an interference fit with at least one first through hole of the first reinforcement part. The first and / or second reinforcement parts may comprise yet further engaging projections and corresponding through holes as necessary depending on the intended application of the system. The present disclosure further provides a kit comprising exterior packaging and at least one packaging reinforcement system as disclosed herein. The system is configured to be mounted inside the exterior packaging at least partially around an item therein and located between the item and the exterior packaging. In preferred embodiments, the exterior packaging comprises a cardboard box. The kit may comprise a plurality of packaging reinforcement systems, with a plurality of pairs of first and second reinforcement parts mounted to the item between the item and exterior packaging. At least one packaging reinforcement system may be mounted at a corner of the exterior packaging for mounting to a corner of the item and / or at least one packaging reinforcement system may be mounted between corners of the exterior packaging for mounting to a side of the item. The kit may further comprise the item itself. In a particular embodiment the item is a substantially square or rectangular shower tray, and a packaging reinforcement system is mounted at each corner of the shower tray. At least one further packaging reinforcement system may be mounted between each corner of the shower tray. When assembled, the reinforcement systems are preferably not in contact with one another and have spaces therebetween. Brief Description of the Drawings By way of example only, embodiments of a packaging reinforcement system and reinforcement parts of the present invention are now described with reference to, and as shown in, the accompanying drawings, in which: FIGURE 1 illustrates a top perspective view of a first embodiment of a packaging reinforcement system in accordance with the present invention in an engaged configuration; FIGURE 2 illustrates a top perspective view of the first embodiment in a separated or exploded configuration; FIGURE 3 illustrates a bottom side perspective view of the first embodiment in the engaged configuration; FIGURE 4 illustrates a side view of the first embodiment in the separated configuration; FIGURE 5 illustrates a side view of the first embodiment in an initially engaged configuration; FIGURE 6 illustrates a side view of the first embodiment in a fully engaged configuration; FIGURES 7 AND 8 illustrate top and bottom views respectively of a first reinforcement part of the first embodiment of the packaging reinforcement system; FIGURES 9 AND 10 illustrate top and bottom views respectively of a second reinforcement part of the first embodiment of the packaging reinforcement system; FIGURE 11 illustrates a side perspective view of a second embodiment of a packaging reinforcement system in accordance with the present invention in an engaged configuration; FIGURE 12 illustrates an embodiment of a kit of the present invention comprising a plurality of the first and second embodiments of the packaging reinforcement systems mounted to an item, in this example a shower tray; FIGURE 13 illustrates a side perspective view of a third embodiment of a packaging reinforcement system in accordance with the present invention in an engaged configuration; and FIGURE 14 illustrates a further embodiment of a kit of the present invention comprising the third embodiment of the packaging reinforcement system mounted to an item, in this example a cuboidal-shaped item. Detailed Description A first embodiment of a packaging reinforcement system 100 in accordance with the present invention, particularly for mounting and covering at least one item corner 102 and at least part of opposing sides 103, 104 of an item 101, having a substantially smaller thickness that width or depth (such as the illustrated shower tray), is illustrated in Figures 1 to 10. Figure 11 illustrates a second embodiment of a packaging reinforcement system 200 of the present invention for mounting and covering at least part of the opposing sides 103, 104 of the item 101. A plurality of such corner and side packaging reinforcement systems 100, 200 are shown mounted to the item 101 in Figure 12. Figures 13 and 14 illustrate a third embodiment of a packaging reinforcement system 300 of the present invention, configured to be mounted to a single corner 302 and at least part of three sides 303, 304, 305 of an item 301 (such as a fridge or the like), the three sides 303, 304, 305 being substantially perpendicular to each other and extending from the corner 302. Although not illustrated, during transportation and storage exterior packaging is mountable around the items 101,301 and systems 100, 200, 200. The exterior packaging may be of any suitable type, such as comprising a cardboard box, a box of another material (e.g. paperboard, plastic) and / or a wrap (e.g. flexible plastic sheet). The systems 100, 200, 200 each comprise first and second reinforcement parts 105, 106 with different shapes for mounting to the different items 101,301 and parts of such items 101,301. In each system 100, 200, 300, the first reinforcement part 105 is connectable to the second