SHIPPING CONTAINER FOR USE WITH PREHUNG DOOR AND FRAME ASSEMBLY

Abstract

A container is provided for shipping hardware such as door knobs, binges, framing wedges and the like with prehung door and frame assemblies. The container has a substantially rectangular configuration having a closed container portion and a jamb panel that extends from the top of the container that wraps around the outside of one of the jambs of the frame to secure the container to the prehung door and frame assembly. The depth of the container is less than the depth of the cavity side of the prehung door and frame assembly and the front wall of the container fits beneath or flush with the edge of the jamb on the cavity side of the frame.

Description

FIELD OF THE INVENTION

The present invention relates to the field of packaging preassembled (prehung) door and frame assemblies for shipping and handling.

BACKGROUND OF THE INFORMATION

It is common practice in the building industry to preassemble doors and frames into a unit (called a prehung door and frame assembly) at a factory and ship the same for eventual use in constructing buildings. These prehung doors are packaged with bands and corner boots to secure their shipment to stores and construction sites.

SUMMARY OF THE INVENTION

The present invention comprises a container for shipping hardware such as door knobs, hinges, framing wedges and the like with prehung door and frame assemblies. The container comprises a substantially rectangular configuration having a container portion and a jamb panel extending therefrom that wraps around the outside one of the jambs of the frame to secure the container to the prehung door and frame assembly and to protect the jamb during shipment. The depth of the container is the same or less than the depth of the cavity side of the prehung door and frame assembly and the front wall of the container fits beneath or flush with the edge of the jamb on the cavity side of the frame. The combined container and jamb protector may be formed by a single blank of foldable protective sheet material folded to define said container and said jamb panel.

These and other features, objects and advantages of the corner protector container will be more fully understood and appreciated by reference to the description of the preferred embodiments, and the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the container will become apparent from the following description and claims, and from the accompanying drawings, wherein:

FIGS. 1 and 1a show isometric images of cavity side and flush door side of a prehung door and frame assembly with two corner protector containers 10 embodiments positioned in place on upper left and right coolers and one container embodiment 100 positioned in place along the lower right side.

FIG. 2 is a top plane view of a blank used to form the corner protector container 10.

FIG. 3 is a front view of the folded corner protector container 10.

FIG. 4 is an end view of the folded corner protector container 10.

FIG. 5 is a view of the corner protector container 10 mounted in the upper right hand corner of a prehung door assembly.

FIG. 6 is door side view of the tipper right hand corner mounted corner protector container 10 as shown in FIG. 5.

FIG. 7 is a perspective view illustrating an intermediate folding of the blank of FIG. 2 to form the corner protector container 10 of the present invention.

FIG. 8 is a top plane view of a blank that may be used to prepare the container embodiment 100.

FIG. 9 is a perspective vie w illustrating inter mediate folding of the blank used to prepare the container embodiment 100.

FIG. 10 is a perspective view showing the complete folding of the container 121 of container embodiment 100 except for closing of the container first side wall.

FIG. 11 illustrates container embodiment 100 with container 121 abutting the inside of a jamb in combination with a standard corner protector 122.

FIG. 12 illustrates a door side view of container embodiment showing jamb panel 117 and door side panel 118 wrapped around the outside face and door side edge of a hinge jamb.

FIG. 13 is a top plane view of another embodiment of a blank that can be used to prepare the combined container and jamb protector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description of the preferred embodiments, the numbered parts in the Figures have the following meanings:

• 10—corner protector container
• 11—blank
• 12—container first side wall
• 12a—fold line
• 13—container back wall
• 13a—locking key
• 13b—fold line
• 14—container second side wall
• 14a—fold line
• 15—container front wall
• 15a—tie
• 15b—fold line
• 15c—fold line
• 15d—cut line
• 16—container bottom
• 16a—key slot

