Edge protector
An edge protector includes first and second face portions arranged at an angle relative to one another. One of the face portions includes a pair of locking tabs extending from the upper surface of that face portion, which are effective to engage and secure the edge protector to a binding material, such a steel band, during use. The other face portion can have a pair of path guides extending from the upper surface thereof to guide the binding material over the other face portion. By securing the edge protector to the binding material, scattering loose edge protectors over the floors of factories or steel mills is largely circumvented, and a work hazard avoided. Also, if the edge protector and the binding material are made from the same or from recyclably compatible materials, then they can be recycled together.
This application claims the benefit of U.S. Provisional Patent Applications Ser. No. 60/612,375 filed Sep. 23, 2004 and No. 60/621,235 filed Oct. 22, 2004, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTIONThe invention relates generally to an edge protector and more particularly to a metal edge protector comprising tabs that ensure the edge protector remains secured to strapping or banding commonly used to bind together items or goods.
DESCRIPTION OF RELATED ARTIn the storage and transport of goods, such as rolls of steel or steel coils, sheets of glass or sheets of metal, bands or straps often made of steel are commonly used to bind together such goods. Similarly, rope, wire or plastic bands can also be used to bind such goods together. The use of straps or bands to hold together goods presents several disadvantages. Goods bound with metal bands often have damage near the edges adjacent where the band wraps around the edge of the banded goods because the tension of the band can compress or crush the goods at such edges, where the goods are most vulnerable. For example, a metal band can scratch, chip or dent the edge of the goods if the band is secured tightly around the goods. Alternatively, the band may itself become damaged by the goods. For example, if rope or plastic banding is used to band goods together, a sharp edge of the goods may fray or cut the banding, thereby resulting in its breaking or snapping.
Edge protectors are commonly used in the industry to protect the edges of goods from damage caused by bands or straps secured around the goods under high tension. Similarly, edge protectors also protect banding from becoming damaged by the goods that are banded together. While edge protectors consisting of simple L-shaped pieces have been employed to protect against damage to goods, these edge protectors have not been entirely satisfactory. Edge protectors can become easily displaced during installation of straps or bands, particularly while the bands are being fitted into place, before the final tension is applied. Since the banding is usually relatively rigid and does not initially fit tightly around the stack or goods, the L-shaped edge protectors will not stay in place and regularly are pushed out of position as the band is being fitted to and tensioned around the goods. Furthermore, when such bands, which are secured to the banded goods under high tension, are released or cut from around the goods, the edge protectors fall to the floor and often litter the surrounding area. Alternatively, they can be launched into the surrounding area from the band snapping at high speed once it is cut and the tension is release. In addition to presenting a significant danger to personnel in the vicinity from flying metal objects, edge protectors scattered about the floor also are a serious safety hazard that can cause damage, workplace accidents and a host of other problems.
Accordingly, there is a need for an edge protector that can be easily secured to banding during installation and that can be moved along the length of the banding if needed to align with an edge of the banded goods. There is also a need for an edge protector that will not be launched or scattered on the floor on cutting or removal of a high-tension band.
SUMMARY OF THE INVENTIONAn edge protector is provided, which has a first face portion and a second face portion extending at an angle from the first face portion. A pair of locking tabs extend from an upper surface of the second face portion from respective base edges of the locking tabs. The base edges of the locking tabs are spaced apart to accommodate a band therebetween over the upper surface of the second face portion in use. The second face portion is substantially continuous and intact in a region between the locking tabs.
A combination of an edge protector secured to a length of binding material also is provided. The edge protector includes a first face portion and a second face portion extending at an angle from the first face portion. A pair of locking tabs extend from an upper surface of the second face portion. The locking tabs are engaged over the binding material to secure it to the edge protector. The edge protector and the binding material are made from the same material or from materials that are compatible for recycling.
In the description that follows, when a preferred range such as 5 to 25 (or 5-25) is given, this means preferably at least 5 and, separately and independently, preferably not more than 25.
It is understood that the edge protector as discussed herein is preferably made of metal such as 0.029 gage steel. More preferably, the edge protector is coated (i.e. galvanized or plated) metal to prevent rusting. Alternatively, the edge protector can comprise plastic or other composite materials. As will be clear below, if the edge protector is plastic or another composite material, the tabs (described below) of the edge protector should be composed of a material that can be bent or tapped down over a band without snapping off. For example, many plastics are rigid and inflexible and would break if bent from a vertical position to a horizontal position as is desirable of the tabs discussed herein.
