Pallet load corner protector with locking tabs

A method of forming a corner protector for protecting a load of products stacked on a pallet, said corner protector including an upper end and a lower end, said method comprising the steps of:

• (a) forming first and second panels each having an inner layer and an outer layer;
• (b) forming a central fold line between said first panel and said second panel;
• (c) folding said first and second panels relative to each other such that said first panel and said second panel are disposed generally perpendicular to each other;
• (d) forming a first hinged locking flap from said inner layer of said first panel;
• (e) forming a second hinged locking flap from said inner layer of said second panel;
• (f) folding said first and second hinged locking flaps such that each is disposed generally perpendicular to remainders of said respective first and second panels;
• (g) engaging said first hinged locking flap with said second hinged locking flap such that said first and second panels are maintained generally perpendicular to each other;
• and
• (h) forming said first hinged locking flap and said second hinged locking flap at approximately the same distance from the upper end of said corner protector.

A method for installing a corner protector on a palletized load for protecting said load, said method comprising the steps of:

• supplying said load on a pallet, said load including a plurality of vertical corners and a plurality of rows of products;
• supplying a corner protector having an upper end and a lower end including first and second panels hingedly connected to each other along a central fold line, said first and second panels being disposed generally perpendicular to each other, each of said first and second panels including an inner layer and an outer layer, said inner layer of said first panel forming a first hinged locking flap disposed generally perpendicular to a remainder of said first panel, said inner layer of said second panel forming a second hinged locking flap disposed generally perpendicular to a remainder of said second panel, said first and second locking flaps being located at approximately the same distance from said upper end and being engaged to one another to maintain said first and second panels generally perpendicular to each other;
• and
• inserting said engaged first and second locking flaps along one of said rows such that said corner protector is disposed along one of said generally vertical corners of said load.

A corner protector for protecting first and second palletized loads of products, said first load of products each having a first height, said second load of products each having a second height, said corner protector having an upper end and a lower end, said corner protector comprising:

• first and second panels hingedly connected to each other along a central fold line and disposed generally perpendicular to each other, each of said first and second panels including an inner layer and an outer layer;
• said inner layer of said first panel forming a first hinged locking flap disposed generally perpendicular to a remainder of said first panel;
• two sets of first and second hinged locking flaps, said first and second locking flaps in a first of said two sets being hinged at approximately a first distance from said upper end of said corner protector, said first and second locking flaps in a second of said two sets being hinged at approximately a second distance from said lower end of said corner protector;
• flaps in one of said sets being disposed generally perpendicular to remainders of said respective first and second panels and being engaged to one another to maintain said first and second panels generally perpendicular to each other;
• wherein in a first orientation protecting said first load, said first and second locking flaps in a first of said two sets being disposed generally perpendicular to remainders of said respective first and second panels and being engaged to one another to maintain said first and second panels generally perpendicular to each other;
• and
• wherein in a second orientation protecting said second load, said first and second locking flaps in a second of said two sets being disposed generally perpendicular to remainders of said respective first and second panels and being engaged to one another to maintain said first and second panels generally perpendicular to each other.