Curved Edge Protector with Segmented U-Board
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Solution Overview
Problem
Existing packaging solutions for curved and curvilinear objects are inefficient, leading to waste and expense, as they either cause undue stress or require bulky materials that do not effectively protect irregular shapes, especially those with curves greater than 90 degrees.
Innovation Solution
A preformed, rigid laminated U-board with angled cuts forming V-shaped openings and trapezoid-like legs, allowing for flexible bending around curved perimeters and capable of protecting shapes with up to 135 degrees of curvature, along with an end cap closure for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If straight-cut U-boards are used for curved objects, then the board structure is simple and easy to manufacture, but the board cannot bend more than 90 degrees and cannot protect objects with curves greater than 90 degrees
Solution Approach 1:
The U-board is segmented through preformed cuts that divide the sidewalls into multiple sections. These cuts create discrete segments that can rotate and bend relative to each other, enabling the board to conform to curved surfaces with angles exceeding 90 degrees while maintaining structural integrity.
Solution Approach 2:
The preformed cuts transform the rigid, static U-board into a dynamic structure capable of multiple configurations. The cuts allow the sidewalls to bend and adapt to different curvature radii and angles, making the packaging solution versatile for various curved object shapes.
2Reliability
If irregularly-shaped objects are packaged in large bulky boxes with filler material, then the objects are protected from jostling, but undue waste and expense occur
Solution Approach 1:
The invention extracts only the essential protective function needed for curved objects by using a tailored U-board that conforms precisely to the object's shape. This eliminates the need for excessive filler material and bulky packaging, reducing waste while maintaining protection effectiveness.
Solution Approach 2:
The U-board acts as a flexible protective shell that can bend and conform to curved object surfaces. This thin, adaptable structure provides direct protection without requiring voluminous filler materials, achieving reliable protection with minimal material usage.
3Reliability
If large curved objects are wrapped in bubble wrap or bulky material, then protection is provided, but waste and expense increase
Solution Approach 1:
The U-board serves as a flexible protective shell that wraps around curved objects, providing structural protection similar to bulky materials but with significantly reduced material quantity. The preformed cuts enable this thin structure to achieve the flexibility needed for curved surfaces.
Solution Approach 2:
The U-board utilizes a laminated composite construction of paper and/or paper board, combining multiple layers to achieve both rigidity for protection and flexibility for conforming to curved shapes, reducing the need for voluminous single-material packaging.
4Strength
If rigid U-boards with perpendicular walls are used, then structural strength is maintained, but the board cannot fold or bend to accommodate curved shapes
Solution Approach 1:
The rigid U-board is segmented through preformed cuts that create hinge-like joints. These segmented sections can bend relative to each other while maintaining the structural strength of individual wall sections, enabling the board to conform to curved shapes without compromising overall rigidity.
Solution Approach 2:
The U-board is designed with curvature accommodation through preformed cuts that allow the walls to bend and follow curved perimeters. This enables the originally rigid structure to adapt to spherical or curved object shapes while maintaining protective strength.
Data Source
AI summary
A single piece edge protector for curved and curvilinear-shaped objects includes a preformed, rigid, laminated U-board having a bottom wall, and a first sidewall, and a second sidewall which include preformed angled cuts. The preformed cuts are formed at about 15 degrees from a plane perpendicular to the bottom wall. Each sidewall of the edge protector is a mirror-image of the other such that a preformed cut on the first sidewall is directly across from a preformed cut on the second sidewall. A plurality of preformed cuts form both V-shaped openings and a plurality of trapezoid-like legs on the first and second sidewalls. Each leg may have a similar surface area or a different surface area as an adjacent leg along the length of the edge protector. The edge protector is configured to follow a curvilinear perimeter of about 135 degrees and may include an end cap closure.