reinforcement part 106 in an engaged configuration, as illustrated in Figures 1, 3, 5, 6 and 11-14. In the engaged configuration, an interference fit keeps the first and second reinforcement parts 105, 106 held together. As a result, the first and second reinforcement parts 105, 106 do not rely upon the exterior packaging for holding them together, although the exterior packaging may ensure that they remain on the item (for example by applying pressure inwardly in Figure 12, to stop the systems 100, 200 from sliding outwardly away from the item 101). Each system 100, 200, 300 comprises moulded fibre first and second reinforcement parts 105, 106 configured to be mounted to an item 101,301. The first reinforcement part 105, comprises at least one first engaging projection 120 and at least one first support element 130. The second reinforcement part 106 comprises at least one second through hole 150, therethrough and at least one second support element 160. The first and second reinforcement parts 105, 106 are mountable to one another in an engaged configuration, in which the at least one first engaging projection 120 extends through the at least one second through hole 150 so as to extend through the second reinforcement part 106 in an interference fit therewith. The first and second support elements 130, 160 are configured to, in the engaged configuration, at least partially contact the item 101,301 such that the first and second reinforcement parts at least partially cover the item 101,301. Furthermore, in order to improve the connection in each system 100, 200, 300, the first reinforcement part 105 may comprise at least one first through hole 140 therethrough and the second reinforcement part 106 may comprise at least one second engaging projection 170. In the engaged configuration, the at least one second engaging projection 170 extends through the at least one first through hole 140 so as to extend through the first reinforcement part 105 in an interference fit therewith. The first and / or second reinforcement parts 105, 106 may comprise yet further engaging projections and corresponding through holes as necessary depending on the intended application of the system 100. As in the illustrated first embodiment, the first reinforcement part 105 may comprise three first engaging projections 120 and two first through holes 140 and the second reinforcement part 106 may correspondingly comprise three second through holes 150 and two second engaging projections 170. Each reinforcement part 105, 106 comprises a thin walled moulded sheet having first and second outer part surfaces 107, 108, 109, 110 bounded by at least one part edge 108a, 110a. The first and second outer part surfaces 107, 108, 109, 110 have substantially the same shape by virtue of being formed of the thin walled sheet material. However, depending upon the moulding process, there may be variations in thickness through the reinforcement parts 105, 106 such that the shapes of the first and second outer part surfaces 107, 108, 109, 110 differ in minor details. In the engaged configuration, the first outer part surfaces 107,109 of each reinforcement part 105, 106 face inwardly towards each other. The items 101,301 are in contact with the first outer part surfaces 107, 109 such that at least the first outer part surface 107,109 forms the shape of support elements 130, 160 and engaging projection(s) 120. The though hole(s) 140 extend entirely between the first and second outer part surfaces 107, 108, 109, 110. The first embodiment of the packaging reinforcement system 100 illustrated in Figures 1 to 10 and 12 will now be described in further detail, although much of the description equally applies to the second and third embodiments of the system 200, 300. The same reference numerals have been used in Figures 11 to 14 when referring to the equivalent features of Figures 1 to 10. The first reinforcement part 105 comprises a first base 111 from which the at least one first support element 130 and at least one first engaging projection 120 extends. The second reinforcement part 106 comprises a second base 112 from which the at least one second support element 160 and at least one second engaging projection 170 extends. The first and second bases 111, 112 may extend between the support elements 130, 160 and engaging projections 120, 170 such that they each comprise a plurality of base parts 111a, 112a, separated by the support elements 130, 160 and engaging projections 120,170. The first and second bases 111, 112, and thus first and second base parts 111a, 112a, each extend across substantially planar regions. Each first and second base part 111a, 112a may be substantially flat or planar and thus the first and second bases 111, 112 may be substantially flat or planar between the support elements 130, 160 and engaging projections 120, 170. In the present disclosure, the first and second bases 111, 112 form the outermost portions of the reinforcement parts 105, 106 when in the engaged configuration. Thus, all other features of the reinforcement parts 105,106 may be considered to extend away from the first and second bases 111, 112 in the same direction. The engaging projections 120, 170, extend from the bases 111, 112 by a greater