16b—fold line

• 16c—fold line
• 17—jamb panel
• 17a—key slot
• 17b—fold slot
• 17c—fold line
• 18—second jamb panel
• 18a—fold line
• 19—fold under flap
• 19a—key
• 19b—fold line
• 20—door side panel
• 20a—door side tie
• 20b—fold line
• 20c—fold line
• 20d—cut line
• 21—bottom flap
• 22—container
• 23—jamb channel
• 24—second jamb channel
• 25—envelope
• 30—prehung door and frame assembly
• 31—head jamb
• 32—hinge jamb
• 33—striker jamb
• 34—door
• 35—predrilled holes for lock and handles
• 36—hinges
• 37—stop
• 38—shipping band
• 39—deep side cavity of door and frame
• 100—container embodiment
• 110—blank for container embodiment
• 111—container first side wall
• 111a—fold line
• 112—container back wall
• 112a—first locking key
• 112—second locking key
• 112c—fold line
• 112d—fold line
• 113—container second side wall
• 114—container front wall
• 114a—fold line
• 114b—fold line
• 114c—fold line
• 115—container bottom
• 115a—key slot
• 115b—fold line
• 116—container top
• 116a—key slot
• 116b—fold line
• 117—jamb panel
• 117a—fold line
• 117b—fold line
• 118—door side panel
• 119—bottom flap
• 120—top flap
• 121—container
• 122—standard jamb corner protector
• 123—jamb channel
• 210—second embodiment of blank for container embodiment
• 211—container first side wall
• 211a—fold line
• 211b—locking key
• 211c—fold line
• 211d—fold tine
• 212—container back wall
• 213—container second side wall
• 213a—fold line
• 213b—locking key
• 213c—fold line
• 213d—fold line
• 214—container front wall
• 214a—fold line
• 215—container bottom
• 215a—key slot
• 215b—fold Sine
• 216—container top
• 216a—key slot
• 216b—fold line
• 217—jamb panel
• 217a—fold line
• 217b—fold line
• 218—door side panel
• 219—bottom flap
• 220—top flap

It is not intended the invention be limited to the specific embodiments shown and described.

FIGS. 1 and 1a illustrate a prehung door and frame assembly 30 with two corner protector containers 10 positioned in the tipper right and left corners of the prehung door assembly 30 and container embodiment 100 positioned on the lower right (FIG. 1) side i.e. the hinge jamb 32. FIG. 1 shows the cavity side 39 and FIG. 1a the door side of the prehung door and frame assembly 30. In a prehung door assembly the door 34 is usually hung from the hinge jamb 32 with hinges 36 so the door 34 is flush to the edges of head jamb 31, hinge jamb 32 and striker jamb 33 on one side of the assembly (FIG. 1a). Because of the width of the jambs a cavity 39 is formed on the other side of the assembly. The door 34 usually has predrilled holes 35 for mounting lock and handle. The three jambs have a stop 37 running parallel to their edges on the cavity side 39 to prevent the door from moving through the frame formed by the jambs when closed. Two of the corner protector containers 10 are shown mounted in the cavity 39, one in the right upper corner and one in the left upper corner. Container embodiment 100 is shown mounted in the cavity 39 on the hinge jamb 32. The corner protector container 10 is held in place when the corner protector container 10 is assembled over the jambs. It can be further secured with a shipping band 38. In this embodiment the corner protector container 10 is rectangular, it could also be square. The length and width of the corner proctor container can range from about a few inches to about ninety percent of the length and width of the cavity 39, The width of side walls 12 and 14 (W1 and W3) i.e. depth, is preferably no greater than the depth of the cavity 39 or the stops 37 whichever is less so the container front wall 15 is flush with the top edges of the jambs or the front wall is below the level of the edges of the jambs. The corner protector container 10 slips over the head jamb by inserting it into the jamb channel 23 and either the hinge jamb 32 or the striker jamb 33 by inserting it into the second jamb channel 24 and the container 22 sits inside the cavity 39 and the container front wall 15 is shown flush with the edges of the jambs. The open end formed by the top edges of 12, 13 and 14 end of the container portion 22 abuts against inside of the jamb to hold articles put into the container 22 for shipment with the prehung door and frame assembly 30. The jamb panel 17 of the corner protector container 10 fits over either the head jamb 31 or the hinge jamb 32 and the second jamb panel 18 fits over the other jamb. The door side panel 20 folds down over and fits flash with the door 34 and ties into the jamb panel 17 and locks the corner protector 10 onto the prehung door and frame assembly (see FIG. 1a).

Referring to FIGS. 2, 8 and 13, the corner protector container 10 can be formed from a unitary, planar, generally rectangular paperboard blank 11 and the container embodiment 100 from, blank 110 or 210. in the FIGS. a dashed—line indicates fold lines and an x-x-x line represents a cut line (i.e. the paper board is cut along this line to permit folding of that portion of the blank 11). Fold lines are preferably scored such as by press scoring to reduce the paper stiffness along the fold line enabling an accurate fold of the paper board alone the designated fold lines.

