CORNER PROTECTOR, CORNER PROTECTOR ASSEMBLY AND PANE ASSEMBLY INCLUDING THE SAME

Abstract

A corner protector is provided with a body with a recess formed in the body. The recess defines a first surface to receive and contact a pane surface of a pane in the recess. The recess defines a second surface angled relative to the first surface and intersecting the first surface to receive and contact a first edge surface of the pane. The recess defines a third surface angled relative to the first surface and the second surface and intersecting the first surface to receive and contact a second edge surface of the pane. The body defines an aperture formed in the first surface and oriented at a convergence of the first surface, the second surface, and the third surface such that the second surface and the third surface do not intersect. The aperture is formed to a blind depth in the body.

Claims

1. A corner protector comprising a body with a recess formed in the body, the recess defining a first surface to receive and contact a pane surface of a pane in the recess, the recess defining a second surface angled relative to the first surface and intersecting the first surface to receive and contact a first edge surface of the pane, the recess defining a third surface angled relative to the first surface and the second surface and intersecting the first surface to receive and contact a second edge surface of the pane, and the body defining an aperture formed in the first surface and oriented at a convergence of the first surface, the second surface, and the third surface such that the second surface and the third surface do not intersect, wherein the aperture is formed to a blind depth in the body.

2. The corner protector of claim 1, wherein the recess defines a fourth surface spaced apart and opposed from the first surface to contact another pane surface of the pane; and wherein a second aperture is formed in the fourth surface and is oriented at a convergence of the second surface, the third surface, and the fourth surface such that the second surface and the third surface do not intersect.

3. The corner protector of claim 1, wherein the body defines a first exterior surface spaced apart from the first recess surface; wherein the body defines a second exterior surface spaced apart from the second recess surface; wherein the body defines a third exterior surface spaced apart from the third recess surface; and wherein the aperture is formed through the first exterior surface.

4. The corner protector of claim 3, wherein a second aperture is formed through the first surface and the first exterior surface; and wherein the second aperture is spaced apart from the first aperture.

5. The corner protector of claim 1, wherein the recess defines a fourth surface spaced apart and opposed from the first surface to contact another pane surface of the pane; wherein the body defines a first exterior surface spaced apart from the first recess surface; wherein the body defines a second exterior surface spaced apart from the second recess surface; wherein the body defines a third exterior surface spaced apart from the third recess surface; wherein the body defines a fourth exterior surface spaced apart from the fourth recess surface; and wherein the aperture is formed through the first exterior surface.

6. The corner protector of claim 5, wherein the aperture is not formed through the fourth exterior surface.

7. The corner protector of claim 5, wherein a second aperture is formed through the fourth recess surface to a blind depth.

8. The corner protector of claim 5, wherein a second aperture is formed through the fourth recess surface, and not through the fourth exterior surface.

9. The corner protector of claim 1, wherein the body is formed from a polypropylene material.

10. A pane assembly comprising: the corner protector of claim 1; and a pane received in the recess of the corner protector, the pane defining a first pane surface in contact with the first recess surface, the pane defining a first edge surface in contact with the second recess surface, and the pane defining a second edge surface in contact with the third recess surface, wherein the first pane surface, the first edge surface, and the second edge surface converge at a corner of the pane, such that the aperture defines a gap provided between the first pane surface and the first recess surface adjacent the corner of the pane.

11. The pane assembly of claim 10, further comprising a retainer attached to the corner protector and the pane to retain the corner protector on the pane.

12. A pane assembly comprising: a pane defining a first pane surface and a second pane surface spaced apart from the first pane surface, and a plurality of edge surfaces intersecting the first pane surface and the second pane surface, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the pane; and a plurality of corner protectors each according to claim 1, and each receiving one of the corners of the pane.