distance that the support elements 130, 160. In the engaged configuration, the at least one first support element 130 and at least one first engaging projection 120 extend away from the first base 111 towards the second reinforcement part 106 and the at least one second support element 160 and at least one second engaging projection 170 extend away from the second base 112 towards the first reinforcement part 105. The direction of extension of each engaging projection 120,170 and support element 130, 160 may be substantially orthogonal to the respective base 111, 112. When viewed in plan view (e.g. along the direction of extension of the support elements 130, 160 and engaging projections 120, 170), the first and second bases 111, 112, and first and second reinforcement parts 105, 106, may be substantially square or rectangular and may have at least one rounded corner. The reinforcement parts 105, 106 may comprise first and second side walls 113, 114 respectively extending away from a periphery of each of the first and second bases 111, 112 respectively in the same direction as the support elements 130, 160. The first and second side walls 113, 114 may extend around at least one edge of the first and second bases 111,112. In the first embodiment, the first and second side walls 113, 114 extend from two edges of the first and second bases 111, 112 respectively, forming curved corners between the two edges. In the engaged configuration, the first and second side walls 113, 114 may abut against one another and / or be located adjacent to each other. In particular, edges of the first and second side walls 113, 114 distal to the first and second bases 111, 112 may abut against one another and / or be located adjacent to each other. The first and second side walls 113, 114, extend from the first and second bases 111, 112 by a greater distance that the support elements 130, 160 and / or by a smaller distance than the engaging projections 120, 170. The first and second side walls 113, 114 may extend from the first and second bases 111, 112 at an obtuse draft angle therewith. The obtuse draft angle enables the reinforcement parts 105, 106 to be removed from the mould easily. The obtuse draft angle may be in the range of from 0.1° to 45°. As illustrated, the first and second support elements 130, 160 preferably comprise first and second support projections 131, 161 extending from the first and second bases 111, 112 respectively. The first and second support projection 131, 161 terminate in first and second support surfaces 132, 162 respectively and the first and second support surfaces 132, 162 are configured to at least partially contact the item 101 in the engaged configuration. The first and second support projections 131,161 may each be a substantially trapezoidal cuboid as illustrated. The first and second support surfaces 132, 162 may be substantially square as illustrated, such that the first and second support projections 131, 161 each comprise four walls, optionally with rounded corners therebetween as shown. The walls of the first and second support projections preferably extend from the first and second bases 111, 112 at obtuse draft angles therewith, to improve ease of removal from the moulds. The obtuse draft angle may be in the range of from 0.1° to 45°. When the system 100 is in use, the first and second support surfaces 132, 162 are configured to contact the item 101 held between the reinforcement parts 105, 106, particularly the opposing sides thereof. The firsts and second support surfaces 132,162 are preferably flat and / or planar, thereby increasing the contact surface area with the item 101. In the engaged configuration, the at least one first support surface 132 may be substantially parallel to the at least one second support surface 162, such that they are particularly suited to supporting an item 101 with substantially parallel opposing sides 103, 104. Each of the first and second reinforcement parts 105, 106 preferably comprises at least two, and more preferably four (as illustrated) first and second support elements 130, 160. In use the first and second support elements 130, 160 may be configured to absorb impacts to the exterior packaging and may also be configured to at least partially crumple or lose shape when absorbing such impacts. Therefore, the item 101 may be adequately protected from impacts by the system 100. The first and second engaging projections 120, 170 preferably extend from the first and second bases 111, 112 respectively and preferably adjacent to and / or with the first and second side walls 113, 114. In particular, the first and second engaging projections 120, 170 may be located at the periphery of the first and second bases 111, 112, closer to the first and second side walls 113, 114 than the first and second support elements 130,160. The first and second engaging projections 120, 170 extend further from the first and second bases 111, 112 than the first and second support elements 130, 160 and first and second side walls 113, 114 respectively. The first and second engaging projection 120, 170 may comprise first and second projection base portion 121, 171, which is preferably trapezoidal cuboidal in shape, extending from the first and second