Referring to FIG. 2, blank 11 includes a container first side wall 12 connected by a fold line 12a to container back wall 13 which will face toward the door 34 when folded and placed. The container back wall 13 has locking key 13a extending from near the center of its lower edge along fold line 13b. The container back wall 13 is connected by a fold line 14a to container second side wall 14. The container second side wall 14 is connected by a fold line 15b to a container front wall 15 which faces toward the outside of the cavity. Extending from the top of the container front wall 15 and connected by a fold line 15c is a tie 15a which has a cut line 15d running from, the top to the fold line 15c. The tie 15a preferably has a tapering or rounded top edge to facilitate ease in folding the blank into the corner protector container 10. In the embodiment in FIG. 2 extending from the bottom edge of the container front wall 15 and connected thereto by fold line 16b is a container bottom 16 which functions to close the bottom of the container 22. Extending from the bottom edge of the container bottom 16 through fold line 16c is a bottom flap 21. A key slot 16a is centrally formed along the fold line 16c for receiving the locking key 13a when forming the corner protector container 10. The container bottom 16 has a width W4 starting at fold line 15b no greater than the width W2 of the container back wall 13 and less than the width W5 of the container front wall 15. The difference between W2 and W5 forms a jamb channel 23 when the corner protector container 50 is folded into shape. The container bottom 16 can be less than the width of the back wall 16 but should be wide enough to retain the articles placed in the container for shipment. The container bottom 16 has a length L3 equal to the width W1 of the container first side wall 12 which preferably has the same width or can. be less than W3 as the container second side wall 14. The bottom flap 21 has the same width W4 as the container bottom 16 and a length no longer than the length of the container bottom 16. Alternatively the container bottom 16 can be formed by extending the container bottom 16 from the first side 12 wall as shown in FIG. 13 with the locking key being formed at the bottom of the second side wall. The reverse can also be employed i.e. extending the bottom 16 from the bottom of the second side wall 14 with the locking key being formed at the bottom of the first side wall 12. Connected to container front wall 15 by fold line 17b is a jamb panel 17. Defining the top edge of jamb panel 17 is fold line 17c. Formed along the lower edge of the fold line 17c is a centrally located key slot 17a for receiving key 19a. Connected to the upper part of jamb panel 17 through fold line 17c is a second jamb panel 18. The width W6 of the jamb panels 17 and 18 is about the same as width of the jambs making up the frame of the prehung door and frame assembly 30 to which the corner protector container 10 is attached. The fold lines 15c, 17c and 20c lie in a straight line. The length L2 of the jamb panel 17 and door side panel 20 and the fold line 17b is the same as the longest length of the container front wall 15. The length L2 is longer than the length L1 by an amount at least as great as the thickness of the jambs of the frame of the prehung door and frame assembly 30. When folded the additional length L2 forms a second jamb channel 24 in the corner protector container 10 between the top of the first side wall 12, back wall 13 and second side wall 14 when the container is folded into shape. In FIG. 2 the bottom edges of 12, 13, 14, fold line 16b, 17, and 20 are aligned in a straight line, however the bottom edges of 17 and 20 can be above or below the bottom edges of edges of 12, 13, 14 and fold line 16b, Connected to the top edge of the second jamb panel 18 is fold under flap 19 that has a width W8 slightly narrower than the width W6 of the second jamb panel 18. The fold under flap 19 is connected to the second jamb panel 18 through two parallel fold lines 18a and 19b. Defined in the top edge of the fold under flap 19 is key 19a that mates with key slot 17a when the corner protector container 10 is folded into shape. The length L4 of the jamb panel 18 can vary. The length L5 of the fold under flap 19 is about the same as the length L4 of the jamb panel 18. In this embodiment the width W8 of the fold down under flap 19 is slightly less than the width of the jamb panel 18. This facilitates the insertion of the tie 15a and door side tie 20a into the envelope 25 formed when the fold under flap is folded into place under the jamb panel 18. Connected to jamb panel 17 through fold line 20b is door side panel 20. The width W7 of the door side panel 20 can vary. Along the top edge of the door side pane 120 is fold line 20c that has connected to it door side tie 20a. Door side tie 20a has cut line 20d that permits the tie 20a to be folded down away from the door side panel 20 so that when folded perpendicular to jamb panel 17 the door side tie 20a, as is tie 15a, can be inserted into an envelope 25 formed when fold under flap 19 is folded under onto second jamb panel 18 and key 19a is inserted-into key slot 17a. This locks the door side panel into second jamb panel 18. Friction between the parts secures the corner protector container 10 on to the corner of where the head jamb 31 connects to either the hinge jamb 32 or the strike jamb 33 of the frame of the prehung door and frame 30. All parts 12, 13, 14, 15, 16, 17, 18, 19 and 20 are rectangular having square comers as defined by their edges and fold lines. Ties 15a and 2a axe preferably rectangular with tapered or rounded upper edges to facilitate insertion into the envelope 25 formed when fold under flap 19 is folded under second jamb panel 18. The length of the outside edge of container first side wall 12, fold line 12a, 13, fold line 14a and fold line 15b are all about the same L1. Fold line 17b, 20b and the outside edge of door side panel 20 all have the same length L2, said L2 is longer than L1 so that when the container corner protector 10 is folded a jamb channel 23 is formed along the top edges of wall 13, 14 and fold line 15c. The embodiment in FIG. 2 shows key slots and keys to secure the bottom and fold under flap. Other means of securing such as tape, adhesives, staples and the like can be used.