13. The pane assembly of claim 12, wherein the pane further comprises a glass shower door.

14. A packaged pane assembly comprising: a box; and the pane assembly of claim 12 received within the box.

15. The corner protector of claim 1, wherein the recess defines a fourth surface spaced apart and opposed from the first surface to contact another pane surface of the pane; and wherein the aperture is formed in the fourth surface and is oriented at a convergence of the second surface, the third surface, and the fourth surface such that the second surface and the third surface do not intersect.

16. A pane assembly comprising: the corner protector of claim 15; and a pane received in the recess of the corner protector, the pane defining a first pane surface in contact with the first recess surface, the pane defining a second pane surface in contact with the fourth recess surface, the pane defining a first edge surface in contact with the second recess surface, and the pane defining a second edge surface in contact with the third recess surface, wherein the first pane surface, the first edge surface, and the second edge surface converge at a corner of the pane, such that the aperture defines a gap between the first pane surface and the first recess surface adjacent the corner of the pane, and the aperture defines a gap between the second pane surface and the fourth recess surface.

17. A packaged pane assembly comprising: a box; and a pane assembly received within the box, the pane assembly comprising: a pane defining a first pane surface and a second pane surface spaced apart from the first pane surface, and a plurality of edge surfaces intersecting the first pane surface and the second pane surface, wherein each intersection of a pair of adjacent edge surfaces defines a corner of the pane, and a plurality of corner protectors each receiving one of the corners of the pane, wherein each corner protector comprises a body with a recess formed in the body, the recess defining a first surface to receive and contact the first pane surface of the pane in the recess, the recess defining a second surface angled relative to the first surface and intersecting the first surface to receive and contact a first edge surface of the pane, the recess defining a third surface angled relative to the first surface and the second surface and intersecting the first surface to receive and contact a second edge surface of the pane, and the body defining an aperture formed in the first surface and oriented at a convergence of the first surface, the second surface, and the third surface such that the second surface and the third surface do not intersect.

18. The packaged pane assembly of claim 17, further comprising: a plurality of foam members oriented within the box about the pane assembly.

19. A corner protector assembly comprising: a corner protector sized to receive a corner of a pane; and a retainer attached to the corner protector to attach the corner protector to the pane.

20. The corner protector of claim 19, wherein the retainer comprises an adhesive label.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 is a front elevation view of a pane assembly according to an embodiment, illustrating a corner protector assembled to a pane;

[0030] FIG. 2 is a side perspective view of the corner protector of FIG. 1;

[0031] FIG. 3 is a front perspective view of the corner protector of FIG. 1;

[0032] FIG. 4 is a side elevation view of the corner protector of FIG. 1;

[0033] FIG. 5 is a front perspective view of a pane assembly according to another embodiment, illustrating a corner protector assembly assembled to a pane;

[0034] FIG. 6 is a side perspective view of the pane assembly of FIG. 5;

[0035] FIG. 7 is a front elevation view of a pane assembly according to another embodiment, illustrating a corner protector assembled to a pane;

[0036] FIG. 8 is a front elevation view of a pane assembly according to another embodiment, illustrating a corner protector assembled to a pane;

[0037] FIG. 9 is a front perspective view of a package assembly;

[0038] FIG. 10 is another bottom partial perspective view of the package assembly of FIG. 9; and

[0039] FIG. 11 is a front perspective view of a corner protector according to another embodiment;

[0040] FIG. 12 is an enlarged side view of the corner protector of FIG. 11; and

[0041] FIG. 13 is a perspective section view taken along section line 13-13 in FIG. 12.

DETAILED DESCRIPTION

[0042] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0043] It will also be understood that, although the terms first, second, etc., are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another and are presented in order of introduction for a particular embodiment, and may vary in the introduction of various embodiments. For example, a first surface could be termed a second surface, and, similarly, a second surface could be termed a first surface, without departing from the scope of the various described embodiments. The first surface and the second surface are both surfaces, but they are not the same surface in the context of a particular embodiment.