base 111, 112 respectively. The first and second projection base portion 121, 171 may extend from the first and second base 111, 112 by the less than, but at least 75% of, the distance as the first and second side walls 113, 114. The first and second projection base portion 121, 171 may be formed with, as one structure, the first and second base 111, 112 as illustrated. The first and second projection base portion 121, 171 may be trapezoidal cuboids with three walls, with the fourth wall being absent and forming first and second side apertures 122, 172 in the first and second side walls 113, 114. The first and second side apertures 122, 172 may assist in providing strength and with nesting. The first and second engaging projections 120, 170 may comprise first and second main projection portions 123, 173 for engaging with the second and first through holes 150, 140 respectively. The first and second main projection portions 123, 173 extend from the first and second projection base portions 121, 171 and are preferably conically frustum in shape, further preferably with substantially oval cross-sections. The first and second main projection portions 123, 173 each terminate in a closed end. The height of the first and second engaging projections 120, 170 is sufficient such that they extend through the second and first through holes 150, 140 respectively in the engaged configuration. The heigh is such that the first and second engaging projections 120, 170 extend above the level of the first and second side walls 113, 114. Furthermore, when in the fully engaged configuration as discussed below, the first and second engaging projections 120, 170 do not extend beyond the second or first bases 111,112. The first and second through holes 140, 150 preferably extend through the first and second reinforcement parts 105, 106 at a level that is, when measured from the first and second base 111, 112, substantially the same as the distance from the first and second base 111, 112 to the distal edge of the first and second side walls 113, 114. In order to form the through holes 140, 150, the first and second reinforcement parts 105, 106 preferably comprise first and second through hole projections 141, 151 extending from the first and second base 111, 112 respectively to the at least one through hole 140, 150. The first and second through hole projections 141, 151 preferably extend adjacent to and / or with the first and second side walls 113, 114. In particular, first and second through hole projections 141, 151 may be located at the periphery of the first and second bases 111, 112, closer to the first and second side walls 113, 114 than the first and second support elements 130, 160. The first and second through hole projections 141, 151 extend from the first and second bases 111,112 further than the first and second support elements 130, 160 and / or by a similar distance to the first and second side walls 113, 114. The first and second through hole projections 141, 151 may comprise first and second through hole projection base portions 142, 152, each of which is preferably trapezoidal cuboidal in shape, extending from the first and second base 111,112 respectively. The first and second through hole projection base portion 142, 152 may extend from the first and second base 111, 112 by the less than, but at least 75% of, the height of the first and second side walls 113, 114 and have a height greater than the first and second support elements 130, 160. The first and second through hole projection base portion 142,152 may be formed with, as one structure, the first and second base 111, 112 as illustrated. The first and second through hole projection base portion 142, 152 may be trapezoidal cuboids with three walls, with the fourth wall being absent and forming first and second side apertures 122,172 in the first and second side walls 113, 114. The first and second through hole projections 141, 151 may comprise first and second main through hole projection portions 143, 153 for forming the first and second through holes 140, 150 respectively. The first and second main through hole projection portions 143, 153 extend from the first and second through hole projection base portions 142, 152 and are preferably conically frustum in shape, further preferably with substantially oval cross-sections. The first and second main through hole projection portions 143, 153 may terminate in the first and second through holes 140, 150. During production, the first and second main through hole projection portions 143, 153 may be formed with closed ends that are subsequently cut to form the first and second through holes 140, 150. As will be appreciated from the foregoing and figures, first and second through hole projections 141, 151 may have substantially the same size and shape as the first and second engaging projections 120, 170 respectively. The support, engaging and through hole projections 131, 161, 120, 170, 141, 151 are generally arranged in a regular grid or array on the first and second bases 111, 112. The grid may be a 3x3 grid as shown in the first embodiment of the system 100. Four of the first and second support projections 131, 161 are arranged in a 2x2 grid, with the engaging and through hole projections 