The container 22 is formed by folding container first side wall 12 along fold line 12a perpendicular to container back wall 13. Container back wall 13 is folded along fold line 14a perpendicular to container second side wall 14 so the front edge of container first side wall 12 touches the inside of the container front wall 15. When so folded the face of first side wall 12 faces the inside wall of jamb panel 17 forming a second jamb channel 24. Width W1 and W3 are preferably no greater than the depth of the cavity 39 (edge of jambs to the face of the door 34 or stops 37 whichever is less).

To assemble the corner protector container 10 and attach it to the cavity 39 side of the prehung door and frame assembly 30 frame the fold under flap 19 is folded 180 degrees along 19b and 18a, onto second jamb panel 18 and secured by key 19a sliding into key slot 17a. This fold forms an envelope 25 into which ties 15a and 20a are later inserted to lock the corner protector container 10 onto the head jamb 31 and either the hinge jamb 32 or the striker jamb 33 of the prehung door and frame assembly 30.

The formed second jamb 18 & 19 is then folded along fold line 17c until perpendicular to jamb panel 17. Door side tie 20a is then folded along fold line 20c and tie 15a is folded along fold line 15c until perpendicular to jamb panel 17.

Door side panel 20 is then folded along fold line 20b until perpendicular to jamb panel 17. Door side tie 20a is slid into the newly formed envelope 25 formed between second jamb panel 18 and fold under flap 19.

Container 22 is formed by folding container bottom 16 along fold line 16b until perpendicular to container front wall 15. Bottom flap 21 is folded along fold line 16c until perpendicular to contain bottom 16 and container first side wall 12 is folded along fold line 12a until perpendicular to container back wall 13.

Locking key 13a is then folded perpendicular to container back wall 13. Next the container back wall 13 is folded along fold line 14a until perpendicular to container second side wall 14 and container second side wall 14 is folded along fold line 15b until perpendicular to container front wall 15. Locking key 13a is then inserted into key slot 16a. There is formed container 22 having an opening at the top of folded 12, 13 and 14. The opening is where hardware or the like can be placed into the container 22. The opening abuts against the inside of the jamb when the corner protector container 10 is secured at the corner of the frame.

The final assembly is formed by placing desired contents into newly formed container 22 and then placing corner protector container 10 over the corner formed by the jambs of the prehung door and frame assembly 30 using the channels 23 and 24 formed by the folding process. The container front wall 15 is then folded along fold line 17b until perpendicular to jamb panel 17, sliding tie 15a into the envelope 25 formed by 18 and 19 which locks the corner protector container 10 around the corner formed by the jambs of the prehung door and frame assembly 30.

FIG. 7 illustrates an intermediate stage of folding of corner protector container 10.

Referring to FIGS. 8-13, the container embodiment 100 is formed from a unitary, planar rectangular paperboard blank 110, (FIG. 8) or another embodiment of a blank 210 shown in FIG. 13.

Blank 110 includes a container first side wall 111 connected by a fold line 111a to container back wall 112. In the embodiment shown in FIG. S the container back wall 112 has first locking key 112a extending from near the center of its lower edge along fold line 112c. The container back wall 112 has a second locking key 112b extending from near the center of upper edge along fold line 112d. The container back wall 112 is connected by a fold line 113a to container second side wall 113. The container second side wall 113 is connected by a fold line 114a to a container front wall 114. Extending from the bottom of the container front wall 114 and connected by a fold line 114c is container bottom 115. Extending from the bottom edge of container bottom 115 through fold line 115b is bottom flap 119. A key slop 115a is centrally located along fold line 115b for receiving the locking key 12a when forming the container embodiment 100. Extending from the top edge of the container front wall 114 and connected thereto by fold line 114b is a container top 116. Extending from the top edge of the container top 116 through fold line 116b is a top flap 120. A slot 116a is centrally formed along the fold line 116b for receiving the locking key 112b when forming the container embodiment 100. The container bottom 115 has a width W4 shown here as starting along fold line 114a about equal to the width W2 of the container back wall 112 and less than the width W5 of container front wall 114. The container bottom 115 has a length L3 and the container top 116 has a length L4 equal to the width W1 of the container first side wall 111 which has about the same width W3 as the container second side wall 113. The bottom flap 119 and the top flap 116 have about the same width W4 as the container bottom 115 and the container top 116 (which is also about equal to W4) and a length no longer than the length L3 and L4 of the container bottom 115 and container top 116. Connected to container front wall 114 by fold line 117a is a jamb panel 117. Connected to the jamb panel 117 through fold line 117b is door side panel 118. The width W6 of jamb panel 117 is about the same as width of the jambs making up the frame of the prehung door and frame assembly 30. The length L2 of the jamb panel 117 and door side panel 118 and the fold line 117b is preferably the same as, or as shown in FIG. 8, is greater than L1. The width W5 is greater than width W2. When folded the additional length forms a jamb channel 123 between, the first side wall 111 and jamb panel 117 in the container embodiment 100. The bottom edge of 111, 112, 113, and fold lines 111a, 113a, 114a, 114b 114c and 117a are aligned in a straight line. The width W7 of the door side panel 118 can vary. All parts 111, 112, 113, 114, 115, 116, 117, and 118 are rectangular having square corners as defined by their edges and fold lines. Width W7 of the door side panel 118 is preferably at least about the same as the thickness of the jamb members of the frame. The length of the outside edge of container first side wall 111, fold line 111a, fold line 113a, fold line 114a and 117a are all the same, i.e. L1. Fold line 117b and the outside edge of door side panel 118 all about the same length L2 and said L2 is preferably longer than L1. Key locks 112a and 112b and key slots 115a and 116a are illustrated as the means for securing the container top 116 and container bottom, however, other means of securing can be employed such as for example, tape, adhesives, staples or the like.