[0044] Shower door assemblies are utilized with shower enclosures, and are designed to contain water within the enclosure and prevent it from spilling out onto a bathroom floor. Shower doors are typically made from glass, though some might employ acrylic, plastic, or any suitable pane. Glass doors can be clear, frosted, or patterned to offer varying degrees of privacy and style.

[0045] Shower door assemblies offer various options and styles. For example, sliding shower door assemblies consist of two or more panels that slide along a track. Sliding shower door assemblies are compact and conserve space by not requiring extra room to swing open. Hinged or swing shower door assemblies open outward on hinges. Swing shower door assemblies require adequate space to swing open but can provide a traditional look and ease in ingress and egress. Bi-fold shower door assemblies fold in on themselves and are optimal for very tight spaces. Frameless shower door assemblies are made of tempered glass with minimal metal framing, to offer a sleek, modern look that are easier to clean. Framed shower door assemblies include a metal frame that surrounds the glass, offering extra support and sometimes additional features like built-in hardware.

[0046] Shower door assemblies offer additional features and hardware. Handles are mounted through the pane of the door. In framed designs, the handle may be mounted to the frame along an edge of the door. Handles come in various styles and finishes, from sleek chrome to brushed nickel. Rubber or silicone seals may be provided along the edges of shower doors to help prevent leaks and maintain water containment. For sliding doors, track subassemblies may include a top and sometimes a bottom track, to guide movement of the door. Some doors have built-in towel bars or hooks for added convenience, which may also be utilized as handles.

[0047] The design of a shower door can range from minimalist to ornate, depending on the overall bathroom decor. Clear glass doors can make a space feel larger and more open, while frosted or patterned glass can provide additional privacy. A selected shower door assembly combines functionality with aesthetics, helping to define a look and usability of the shower enclosure.

[0048] Shower door assemblies are often manufactured at one or more facilities, and then shipped to retail locations for retail. Alternatively, the shower door assemblies may be shipped directly to an end customer. The shower door assemblies are packaged for transportation to retail and to the end user. The shower door assemblies may be packaged with the shower door panes packaged separately from other components. Alternatively, shower door assemblies can be packaged with other features and hardware, such as handles, seals, track subassemblies, towel bars, or the like.

[0049] With reference to FIG. 1, a corner of a shower door pane 20 is illustrated partially packaged with a corner protector 22. The shower door pane 20 has a first pane surface 24 and a second pane surface 26 that is spaced apart from the first pane surface 24 by a thickness dimension. The first pane surface 24 and the second pane surface 26 are generally parallel within customary manufacturing tolerances. The shower door pane 20 may be embodied by a typical shower door pane shape, such as a rectangular shape whereby each of the pane surfaces 24, 26 is generally a rectangle. The shower door pane 20 also includes a plurality of edge surfaces 28, 30, 32, 34 formed about a periphery of the pane 20. FIG. 1 illustrates two of the edge surfaces 28, 30, which may be described as a first edge surface 28 and a second edge surface 30, or as a left side edge surface 28 and a bottom edge surface 30. Each of the edge surfaces 28, 30, 32, 34 may be generally planar within manufacturing tolerances, and may converge at edges that are rounded, chamfered, or otherwise contoured to reduce stress along an edge.

[0050] As illustrated in FIG. 1, the first pane surface 24, the first edge surface 28, and the second edge surface 30 converge at a corner 36. The corner 36 is rounded with a fillet for stress relief. The corner 36 may also provide a corner edge that extends to a convergence or an intersection with the second pane surface 26. Each intersection of the pane surfaces 24, 26 with a pair of the edge surfaces 28, 30, 32, 34 forms a corner 36. The corner 36 of the pane 20 is often the most fragile portion of the product 20.

[0051] Shower door panes 20 are commonly fabricated from glass, which is particularly susceptible to damage at the corners 36 of the panes 20. Although a glass shower door pane 20 is described, other suitable materials, such as transparent materials, such as acrylic or polymeric are contemplated.