120, 170, 141, 151 forming the remaining five elements of the column and row around the 2x2 grid. The first reinforcement part 105 comprises three first engaging projections 120 and two first through hole projections 141, preferably alternating as shown, and the second reinforcement part 106 correspondingly comprises three second through hole projections 151 and two second engaging projections 170, also preferably alternating as shown. Preferably the row and column of the regular grid or array adjacent to the first and second side walls 113, 114 comprise the first engaging projections 120 and first through hole projections 141. Therefore, the lock from the interference fit is entirely around the periphery of the first and second reinforcement parts 105, 106. The first and second reinforcement parts 105, 106 may comprise additional features to assist with strengthening them and to assist in denesting or removing the reinforcement parts 105, 106 from the moulds they are formed in. In particular, the first and / or second support projections 131, 161, first and / or second engaging projections 120, 170 and / or first and / or second through hole projections 141, 151 may each comprise, extending from a side therefrom, lugs 180 for assisting with denesting from a mould. Yet furthermore, the first and second reinforcement parts 105, 106 may comprise ribs 181 extending between adjacent first and / or second support projections 131, 161, first and / or second engaging projections 120, 170 and / or first and / or second through hole projections 141, 151, for providing additional support and strength therebetween. The first and second base parts 111a, 112a may be separated from one another by the lugs 180 and ribs 181, in addition to the first and / or second support projections 131,161, first and / or second engaging projections 120, 170 and / or first and / or second through hole projections 141, 151. The method of mounting the first and second reinforcement parts 105, 106 is best illustrated with reference to Figures 4 to 6. Firstly, the first and second reinforcement parts 105, 106 are aligned over one another as in Figure 4. Subsequently, they are brought together such that at least one engaging projection 120, 170 on one reinforcement part 105, 106 passes through the corresponding at least one through hole 150, 140 on the other reinforcement part 106, 105. Figure 5 illustrates the first and second reinforcement parts 105, 106 in an initially engaged configuration. The at least one engaging projection 120, 170 and corresponding at least one through hole 150, 140 are in an interference fit with each other, since the at least one engaging projection 120, 170 on one reinforcement part 105, 106 is in contact with the other reinforcement part 106, 105 around the edge or rim of the corresponding at least one through hole 150, 140. As illustrated, the first and second side walls 113, 114 are separated from one another and thus the first and second reinforcement parts 105,106 could be pushed closer towards one another. However, in the initially engaged configuration of Figure 5, the first and second reinforcement parts 105, 106 still hold onto one another via the interference fit. As a result, the item 100 can fit between the first and second support elements 130, 160, where a receiving volume is defined therebetween. The receiving volume is further bounded by the engaging projection(s) 120, 170 and / or through hole projection(s) 141, 151 located around the support elements 130, 160. Hence, in the case of the item 100 comprising a relatively thin or elongate shape having two opposing sides 103, 104 and an item edge 101a therebetween, the support elements 130, 160 contact and support the opposing sides 103, 104 whilst the item edge 101a is in contact with and supported by the engaging projection(s) 120, 170 and / or through hole projection(s) 141,151. The initially engaged configuration is therefore suitable if the thickness of the item 101 is relatively large. However, if it is smaller, the first and second reinforcement parts 105, 106 can be pushed closed together up to a fully engaged configuration as shown in Figure 6, in which the reinforcement parts 105,106 are as close together as possible, with the first and second side walls 113, 114 at least partially touching at their distal edges to the first and second bases 111, 112. In this arrangement, the interference fit is still maintained, with the at least one engaging projection 120, 170 located further into the corresponding at least one through hole 150, 140. The receiving volume is similarly bounded as in the initially engaged configuration, but the receiving volume itself is smaller to account for the thinner item 101. In order to achieve the interference fit in the initially and fully engaged configurations, the reinforcement parts 105, 106 are sufficiently flexible due to their composition of moulded fibre. The at least one engaging projection 120, 170 is compressed further between the initially and fully engaged configurations, whilst the at least one through hole 140, 150 (and thus at least one through hole projection 141,151) expands further. Such an interference fit can be ensure by the at least one through hole projection 