Expandable foam corner protector

A method of forming an expandable foam plank, comprising:

• (i) forming a foamable polymeric composition;
• (ii) extruding the foamable polymeric composition into the form of a plank having (a) a top edge and a bottom edge opposing the top edge that defines a width of the expandable foam plank in a Y-direction in an unexpanded state, (b) a first side edge and a second side edge opposing the first side edge that defines a length of the expandable foam plank in a X-direction in the unexpanded state, and (c) a first surface and a second surface opposing the first surface that defines a thickness of the expandable foam plank in a Z-direction in the unexpanded state;
• (iii) defining an interior channel portion extending from the first side edge to the second side edge and imparting a plurality of arc-shaped cuts extending through the thickness of the expandable foam plank in the interior channel portion, wherein at least a portion of the arc-shaped cuts are aligned along the X-direction and being free to expand to form expanded openings along the Y-direction in response to an external force applied to the expandable foam plank along the Y-direction;
• (iv) defining a first bracketing portion extending from the first side edge to the second side edge, and defining a second bracketing portion extending from the first side edge to the second side edge, wherein the interior channel portion is located between the first bracketing portion and the second bracketing portion;
• and
• (v) forming a one or more pre-notched-out sections each defined by imparting corresponding individual perforation networks defining respective pre-notched-out sections in each of the first bracketing portion and the second bracketing portion, wherein the pre-notched out sections are removable to define corresponding notched-out portions.