[0052] The prior art has adopted corner protectors to protect the corners 36 from direct edge contact or impact and to distribute loads along the surfaces 24, 26, 28, 30, 32, 34 of the pane 20 away from the corner 36. The corner protector 22 suspends the corner 36 within the corner protector 22 to further isolate the corner 36 to contact, and to distribute loading away from the corner 36, and away from the pane surfaces 24, 26 and the edge surfaces 28, 30, 32, 34 of the pane 20.

[0053] The corner protector 22 is illustrated in further detail in FIGS. 1-4. The corner protector 22 has a body 38, which may be formed from a polymeric material, such as polypropylene, or any suitable structural material. Polypropylene is useful with a balance of strength, flexibility, and chemical resistance, making it a versatile material in both industrial and consumer products. Polypropylene offers elasticity and reduced hardness to absorb loads, while resistant to breakage or failure. Other suitable materials may include polycarbonate compounds, which are high-functional engineering plastics with physical properties enhanced through reinforcement by fillers and alloying with styrene resins such as acrylonitrile butadiene styrene. The corner protector 22 may be molded, extruded, machined, fabricated from an additive manufacturing process, or other suitable manufacturing process.

[0054] The corner protector 22 includes a recess 40 or slot formed into the body 38. The recess 40 is sized to receive the corner 36 of the pane 20. The recess 40 separates the body 38 into a pair of spaced apart walls 42, 44, interconnected by a pair of webs 46, 48. The recess 40 provides access to a pair of wall surfaces 50, 52 provided within the recess 40 on one of the walls 42, 44. The wall surfaces 50, 52 are spaced apart and sized to receive and contact the pane surfaces 24, 26 respectively, of the pane 20 therebetween. The wall surfaces 50, 52 may each be generally flat within manufacturing tolerances, and generally parallel within manufacturing tolerances.

[0055] The recess 40 is formed to a blind depth, thereby leaving the webs 46, 48 angled relative to each other, and interconnecting the walls 42, 44. For example, the webs 46, 48 are generally perpendicular to each other, within manufacturing tolerances. The webs 46, 48 each provide a web surface 54, 56 within the recess 40. The web surfaces 54, 56 may also be generally perpendicular to each other, within manufacturing tolerances. The wall surfaces 50, 52 each intersect the first web surface 54 and the second web surface 56. The wall surfaces 50, 52 are each generally perpendicular to each of the first web surface 54, and the second web surface 56 within manufacturing tolerances. The web surfaces 54, 56 are sized to receive two adjacent edge surfaces 28, 30 of the pane 20. Four corner protectors 22 can be assembled to the four corners 36 of the rectangular pane 20, as a pane assembly 58.

[0056] An aperture 60 is formed in the body 38 at a convergence of the first wall surface 50, the first web surface 54 and the second web surface 56, thereby preventing these three surfaces 50, 54, 56 from intersecting at a corner. The aperture 60 is formed through the body 38, and therefore extends through the second wall surface 52 as well, at a convergence with the first web surface 54 and the second web surface 56. The aperture 60 thereby prevents the second wall surface 52, the first web surface 54, and the second web surface 56 from intersecting at a corner. The aperture 60 is partially separated by the recess 40 thereby defining two separate apertures 60 through the walls 42, 44. Although the aperture 60 is illustrated formed through both walls 42, 44, the aperture 60 could be formed through one wall, such as the wall 42.

[0057] The aperture 60 defines a cavity 62 within the body 38, which provides a gap between the wall surfaces 50, 52 of the body 38 and the pane surfaces 24, 26 of the pane 20 adjacent the corner 36 of the pane 20. The gap may be a suitable dimension to suspend the corner 36 within the body 38, for example 3.5 millimeters. The aperture 60 is formed through the walls 42, 44 at an intersection of the wall surfaces 50, 52 and the web surfaces 54, 56. Thus, the cavity 62 also provides a gap between the first web surface 54 and the first edge surface 28 of the pane 20. The gap between the first web surface 54 and the first edge surface 28 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 38, for example 3.5 millimeters. The cavity 62 also provides a gap between the second web surface 56 and the second edge surface 30 of the pane 20. The gap between the second web surface 56 and the second edge surface 30 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 38, for example 3.5 millimeters. Overall, the corner 36 is suspended from the body 38 along four surfaces 24, 26, 28, 30 of the pane 20.

