Paperboard corner, and method of manufacturing the same

An in-line method for creating an elongated paperboard corner for applying against a portion of a product during transport or packaging so as to protect the portion of the product, the method comprising the steps of:

• providing three non-corrugated paperboard plies, each ply being made from a paperboard having a grammage of about 120 to about 380 g/m2;
• superimposing the three plies to form an overlapped ply;
• folding the overlapped ply into a plurality of sections so as to create first and second wings intersecting substantially perpendicularly at an apex, a section being defined by two consecutive folds or by a fold line and an end of the overlapped ply, the first and second wings having a thickness of about 100 to about 250 points;
• and
• configured the overlapped ply to traverse the apex at least twice and such that at least two of the sections overlap two other sections;
• wherein the overlapped ply comprise first, second, third, fourth, fifth, and sixth sections;
• wherein the first and second sections are folded so as to intersect substantially perpendicularly so as to form an inner portion of the paperboard corner, the second and third sections are folded so as to form part of the first wing, the third and fourth sections are folded so as to intersect substantially perpendicularly, the fourth and fifth sections are folded to form the second wing, and the fifth and sixth sections facing the first and second sections, respectively, the sixth region forming part of the first wing;
• and
• wherein the apex has a resistance force of about 100 lbs to about 300 lbs, the resistance force being measurable by mounting the paperboard corner upon two blocks, both blocks being about 1.5 inches wide and separated by about 10 inches, and a force being applied to the apex at a middle of the paperboard corner until a fracture in the paperboard corner is detected, the resistance force being the force at which the paperboard corner fractures, and wherein the resistance force of the apex and the thickness of the wings are related in an exponential manner.