With reference to
With reference to
The edge protectors are further explained and illustrated with reference to
In the alternative, the angle between surfaces 62 and 64 can be 85-115 degrees (e.g. for a right-angle edge), or any other suitable angle to accommodate any particular edge over which the edge protector 60 is to be applied.
The face portion 62 in
The path guides 66 and 68 are provided to keep the band 74 centered on the face portion 62 of the edge protector 60, and also to prevent the band 74 from moving or shifting laterally during transport.
The second face portion 64, which is joined to and extends at an angle from the first face portion 62, has a pair of locking tabs 70, 72 that extend from the upper surface thereof. In an example embodiment, the tabs 70 and 72 are provided by punching through from the under surface of the face portion 64, such that each tab 70 and 72 is punched out from the planar expanse of the face portion 64 but remains secured thereto and continuous therewith along an edge at the base of each tab, referred to herein as the base edge. The tabs 70 and 72 are punched such that the base edges thereof are parallel and aligned substantially longitudinally relative to the pathway of the band 74 over the face portion 64 in use. The base edges of the tabs 70 and 72 also are spaced laterally from one another a distance substantially corresponding to the width of the band 74, such that the band can be pressed against or in close proximity with the upper surface of the second face portion 64, and then the tabs 70 and 72 bent laterally inward, toward one another, over the band 74 such that the band 74 is secured between the upper surface of the face portion 64 and the overlying tabs 70 and 72.
Initially, the tabs 70, 72 extend upward at a significant angle, preferably almost or about 90°, from the upper surface of the second face portion 64 of the edge protector 60. This permits insertion of the band 74 between the extending tabs 70 and 72 so that it can be either pressed against or provided in close proximity with the upper surface of the face portion 64, in between the base edges of the opposing tabs 70 and 72. In practice, the edge protector 60 first is positioned and aligned over the edge of the goods that is to be protected against damage from the tensioned band 74. The band 74 then is aligned over the first and second face portions 62 and 64 of the edge protector 60 and then is tensioned down over the edge protector 60 as more fully described below. Once the band 74 has been adequately tensioned over the face portion 64 so that it is received between the tabs 70 and 72, the tabs are bent toward one another over the underlying band 74 to secure the band 74 between the tabs and the upper surface of the face portion 64. The tabs 70 and 72 can be bent or pressed downward using, e.g., a hammer, block, or other blunt tool or object.
Preferably the locking tabs 70, 72 are stamped from the second face portion 64 such that they remain continuous with and extend from the upper surface of the second face portion 64, as most clearly illustrated in
As evident from above, the tabs 70, 72 preferably are initially angled toward one another, toward the center of the upper surface of face portion 64 so as to form an acute angle between each tab and the upper surface of the face portion 64. Preferably, the acute angle is slightly less than 90 degrees, such as 60-89, 62-80, 65-75, or about 70 degrees. As such, the distance between the tips of the tabs 70, 72 is somewhat less than the width of the band 74, which will help prevent the band 74 from coming out from between the tabs during installation, after it has been inserted in between the tabs 70 and 72 but prior to bending the tabs thereover following tensioning of the band 74. Another benefit is that because the band 74 is loosely secured between the tabs prior to complete or final tensioning, the edge protector 60 itself is less likely to become dislodged or ejected from between the band and the edge of the goods before the band is fully tightened. Another advantageous feature is that even when the tabs are fully secured (bent) over the tensioned band 74, the band 74 still has the freedom to slide longitudinally (translate) over the edge protector 60, through the passage defined between the upper surface of face portion 64 and the tabs 70, 72, but not laterally with respect thereto. This is advantageous, e.g., if it is desirable first to secure an appropriate number of edge protectors to a band 74 (corresponding to the number of edges over the goods that the band will traverse when secured thereto), and then to position the band, with attached edge protectors, over the goods prior to final tensioning the band 74.