[0058] By suspending the corner 36, loads applied to the corner protector 22 are distributed to the pane 20 along the pane surfaces 24, 26 and the edge surfaces 28, 30, away from the corner 36 to avoid shocks or stress directly upon the corner 36 or the edge formed along the corner 36. Therefore, loads are distributed to surfaces 24, 26, 28, 30 of the pane 20 that are less fragile than the corner 36.

[0059] The corner protector 22 optimizes structural integrity to support and protect the corner 36 of the pane 20. The walls 42, 44 have exterior surfaces 64, 66 to protect a region of the pane surfaces 24, 26 beyond the corner 36. Likewise, the webs 46, 48 also have external surfaces 68, 70 to protect a region of the edge surfaces 28, 30 beyond the corner 36. Structural ribs 72 are provided upon the external wall surfaces 64, 66 to add structural enhancements and additional stiffness to the walls 42, 44.

[0060] The aperture 60 is formed through the external wall surfaces 64, 66 to provide a window 60 for viewing the corner 36. When the aperture 60 is formed through only one wall surface 64 according to an embodiment, the aperture 60 provides a window 60 for viewing the corner 36 through one side 64 of the corner protector 22. During unpackaging of the pane 20, an end user may employ the window 60 for visual inspection of the corner 36 to determine whether the pane 20 completed transit without damage. If so, the end user may proceed with unpackaging and installation of the pane 20. If the corner 36 of the pane 20 is damaged, the end user may repackage the pane 20 without removal of the corner protectors 22. According to another embodiment, the aperture 60 is formed to a blind depth without the window to provide additional protection to avoid inadvertent contact with the corner 36.

[0061] The corner protector 22 is designed to optimize protection of the pane 20, while being compact enough for minimal packaging for transportation. Likewise, the corner protector 22 is sufficiently compact to protect the corner 36 during installation of the pane 20. The corner protector 22 can be removed after installation of the pane 20 is complete.

[0062] With reference now to FIGS. 5 and 6, a retainer 74 is employed to retain the corner protector 22 upon the corner 36 of the pane 20. The retainer 74 is illustrated as an adhesive label 74 that adheres to the corner protector 22 and to the pane 20 to retain the corner protector 22 in the installed position. Upon completion of installation, the end user may peel the label 74 off the pane 20 and then remove the corner protector 22 and the label 74. The corner protector 22 and label 74 collectively provide a corner protector assembly 76 according to an embodiment. The label 74 may include informational indicia with instructions to remove the label 74 after installation of the pane 20.

[0063] The corner protector 22 permits a manufacturer to ship panes 20 of shower door assemblies through a parcel shipment distribution chain to retailers or directly to an end user. The robustness of the corner protector 22 may be embodied in a variety of shapes, thicknesses, materials, etc., as applicable for a specific application.

[0064] The corner protector 22 is provided with generally square walls 42, 44. However, other shapes may be employed. The corner protectors 22 may be provided with the recess 40 of varying widths to receive panes 20 of varying thicknesses or varying materials. The corner protector 22 suspends the corner 36 of the pane 20 so that the corner 36 does not come in contact with the corner protector 22, other objects or surfaces, or other packaging. The thickness of the walls 42, 44 and the webs 46, 48 can vary depending on size, weight, fragility, designed transport, or design use of a particular pane 20. The corner protector 22 provides a streamlined appearance without additional bumpers associated with prior art corner protectors. The corner protector 22 can be embossed with company logos, text, or the like.