141, 151 and at least one engaging projection 120, 170 having substantially the same shape and size. Yet furthermore, the interference fit can be secured yet further by the at least one engaging projection 120, 170 having a high surface roughness, to increase the friction at the at least one through hole 140, 150. Following on from manufacture, one of the first and second outer part surfaces 107, 108, 109, 110 will have a rougher surface than the other. By ensuring that the first outer part surfaces 107, 109 have the rougher surface, and thus that the at least one engaging projection 120, 170 has the rougher surface where it engages with the at least one through hole 140,150, the interference fit can be secured further. By virtue of the first and second side walls 113, 114 and engaging projection(s) 120, 170 and / or through hole projection(s) 141, 151 extending around two sides of the first and second bases 111, 112, the system 100 of Figures 1 to 10 is mountable at a cover of a thin or elongate item, such as a shower tray. In particular, as best shown in Figure 12, the system 100 can protect an item corner 102, where two item edges 101a, 101b of the item 101 meet, and thus protecting the two item edges 101a, 101 band opposing sides 103, 104 where they meet at the item corner 102. In this arrangement the item corner 102 has two vertices; one where the first opposing side 103 meets the edge along the thickness and a second where the second opposing side 104 meets the edge along the thickness. Both vertices are covered by the system 100. Figure 11 illustrates the second embodiment of the system 200. As best shown in Figure 12, the system 200 is for protecting the item edge 101a, 101b away from the item corner 102 by partially covering an item edge 101a, 101b and the opposing sides 103, 104 of the item 101 extending from the item edge 101a, 101b. As will be apparent, the system 200 comprises substantially similar parts to the system 100 and thus the foregoing description substantially also applies to the system 200. However, the first and second side walls 113, 114 and engaging projection(s) 120, 170 and / or through hole projection(s) 141, 151 extend along only one side of the first and second bases 111,112. Hence, in the regular grid or array having a 3x3 size, the first and second support elements 130, 160 form a 2x3 grid. The final row is formed by one or two engaging projection(s) 120, 170 and / or two or one through hole projection(s) 141, 151. Hence, in the system 200, the receiving volume between the first and second support elements 130, 160 is open on three sides (as opposed to only two sides in the system 100). Therefore, the system 200 can be mounted to an item edge 101 a, 101 b of the item 101. Figure 12 illustrates how the systems 100, 200 can be arranged around an item 101, in this example a shower tray, for supporting the item 101 within external packaging (not shown). In particular, a system 100 is provided at each item corner 102 whilst a system 200 is provided on the item edge 101a, 101b between the item corners 102. The systems 100, 200 are separated from each other and do not need to contact each other in order to provide sufficient reinforcement. The features of the present invention can also be applied to applications where the item 301 is not thin or elongate and instead where the system 300 cannot wrap around an edge of the item like the systems 100, 200. Such a system 300 is illustrated in Figures 13 and 14, with Figure 14 illustrating how the system 300 is mountable to a single vertex 302 of the item 301. As illustrated, the second reinforcement part 106 is substantially the same as in the above mentioned system 100 of Figures 1 to 10, with the second side wall 114 and engaging projection(s) 170 and / or through hole projection(s) 151 extending around two sides of the second base 112. The first reinforcement part 105 also comprises the first side wall 113 and engaging projection(s) 120 and / or through hole projection(s) 141 extending around two sides of the first bases 111. The first reinforcement part 105, however, does not comprise any support elements or a first base 111 other than under the engaging projection(s) 120, 170 and / or through hole projection(s) 141, 151. The receiving volume is therefore bounded by the second support elements 160 and the engaging projection(s) 120, 170 and / or through hole projection(s) 141, 151 only. As a result, the item 301 can be mounted so that two of its sides 304, 305 are only supported by the first reinforcement part 105 by the engaging projection(s) 120, 170 and / or through hole projection(s) 141, 151. Hence, the system 300 can be mounted to a single vertex of an item, with the interference fit still providing substantial benefit in preventing the first and second reinforcement parts 105, 106 from separating during transportation. Whilst the first and second main projection portions 123, 173 and first and second main through hole projection portions 143, 153 are preferably conically frustum in shape, other suitable shapes include those that have the same shape and a draft angle. Hence other suitable shapes include a hexagonal extrusion with a hexagonal aperture, a square extrusion with a square aperture etc.