The locking tabs 70, 72 are formed in or provided to the second face portion 64 in such a way that the planar expanse of the face portion 64 remains present and substantially intact, except for the two relatively small cut out portions in the face portion 64 corresponding in dimension to the respective tabs 70 and 72, from which those tabs have been stamped. In other words, except for the cut out portions from which the tabs 70 and 72 are stamped, the face portion 64 is continuous and intact in the region between the tabs 70 and 72. Alternatively, if the tabs 70 and 72 are to be separately provided to the upper surface of the face portion 64, such as by brazing or welding, then the face portion 64 can be completely continuous and intact in the region between the tabs. As a result of this construction, the underlying goods, such as a steel coil, are significantly protected from contact with and damage from the band. As a band 74 is tensioned around a coil, a stack of metal sheets or other goods, the band presses against the goods with the most force at the edges. Thus, shielding the goods underlying the edge protector 60 from the band is desirable. Also, as noted above once the band 74 is in place between the tabs 70 and 72, those tabs typically are bent over the band 74 by hammering with a hammer, a block or other blunt tool or object. The substantially continuous planar expanse of the face portion 64 in between the tabs 70 and 72, which it will be understood is in between the band 74 and the underlying goods, protects and shields the goods from being damaged when the tabs 70 and 72 are pounded down. Otherwise, the band 74, which typically has relatively sharp edges, or the hammering tool itself may be knocked into the underlying goods and cause damage. Shielding the underlying material or goods from the band 74 and from the hammering tool or object used to pound the tabs significantly reduces the potential for damage to the surface of the underlying material.
The preferred shape of the locking tabs 70 and 72 is a square or rectangle. A square or rectangle shape provides the largest tab area over the underlying band when the tab is hammered down, thus providing a more dependable means to secure the edge protector to the band. However, the tabs 70, 72 may be triangular, crescent or any other shape capable of being tapped down over an underlying band.
The edge protector described herein presents many benefits. For example, the edge protector 60 improves the stability of a band by providing a consistent alignment that will eliminate potential shearing or shifting of the band during transport. The edge protector 60 also protects the outer laps or edges of a coil or sheet stack, thereby eliminating excessive scrap of damaged goods. Less scrap leads to more usable material, which results in more products being manufactured, improved productivity, increased profits and a lower cost to the consumer. Another significant benefit of the edge protector 60 is that it will remain secured to the tensioned band after the band is cut to release the goods due to the engagement of the locking tabs 70, 72, thus eliminating potential hazards on a manufacturing floor. Conventional edge protectors fall to and scatter on the floor after the bands are removed from around the banded goods, as noted above. Edge protectors scattered about the floor, such as in a manufacturing plant or a steel mill, can easily find their way under the feet of workers, into expensive operating equipment, under the wheels of tow motors, etc. Indeed, conventional edge protectors scattered over the floor has been a serious safety hazard in steel mills. By eliminating edge protectors from falling to the floor, workers will have a safer working environment and manufacturers will see reduced clean-up costs, reduced equipment repair costs and enhanced life span of processing equipment.
By remaining attached to the band, the edge protector 60 provides a benefit to the environment as well. Bands, whether composed of metal or plastic, are often recycled after being used. Thus, because the edge protector remains attached to the band, recycling of edge protectors is assured. For this reason, it is desirable that the edge protector 60 be made from the same material or from a compatible material for recycling purposes as the band 74 to which it will be secured. For example, a steel edge protector is preferred when steel bands are to be used. When a plastic band is to be used, preferably the edge protector 60 is made from the same type of plastic as the band, or alternatively from a compatible class of plastic so they can be recycled together. Ensuring the recycling of edge protectors benefits the environment and reduces scrap costs to the manufacturer.
In addition to the applications in which the edge protector 60 can be used as discussed above, other uses include, but are not limited to, protecting the edges of a stack of plywood, sheetrock, drywall, lumber, trusses, cardboard, packaging materials, etc. Edge protectors of the present invention can be used with steel or other banding (less preferably plastic or fiber-reinforced plastic banding) wherever such banding is used to band together items or goods such as equipment or hardware, whether alone or to a pallet as known in the art. Broadly, any good or goods that is/are palletized, as well as any goods that are banded with steel or other bands, can utilize the edge protectors described herein to protect the edges thereof from high-tension bands, and to keep those bands in place during transport.