The container 121 is formed by folding container first side wall 111 along fold line 111a perpendicular to container back wall 112. Container back wall 112 is folded along fold line 113a perpendicular to container second side wall 113 so the front edge of container first side wall 111 touches the inside of the container front wall 114. When so folded the lace of first side wall 111 faces the inside wall of jamb panel 117 when folded along fold line 117a perpendicular to container front wall 114 forming a jamb channel 123. Container bottom 115 is folded perpendicular to container front wall 114 along fold line 114c and bottom flab 119 is folded perpendicular to container bottom 115 along fold line 115b and key slot 115a is engaged with previously folded container back wall 112 and first locking key 112a. Container top 116 is folded perpendicular along fold line 114b to front wall 114 to face container bottom 115. Top flap 120 is folded perpendicular to container top 116 and key slot 116b is engaged with second locking key 112b.

To assemble the container 121 and attach to the frame and into the cavity 39 side of the prehung door assembly 30 frame, the contents of the container are placed inside the container either before the container top 116 or the container bottom 115 are secured (or the container can be filled through the first side wall 111 before it is closed). The container is then placed into the cavity 39 with the container first wall 111 snug against the inside surface of one of the jambs. The jamb panel 117 is then folded perpendicular along fold line 117a, to form the jamb channel 123, so that the inside surface of jamb panel fits flush with the outside surface of the frame jamb. Door side panel 118 is then folded along fold line 117b perpendicular to jamb panel 117 to fit flush with the door side edge of the jamb and secured in place with glue, staple, or banding. In one embodiment the container embodiment 100 is employed with a standard jamb corner protector 122 as shown in FIGS. 11 and 12 such that the standard jamb corner protector holds the container embodiment 100 in place.

FIGS. 9 and 10 illustrate the container embodiment 100 in various stages of folding before

being attached to a jamb so the container 121 sits in the inside of cavity 39. When attached the size of the container depth wise (W1 and W3) is preferably no greater than the depth of the cavity 39 so the container front wall 114 is essentially the same or less than the depth of the cavity.

FIG. 13 illustrates another embodiment of a blank 210 for preparing a container 100. Blank 210 includes a container first side wall 211 connected by a fold line 211a to container back wall 212. The container back wall 212 is connected by a fold line 213a to container second side wall 213. The container second side wall 113 is connected by a fold line 114a to a container front wall 214. Extending from the bottom of the first side wall 211 and connected by a fold line 211d is container bottom 215. Extending from the bottom edge of container bottom 215 through fold line 215b is bottom flap 219. A key slop 215a is centrally located along fold line 215b for receiving the locking key 213b extending from the bottom edge of second side wall 213 when forming the container embodiment 100. Extending from the top edge of the second side wall 213 and connected thereto by fold line 213d is a container top 216. Extending from the top edge of the container top 216 through fold line 216b is a top flap 220. A key slot 216a is centrally formed along the fold line 216b for receiving a locking key 211b extending form the top edge of first side wall 211 when forming the container embodiment 100. The container bottom 215 and the first side wall 211 have about the same width W1. The container bottom 215 has a length L2 and the container top 216, L3, about equal to the width W2 of the container back wall 212. The container second side wall 213 and the container top have about the same width W3. The bottom flap 219 and the top flap 220 have about the same width as the width W1 and W3 of the first side wall 211 and the second side wall 213. Connected to the second side wall 213 through fold line 214a is a front wall 214. Connected to container front wall 214 through fold line 217a is a jamb panel 217 . Connected to the jamb panel 217 through fold line 217b is door side panel 218. The width W6 of jamb panel 217 is about the same as width of the jambs making up the frame of the prehung door and frame assembly 30. The length of the jamb panel 217 and door side panel 218 and the fold line 217b is preferably the same as, or as shown in FIG. 13, is greater than L1. The width of the front wall 214, W5, is greater than width W2 of the container back wall 212. When folded the additional length forms a jamb channel 123 between the first side wall 211 and jamb panel 217 in the container embodiment. The width W7 of the door side panel 218 can vary. All parts 211, 212, 213, 214, 215, 216. 217, and 218 are rectangular having square comers as defined by their edges and fold lines. Width W7 of the door side panel 218 is preferably at least about the same as the thickness of the jamb members of the frame. The length of the outside edge of container first side wall 211, fold line 211a, fold line 213a, fold line 214a and 217a are all about the same, i.e. L1. Other embodiments of blanks that can make the container embodiment 100 can be similar to that illustrated in FIG. 13 with the location of the container bottom 215 extending from the bottom of second side wall 213 and the container top 216 either extending as shown form the second side wall or from the top of the first side wall with key locks located on the opposite wall. Key locks 112a and 112b and key slots 115a and 116a are illustrated as the means for securing the container top 116 and container bottom, however, other means of securing can be employed such as for example, tape, adhesives, staples or the like.