[0065] The corner protector 22 creates a cavity 62 of a specific shape inside the body 38 of the corner protector 22. This internal geometry is designed to work with the required material type and thickness so that when placing the corner protector 22 on the pane 20, it will stop at a certain point to create a certain amount of spacing between the corner 36 of the product 20 and end of the corner protector 22. The corner protector 22 could be utilized with mirrors, panes of glass, wood, metal, or any suitable material, and at any suitable thickness.

[0066] The cavity 62 of the corner protector 22 may or may not have a window 60 to see the corner 36 of the product for visibility of the state of the product 20 and that the corner protector 22 is properly installed. The thickness and material of the corner protector 22 is variable depending on product fragility and use case with embossed design criteria used for additional strength and/or branding opportunities. An area around the cavity 62 is solid to frame in the cavity 62 and help with protection for both the product 20 and the corner protector 22. This framing could be removed at an inward corner of the corner protector 22 to further expose the product 20 but still protect by transferring stresses to the edge surfaces 28, 30, 32, 34. The corner protector 22 may embody an array of shapes depending on cost, level of protection, adherence to brand, etc. Adhesive (tape, label 74, etc.) or the like may be used to keep the corner protector 22 attached to the product 20 for installation (if required).

[0067] FIG. 7 illustrates a corner protector 90 according to another embodiment. The corner protector 90 has a body 92, which may be formed from a polymeric material, such as polypropylene, polycarbonate compounds, or any suitable structural material. The corner protector 90 may be molded, extruded, machined, fabricated from an additive manufacturing process, or other suitable manufacturing process.

[0068] The corner protector 90 includes a recess 94 or slot formed into the body 92. The recess 94 is sized to receive the corner 36 of the pane 20. The recess 94 separates the body 92 into a pair of spaced apart walls 96, interconnected by a pair of webs 98, 100. The recess 94 provides access to a pair of wall surfaces 102 provided within the recess 94, each on one of the walls 96. The wall surfaces 102 are spaced apart and sized to receive and contact the pane surfaces 24, 26 respectively, of the pane 20 therebetween. The wall surfaces 102 may each be generally flat within manufacturing tolerances, and generally parallel within manufacturing tolerances.

[0069] The recess 94 is formed to a depth, thereby leaving the webs 98, 100 angled relative to each other, and interconnecting the walls 96. For example, the webs 98, 100 are generally perpendicular to each other, within manufacturing tolerances. The webs 98, 100 each provide a web surface 104, 106 within the recess 94. The web surfaces 104, 106 may also be generally perpendicular to each other, within manufacturing tolerances. The wall surfaces 102 each intersect the first web surface 104 and the second web surface 106. The wall surfaces 102 are each generally perpendicular to each of the first web surface 104, and the second web surface 106 within manufacturing tolerances. The web surfaces 104, 106 are sized to receive two adjacent edge surfaces 28, 30 of the pane 20. Four corner protectors 90 can be assembled to the four corners 36 of the rectangular pane 20, as a pane assembly 108.

[0070] An aperture 110 is formed in the body 92 at a convergence of the first wall surface 102, the first web surface 104 and the second web surface 106, thereby preventing these three surfaces 102, 104, 106 from intersecting at a corner. The aperture 110 is formed through the body 92, and therefore extends through the second wall surface 102 as well, at a convergence with the first web surface 104 and the second web surface 106. The aperture 110 thereby prevents the second wall surface 102, the first web surface 104, and the second web surface 106 from intersecting at a corner. The aperture 110 is partially separated by the recess 94 thereby defining two separate apertures 110 through the walls 96. Although the aperture 110 is illustrated formed through both walls 96, the aperture 110 could be formed through one wall 96.