Alternatively, the edge protector 60 described herein also can be used with other forms of binding, such as rope, wire, cord, etc. It will be understood that the lateral distance between both the path guides 66 and 68 and the locking tabs 70 and 72 can be varied to accommodate whatever form and dimension of binding is used. Alternatively, if a binding such as cord, wire or twine is to be used, which has no significant width compared to its height, then the locking tabs 70 and 72 can be positioned at substantially the same lateral location, preferably central of the face portion 64, but spaced longitudinally from one another so that the cord, wire or twine is held down against the upper surface of the face portion 64 by the successive tabs 70 and 72 which are bent thereover from opposite lateral directions.
The edge protector 60 can be offered or supplied in a variety of sizes and configurations, for compatibility with a variety of forms and sizes of bindings, such as different widths and materials for bands 74, as well as for other forms of binding such as cord, rope or twine.
For example, for steel bands 74, the edge protector 60 can be supplied in two sizes to accommodate the two common widths of steel banding −¾ inch and 1¼ inch width steel banding.
In an example embodiment, the edge protector is made from a sheet metal blank measuring 2½ inches wide×3⅝ inches long× 1/32 inch thick, with ⅜ inch radius corners. The respective first and second face portions 62 and 64 are provided by bending the blank at the center of the 3⅝ inch length dimension, to form their common edge 63 referred to above, to a 95-degree angle. As illustrated in
Continuing with the foregoing example embodiment, the second face portion 64, which is perpendicular to the underlying sheets in
In another example embodiment, suitable for a band 74 measuring ¾ inches wide, the edge protector 60 is made from a sheet metal blank that measures 2 inches wide×3⅝ inches long× 1/32 inch thick and has ⅜ inch radius corners. The differences between this embodiment and the immediately preceding embodiment are that here the edge protector 60 has a width of 2 inches, and the spacing between the path guides 66 and 68 and between the locking tabs 70 and 72 are different. Here, the path guides and the tabs are spaced ⅞ inch, or slightly further, apart.
When banding a coil, such as steel, the edge protectors 60 can be installed as follows. Loop the band 74 through the eye 40 of the coil 10; tension the band 74 just enough to allow the edge protectors 60 to be set in place with the banding 74 between the two locking tabs 70, 72 in their initial, raised position. Tension the band 74 to the desired final tension. Using a hammer or similar device, hammer the tabs 70, 72 down to secure the edge protector 60 to the band 74 as shown in
Although the above-described embodiments constitute preferred embodiments, it will be understood that various changes or modifications can be made thereto without departing from the spirit and the scope of the present invention as set forth in the appended claims.
Claims
1. An edge protector comprising a first face portion and a second face portion extending at an angle from the first face portion, and a pair of locking tabs extending from an upper surface of said second face portion from respective base edges of said locking tabs, said base edges being spaced apart to accommodate a band therebetween over said upper surface of said second face portion in use, said second face portion being substantially continuous and intact in a region between the locking tabs.
2. An edge protector according to claim 1 said locking tabs being stamped from said second face portion such that each of said tabs is continuous therewith, and such that said region of said second face portion between said locking tabs is continuous and intact except for a pair of cut outs in said second face portion corresponding to the shape of the respective locking tabs, from which said pair of locking tabs has been stamped.
3. An edge protector according to claim 1, each of said locking tabs having the shape of a square or a rectangle.
4. An edge protector according to claim 1, said pair of locking tabs being angled toward one another so as to form an acute angle between each of said tabs and the upper surface of said second face portion.
5. An edge protector according to claim 4, said acute angle being 60-89° for each of said locking tabs.
6. An edge protector according to claim 1, said locking tabs being capable of being bent down over said band in use so as to secure said band between said upper surface of said second face portion and said locking tabs overlying said band.
7. An edge protector according to claim 6, said locking tabs being of sufficient length as to effectively secure said band to said edge protector in use after said tabs are bent down over said band.
8. An edge protector according to claim 1, said edge protector being made of metal.
9. An edge protector according to claim 1, said edge protector being made of steel.
10. An edge protector according to claim 1, the angle between said first and said second face portions being 85-115 degrees.