Mirror images of the blanks shown in FIGS. 2, 8 and 13 can also be employed to prepare container and jamb protectors of the present invention.

EXAMPLES

Example 1

A blank formed from corrugated cardboard was prepared as shown in FIG. 2 and described above.

The dimensions were: Dimensions are in inches (″).

• L1—8.75″
• L2—10.25″
• L3—3.125″
• L4—3″
• L5—3″
• W1—2″
• W2—5″

W3—2.25″

• W4—4.25″
• W5—5 and 10/16″
• W6—4 and 14/16″
• W7—2.75″
• W8—5″

The blank was folded and locked onto the corner formed by the perpendicular connection of the head jamb 31 and either the hinge 32 or strike jamb 33 of the frame of a prehung door and frame assembly so the container 22 sat inside the cavity 39 of the door and frame assembly. The jambs of the frame were 4.55 inches wide and 0.675 inches thick. The width of the ties were 2¾ inches and the length along the cut lines were less than L4 (3″).

Example 2

A blank formed from corrugated cardboard was prepared as shown in FIG. 8 and described above. The dimensions were: Dimensions ate m inches (″).

• L1—5″
• L2—13″
• L3—2 and ⅛″
• L4—2 and ⅛″
• W1—2.25″
• W2—5″
• W3—2.25″
• W4—5″
• W5—5 and ⅝″
• W6—4.25″
• W7—2 and ⅛″.

The blank was folded and locked onto the jamb of a prehung door and frame assembly so the container 121 sat inside the cavity 39. The jambs of the frame were 4.55 inches wide and 0.675 inches thick.

Claims

1. A combined container and jamb protector for use with a prehung door and frame assembly having a cavity side, said container comprising: a substantially rectangular container comprising a top, a bottom, a first side wall, a second side wall, a front wall and a back wall and a jamb panel extending from the container which wraps around the outside of a jamb of said frame to secure the container to said frame in said cavity side and to protect said jamb.

2. The combined container and jamb protector of claim 1 wherein said container has a depth equal to or less than the depth of said cavity.

3. The combined container and jamb protector of claim 1 wherein said jamb panel folds around the outside of the jamb and also onto the door side of the prehung door and frame assembly. 4. The combined container and jamb protector of claim 1 wherein the length of said jamb panel is greater than the length of said front wall. 5. The combined container and jamb protector of claim 1 wherein connected to the top edge of said jamb panel through a fold line is a second jamb panel that when folded perpendicular to said jamb panel and said container is placed at the corner of said frame said second jamb panel lays on a second jamb of said frame connected perpendicular to said jamb that the jamb panel is wrapped around.

6. The combined container and jamb protector of claim 1 formed by a single blank of foldable protective sheet material folded to define said container and said jamb panel.

7. A container corner protector for a prehung door and frame assembly comprising:

a container defined by a container first side wall, a container front waif a container back wall folded perpendicular to said container first side wall and running parallel to said container front wall and a second side wall folded perpendicular to said back wall and running parallel to said container first side wall and a container bottom having a width about equal to the container back wall and length equal to the width of the container first and second side walls which are about equal, a jamb panel connected through a fold line to said front wall, said container front wall having a width that is greater than the container back wall such that when the container first side wall is folded perpendicular to the container back wall a jamb channel is formed between the container second side wall and said jamb panel and a tie folded perpendicularly from the top of container front wall and running parallel to said container bottom;

a second jamb panel folded perpendicular to the top of said jamb panel and a fold under flap folded at 180 degrees from said second jamb panel and lying flat with the bottom of said second jamb panel to form an envelope, said second jamb panel forming a second jamb channel running perpendicular to and connecting with said jamb channel; and

a door side panel folded perpendicular to said jamb panel and running parallel to said container front wall and a door side tie folded perpendicular from the top of said door side panel said second tie running parallel to said container bottom, said tie and door side tie fitted into said envelope.

