Paperboard Corner Design with Overlapping Plies for Rigidity

The patent applies composite materials by combining multiple plies of paperboard with different properties (corrugated and non-corrugated layers) to achieve the desired strength and rigidity. This allows the corner to meet performance requirements while using thinner, less expensive materials compared to conventional single-material thick paperboard corners.

The patent changes the structural parameters of the paperboard corner by introducing specific fold configurations (first fold, second fold, third fold) and overlap arrangements. These parameter changes enable the corner to achieve enhanced rigidity and tear resistance through geometric reinforcement rather than relying solely on increased material thickness, thereby reducing manufacturing costs.

The patent segments the paperboard corner into distinct functional plies with specific roles: a first ply forming the base structure, a second ply providing reinforcement through overlapping, and a third ply offering additional protection. Each ply is folded and positioned to perform its specific function, allowing the corner to achieve high structural rigidity while maintaining manageable complexity through organized segmentation.

The patent implements a nested structure where multiple plies are folded and overlapped in a compact arrangement. The plies are nested within each other through systematic folding patterns, creating a space-efficient configuration that maximizes structural rigidity within a compact form factor, thereby avoiding the need for excessive material or complex assembly.