Claims

1. A packaging reinforcement system comprising moulded fibre first and second reinforcement parts configured to be mounted to an item, wherein:the first reinforcement part comprises at least one first engaging projection and at least one first support element;the second reinforcement part comprises at least one second through hole therethrough and at least one second support element;the first and second reinforcement parts are mountable to one another in an engaged configuration, in which the at least one first engaging projection extends through the at least one second through hole so as to extend through the second reinforcement part in an interference fit therewith; andthe first and second support elements are configured to, in the engaged configuration, at least partially contact the item such that the first and second reinforcement parts at least partially cover the item.

2. The system of claim 1 wherein the first and second reinforcement parts are formed from thin walled moulded material “in which a thickness of the first and second reinforcement parts is smaller than a width, depth or height of the first and second reinforcement parts.

3. The system of any preceding claim wherein, in the interference fit, the at least one first engaging projection is compressed and the at least one second through hole is expanded.

4. The system of any preceding claim wherein the engaged configuration is a fully engaged configuration or an initially engaged configuration, wherein in both the fully and initially engaged configurations the at least one first engaging projection is in the interference fit with the second reinforcement part at the at least one second through hole, wherein in the fully engaged configuration the at least one engaging projection extends further through the at least one second through hole than in the initially engaged configuration.

5. The system of any preceding claim wherein the first reinforcement part extends across a thickness between a first part inner surface and a second part outer surface, wherein the first part inner surface has a higher surface roughness than the second part outer surface and the first part inner surface of the at least one first engaging projection is configured to engage the second reinforcement part in the interference fit at the at least one second through hole.

6. The system of any preceding claim wherein the first and second support elements are configured to, in the engaged configuration, at least partially contact:the item in at least two different directions, the different directions having an angle of at least 45 degrees to each other;opposing item surfaces of the item such that the first and second reinforcement parts at least partially cover both item surfaces, and the item is located between the first and second reinforcement parts; and / ora surface of the item and an edge of the item to which the surface extends such that the first and second reinforcement parts at least partially cover the surface and the edge of the item.

7. The system of any preceding claim wherein the first reinforcement part comprises at least one first through hole therethrough and the second reinforcement part comprises at least one second engaging projection, wherein in the engaged configuration the at least one second engaging projection extends through the at least one first through hole so as to extend through the first reinforcement part in an interference fit therewith.

8. The system of any preceding claim wherein the first and second reinforcement parts comprise first and second bases respectively from which the first and second support elements extend, wherein the at least one first engaging projection extends from the first base.

9. The system of claim 8 wherein the at least one first engaging projection extends from the first base by a greater distance that the at least one first support element.

10. The system of claim 8 or claim 9 wherein the second reinforcement part comprises at least one second through hole projection extending from the second base to the at least one through hole therethrough.

11. The system of claim 10 wherein the at least one second through hole projection has the same size and shape as the at least one first engaging projection.

12. The system of any preceding claim wherein the first support element comprises a first support projection extending from the first base, the first support projection terminating in a first support surface configured to at least partially contact the item in the engaged configuration.

13. The system of any preceding claim wherein the second support element comprises a second support projection extending from the second base, the second support projection terminating in a second support surface configured to at least partially contact the item in the engaged configuration.

14. The system of any preceding claim wherein the first support element comprises a first side wall extending from a periphery of the first base in the same direction as the first support element.

15. The system of any preceding claim wherein the second support element comprises a second side wall extending from a periphery of the second base in the same direction as the second support element and a second flange extending outwardly from the second side wall parallel to the second base.

16. A kit comprising:exterior packaging; andat least one packaging reinforcement system according to any one of the preceding claims and configured to be mounted inside the exterior packaging at least partially around an item therein and located between the item and the exterior packaging.