8. The container corner protector of claim 7 wherein said container bottom is folded perpendicular from the lower edge of said container front wall and includes a bottom flap folded perpendicular from the container bottom edge and running parallel to the container front wall and said bottom flap defines a key slot and said container back wall defines a locking key at the bottom that mates with said key slot.

9. The container corner protector of claim 7 wherein said container bottom is folded perpendicular from the lower edge of said container first side wall and includes a bottom flap folded perpendicular from the first side wall bottom edge and running parallel to the container second side wall and said bottom flap defines a key slot and said container second side wall defines a locking key at the bottom that mates with said key slot.

10. The container corner protector of claim 7 wherein said container bottom is folded perpendicular from the lower edge of said container second side wall and includes a bottom flap folded perpendicular from the second side wall bottom edge and running parallel to the container first side wall and said bottom flap defines a key slot and said container first side wall defines a locking key at the bottom that mates with said key slot.

11. The container corner protector of claim 7 wherein said tie and door side tie have a curved top edge.

12. The container corner protector of claim 7 wherein the top edge of said jamb panel defines a key slot and the top edge of said, fold under.flap defines a key that mates with said key slot.

13. A one-piece, planar, paperboard blank for forming the container corner protector of claim 7.

14. A one-piece, planar, paperboard blank for forming a container corner protector for a prehung door and frame assembly comprising a plurality of rectangular panels connected by fold lines comprising:

a container first side wall connected by a fold Sine to a container back wall, said container back wall defining a locking key extending from near the center of its lower edge along a fold line,

a second side wall connected by a fold line to said container back wall,

a container front wall connected to said container second side wall through a fold line,

a tie connected from the top of said container front wall by fold line,

a container bottom extending from the bottom edge of said container front wall through a fold line,

a bottom flap extending from the bottom edge of said container bottom through a fold line and a slot centrally formed along said fold line for receiving said locking key,

a jamb panel connected to said container front wall through a fold line,

a second jamb panel connected to the top of said jamb panel through a fold line,

a fold under flap connected to the top edge of the second jamb panel through a fold line,

a door side panel connected by a fold line to said jamb panel,

a door side tie connected to the top edge of said door side panel through a fold line, and

the bottom edge of the connected container first side wall, container back wall, container second side wall, container front wall and the fold line connecting the container front wall and the container bottom are aligned in a straight line.

15. The blank of claim 14 wherein the widths of the jamb panel and second jamb panel are about the same as width of the width of the jambs making up the frame of the prehung door and frame assembly and the length of the jamb panel and door side panel are about the same and said length is longer than the length of said container first side wall, container back wall and container second side wall by an amount at least as great as the thickness of the jambs of the frame of the prehung door and frame assembly such that when the blank is folded to make the corner protector container the additional length forms a jamb channel within the corner protector container.

16. The blank of claim 14 wherein said fold under flap that has a width slightly narrower than the width of the second jamb panel.

17. The blank of claim 14 wherein said fold under flap is connected to the second jamb panel through two parallel fold lines.

18. The blank of claim 14 wherein defined in the top edge of the fold under flap is a key and located along the fold line connecting the jamb panel with the second jamb panel is a key slot said key and said key slot mate when the blank is folded.

19. The blank of claim 14 wherein the outside edge of container first side wall, the fold line connecting said container first side wall to said container back wall and the fold line connecting container back wall to the container second side wall are about the same length and said fold line connecting said jamb panel to said door side panel and the outer edge of said door side panel are about the same length and said lengths of said fold line connecting said jamb panel to said door side panel are greater than said outside edge of container first side wall, the fold line connecting said container first side wall to said container back wall and the fold line connecting said container back wall to said container second side wall.

20. The blank of claim 14 wherein the length of said fold under flap is about the same as the length of the second jamb panel.

21. The blank of claim 14 wherein tie and door side tie have a rounded top edge.

22. The blank of claim 14 where in the container bottom has a width about equal to the width of the container back wall and less than the width of the container front wall and said container bottom has a length about equal to the width of the container first side wall the container second side wall which are about equal to each other.

23. The blank of claim 14 wherein a key slot is defined along the fold line that connects said jamb panel with said second jamb panel and a key formed along the top edge of the fold under flap.