11. An edge protector according to claim 1, further comprising a pair of raised band path guides extending from an upper surface of said first face portion, said path guides being spaced laterally from one another to accommodate said band in a region defined between said path guides over said upper surface of said first face portion in use.
12. An edge protector according to claim 11, said path guides being provided as raised portions of said first face portion, extending from and continuous with the upper surface thereof.
13. An edge protector according to claim 11, said path guides being provided as deflected regions of the first face portion, which protrude from the upper surface thereof, and which are continuous with the remainder of said first face portion.
14. A combination comprising an edge protector secured to a length of binding material, said edge protector comprising a first face portion and a second face portion extending at an angle from the first face portion, and a pair of locking tabs extending from an upper surface of said second face portion, said locking tabs being engaged over said binding material to secure it to said edge protector, said edge protector and said binding material being made from the same material or from materials that are compatible for recycling.
15. A combination according to claim 14, said binding material being a band.
16. A combination according to claim 15, said locking tabs extending from respective base edges at the upper surface of said second face portion, said band being accommodated over said upper surface of said second face portion between said base edges of said locking tabs, said locking tabs being bent over said band to thereby secure it between the upper surface of said second portion and said locking tabs overlying said band.
17. A combination according to claim 16, said band being slidable over said edge protector, through a passage defined between said upper surface of said second face portion and said tabs engaged over said band.
18. A combination according to claim 14, said second face portion being substantially continuous and intact in a region between the locking tabs.
19. A combination according to claim 18, said locking tabs being stamped from said second face portion such that each of said tabs is continuous therewith, and such that said region of said second face portion between said locking tabs is continuous and intact except for a pair of cut outs in said second face portion corresponding to the shape of the respective locking tabs, from which said pair of locking tabs has been stamped.
20. A combination according to claim 14, further comprising a pair of raised path guides extending from an upper surface of said first face portion, said path guides being spaced laterally from one another to accommodate said binding material in a region defined between said path guides over said upper surface of said first face portion.
21. A combination according to claim 20, said path guides being provided as raised portions of said first face portion, extending from and continuous with the upper surface thereof.
22. A combination according to claim 20, said path guides being provided as deflected regions of the first face portion, which protrude from the upper surface thereof, and which are continuous with the remainder of said first face portion.
23. A combination according to claim 14, further comprising an assembly of banded goods having a first surface of the goods and a second surface of the goods intersecting at an edge of the goods,
- said edge protector being provided against said edge of the goods such that said first and second face portions of said edge protector extend over respective surfaces of the goods that intersect at the edge of the goods,
- said binding material being tensioned against said edge protector, thereby securing said edge protector in place against said edge of the goods, such that said binding material follows a pathway around said edge protector,
- said binding material passing over said first face portion, and over said second face portion between said base edges of said locking tabs extending from the upper surface thereof.
24. A combination according to claim 23, further comprising a pair of raised path guides spaced laterally from one another and extending from an upper surface of said first face portion of said edge protector, said binding material being accommodated and passing over said first face portion between said path guides extending from the upper surface thereof.
25. A combination according to claim 23, the angle between said first and second face portions of said edge protector being slightly greater than the angle between the surfaces of the goods that intersect at and define the edge of the goods, such that tensile force of said tensioned binding material tends to compress each of said face portions, thus forcing the binding material more tightly against said face portions and against the underlying assembly of goods.
26. A combination according to claim 23, said binding material being a metal band, said edge protector being made of metal.
27. A combination according to claim 23, said binding material being a steel band, said edge protector being made of steel.
28. A combination according to claim 23, said assembly of goods being a steel coil, said edge of the goods being a coil edge formed at the intersection of a first coil surface defined by a sheet of steel that has been wound into said coil, and a second coil surface defined by edges of a plurality of windings of said sheet of steel that has been wound into said coil.
29. A combination according to claim 28, said first face portion of said edge protector being provided extending over said first coil surface and said second face portion of said edge protector extending over said second coil surface.
Type: Application
Filed: Sep 21, 2005
Publication Date: May 25, 2006
Inventors: Charles Riddleburgh (Westfield Center, OH), Irene Riddleburgh (Westfield Center, OH)
Application Number: 11/231,592
International Classification: B65D 85/48 (20060101); B65D 85/67 (20060101); B65D 19/00 (20060101);