17. The kit of claim 16 further comprising the item mounted in the at least one packaging reinforcement system.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS:-26 06 2522CLAIMS:

1. A packaging reinforcement system comprising moulded fibre first and second reinforcement parts configured to be mounted to an item, wherein:the first reinforcement part comprises at least one first engaging projection and at 5 least one first support element;the second reinforcement part comprises at least one second through hole therethrough and at least one second support element;the first and second reinforcement parts are mountable to one another in an engaged configuration, in which the at least one first engaging projection extends through 10 the at least one second through hole so as to extend through the second reinforcement part in an interference fit therewith such that the reinforcement parts are held together by a joint created by friction of the interference fit; andthe first and second support elements are configured to, in the engaged configuration, at least partially contact the item such that the first and second reinforcement 15 parts at least partially cover the item.

2. The system of claim 1 wherein the first and second reinforcement parts are formed from thin walled moulded material in which a thickness of the first and second reinforcement parts is smaller than a width, depth or height of the first and second reinforcement parts.

203. The system of any preceding claim wherein, in the interference fit, the at least one first engaging projection is compressed and the at least one second through hole is expanded.

4. The system of any preceding claim wherein the engaged configuration is a fully engaged 25 configuration or an initially engaged configuration, wherein in both the fully and initially engaged configurations the at least one first engaging projection is in the interference fit with the second reinforcement part at the at least one second through hole, wherein in the fully engaged configuration the at least one engaging projection extends further through the at least one second through hole than in the initially engaged configuration.

305. The system of any preceding claim wherein the first reinforcement part extends across a thickness between a first part inner surface and a second part outer surface, wherein the first part inner surface has a higher surface roughness than the second part outer surface and the first part inner surface of the at least one first engaging projection is configured to 35 engage the second reinforcement part in the interference fit at the at least one second through hole.26 06 256. The system of any preceding claim wherein the first and second support elements are configured to, in the engaged configuration, at least partially contact:the item in at least two different directions, the different directions having an angle5 of at least 45 degrees to each other;opposing item surfaces of the item such that the first and second reinforcement parts at least partially cover both item surfaces, and the item is located between the first and second reinforcement parts; and / ora surface of the item and an edge of the item to which the surface extends such that 10 the first and second reinforcement parts at least partially cover the surface and the edge of the item.

7. The system of any preceding claim wherein the first reinforcement part comprises at least one first through hole therethrough and the second reinforcement part comprises at 15 least one second engaging projection, wherein in the engaged configuration the at leastone second engaging projection extends through the at least one first through hole so as to extend through the first reinforcement part in an interference fit therewith.

8. The system of any preceding claim wherein the first and second reinforcement parts 20 comprise first and second bases respectively from which the first and second support elements extend, wherein the at least one first engaging projection extends from the first base.

9. The system of claim 8 wherein the at least one first engaging projection extends from the 25 first base by a greater distance that the at least one first support element.

10. The system of claim 8 or claim 9 wherein the second reinforcement part comprises at least one second through hole projection extending from the second base to the at least one through hole therethrough.3011. The system of claim 10 wherein the at least one second through hole projection has the same size and shape as the at least one first engaging projection.

12. The system of any preceding claim wherein the first support element comprises a first 35 support projection extending from the first base, the first support projection terminating in a26 06 25first support surface configured to at least partially contact the item in the engaged configuration.

13. The system of any preceding claim wherein the second support element comprises a5 second support projection extending from the second base, the second support projection terminating in a second support surface configured to at least partially contact the item in the engaged configuration.

14. The system of any preceding claim wherein the first support element comprises a first10 side wall extending from a periphery of the first base in the same direction as the first support element.

15. The system of any preceding claim wherein the second support element comprises a second side wall extending from a periphery of the second base in the same direction as15 the second support element and a second flange extending outwardly from the second side wall parallel to the second base.

16. A kit comprising:exterior packaging; and20 at least one packaging reinforcement system according to any one of the precedingclaims and configured to be mounted inside the exterior packaging at least partially around an item therein and located between the item and the exterior packaging.

17. The kit of claim 16 further comprising the item mounted in the at least one packaging25 reinforcement system.

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