24. The blank of claim 14 wherein the width of the jamb panel and the second jamb panel are about the same.

25. A container corner protector for a prehung door and frame assembly comprising: the assembled blank of claim 14.

26. A combined container and jamb protector for attachment to a prehung door and frame assembly comprising:

a container defined by a container first side wall, a front waif a container back wall folded perpendicular to said container first side wall and running parallel to said container front wall and a second side wall folded perpendicular to said back wall and to said container front wall and running parallel to said container first side wall, a container bottom starting at the fold of the second side wall folded perpendicular to said container front wall having a width about equal to the container back wall and length equal to the width of the container first and side wails which are about equal, a container top starting about at the fold of the second side wall folded perpendicular to said container front wall having a width about equal to the container back wall and length about equal to the width of the container first and side walls which are about equal, said container front wall having a width that is greater than the container back wall such that when the container second side wall is folded perpendicular to the container back wall and to said container front wall a jamb channel is formed between the container first side wall and a jamb panel that is folded perpendicular to said front wall parallel to the second side wall, and

a door side panel folded perpendicular to said jamb panel and running parallel to said container front wall.

27. The container of claim 26 including a bottom flap folded perpendicular from the bottom edge of said container bottom and running parallel to the container front wall and said bottom flap defines a key slot and said lower edge of said container back wall defines a locking key at the bottom that mates with, said key slot and a top flap folded perpendicular from the top edge of said container top running parallel to the container front wall and said top flap defines a key slot and the top edge of said container back wall defines a locking key at the top that mates with said key slot and a top flap.

28. A one-piece, planar, paperboard blank for forming the container of claim 26.

29. A one-piece, planar, paperboard blank for forming a container and jamb protector for a prehung door and frame assembly comprising a plurality of rectangular panels connected by fold lines comprising:

a container first side wall connected by a fold line to a container back wall;

a container second side wall connected to the second side of the container back wall by a fold line:

a container front wall connected to said container second side wall by a fold line said container front wall having a width wider than said container back wall;

a container bottom extending from the bottom edge of the container front wall and connected by a fold line;

a container top extending from the top edge of the container front wall and connected thereto by a fold line;

a jamb panel connected to the container front wall by a fold line, and

a door side panel connected to said jamb panel through a fold line.

30. The blank of claim 29 wherein said back wall has a first locking key extending from near the center of its lower edge along a fold line and a second locking key extending from near the center of upper edge along a fold line of said back wall.

31. The blank of claim 29 including a bottom flap extending from the bottom edge of container bottom through a fold line defining a key slop centrally located along said fold line for receiving the locking key extending from said lower edge of said back wall when forming the container and a top flap extending from the top edge of the container top through a fold line lap and defining a key slot centrally formed along said fold line for receiving the locking key extending from near the center of the upper edge of said back wall when forming the container embodiment, said container bottom has a width about equal to the width of the container back wall and less than the width of container front wall and container bottom has a length and the container top has a length about equal to the width of the container first side wall which has a width about the same as the container second side wall, and said bottom flap and the top flap have about the same width as the container bottom and the container top and a length no longer than the length of the container bottom and container top.

32. The blank of claim 29 wherein the width, of the front wall from the fold line where it connects to the second side wall and the fold line where it connects to said jamb panel is greater than the back wall thereby when the container is folded into shape the additional length forms a jamb channel in the container between the second side wall and the jamb panel.

33. The blank of claim 29 wherein the outside edge of container first side wall, the fold line connecting said container first side wall to said container back wall and the fold line connecting container back wall to the container second side wall, the fold line connecting the front wall to the back wall and the fold line connecting the front wall to said jamb panel are the same length.

34. A one-piece, planar, paperboard blank for forming a combined container and jamb protector for a prehung door and frame assembly comprising a plurality of rectangular panels connected by fold lines comprising:

a container first side wall connected by a fold line a to a container back wall;

a container second side wall connected to said container back wall;

a container front wall connected to said container second side wall said container front wall having a width greater than the width of said container back wall;

a container bottom extending through a fold line from the bottom of said first side wall;

a container top extending through a fold line from the top of said second side wall;

a jamb panel extending through a fold line from said container front wall; and

a door side panel extending through a fold line from said jamb panel.

35. The blank of claim 34 comprising:

a bottom flap extending through a fold line from the bottom edge of said container bottom and a key slot located centrally along said fold line;

a top flat extending through a fold line from the top edge of said container top and a key slot located centrally along said fold line;

a locking key extending from the bottom edge of said second wall that mates with said key slot located in said container bottom; and

a locking key extending from the top edge of said first side wall that mates with said key slot located in said container top.

36. A combined container and jamb protector for use with a prehung door and frame assembly comprising the assembled blank of claim 35.