[0071] The aperture 110 defines a cavity 112 within the body 92, which provides a gap between the wall surfaces 102 of the body 92 and the pane surfaces 24, 26 of the pane 20 adjacent the corner 36 of the pane 20. The gap may be a suitable dimension to suspend the corner 36 within the body 92. The aperture 110 is formed through the walls 96 at an intersection of the wall surfaces 102 and the web surfaces 104, 106. Thus, the cavity 112 also provides a gap between the first web surface 104 and the first edge surface 28 of the pane 20. The gap between the first web surface 104 and the first edge surface 28 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 92. The cavity 112 also provides a gap between the second web surface 106 and the second edge surface 30 of the pane 20. The gap between the second web surface 106 and the second edge surface 30 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 92. Overall, the corner 36 is suspended from the body 92 along four surfaces 24, 26, 28, 30 of the pane 20.

[0072] By suspending the corner 36, loads applied to the corner protector 90 are distributed to the pane 20 along the pane surfaces 24, 26 and the edge surfaces 28, 30, away from the corner 36 to avoid shocks or stress directly upon the corner 36 or the edge formed along the corner 36. Therefore, loads are distributed to surfaces 24, 26, 28, 30 of the pane 20 that are less fragile than the corner 36.

[0073] The corner protector 90 optimizes structural integrity to support and protect the corner 36 of the pane 20. The walls 96 have exterior surfaces 114 to protect a region of the pane surfaces 24, 26 beyond the corner 36. Likewise, the webs 98, 100 also have external surfaces 116, 118 to protect a region of the edge surfaces 28, 30 beyond the corner 36. Structural ribs 120 are provided upon the external wall surfaces 114 to add structural enhancements and additional stiffness to the walls 96.

[0074] The aperture 110 is formed through the external wall surfaces 96 to provide a window 110 for viewing the corner 36. When the aperture 110 is formed through only one wall surface 96 according to an embodiment, the aperture 110 provides a window 110 for viewing the corner 36 through one side 96 of the corner protector 90. During unpackaging of the pane 20, an end user may employ the window 110 for visual inspection of the corner 36 to determine whether the pane 20 completed transit without damage. If so, the end user may proceed with unpackaging and installation of the pane 20. If the corner 36 of the pane 20 is damaged, the end user may repackage the pane 20 without removal of the corner protectors 90.

[0075] The corner protector 90 is designed to optimize protection of the pane 20, while being compact enough for minimal packaging for transportation. Likewise, the corner protector 90 is sufficiently compact to protect the corner 36 during installation of the pane 20. The corner protector 90 can be removed after installation of the pane 20 is complete.

[0076] The corner protector 90 permits a manufacturer to ship panes 20 of shower door assemblies through a parcel shipment distribution chain to retailers or directly to an end user. The robustness of the corner protector 90 may be embodied in a variety of shapes, thicknesses, materials, etc., as applicable for a specific application.

[0077] The corner protector 90 is provided with generally square walls 96. The corner protector 90 creates a cavity 112 of a specific shape inside the body 92 of the corner protector 90. This internal geometry is designed to work with the required material type and thickness so that when placing the corner protector 90 on the pane 20, it will stop at a certain point to create a certain amount of spacing between the corner 36 of the product 20 and end of the corner protector 90. The corner protector 90 could be utilized with panes of glass, wood, metal, or any suitable material, and at any suitable thickness.

[0078] The cavity 112 of the corner protector 90 may or may not have a window 110 to see the corner 36 of the product for visibility of the state of the product 20 and that the corner protector 90 is properly installed. The thickness and material of the corner protector 90 is variable depending on product fragility and use case with embossed design criteria used for additional strength and/or branding opportunities. An aperture 122 is formed through the webs 98, 100 into the cavity 112 to further suspend the corner 36 of the pane 20 within the corner protector 90. The aperture 122 further exposes the product 20 but still protects the pane 20 by transferring stresses to the edge surfaces 28, 30, 32, 34, which are stronger than the corner 36. The corner protector 90 may embody an array of shapes depending on cost, level of protection, adherence to brand, etc.

[0079] FIG. 8 illustrates a corner protector 130 according to another embodiment. The corner protector 130 has a body 132, which may be formed from a polymeric material, such as polypropylene, polycarbonate compounds, or any suitable structural material. The corner protector 130 may be molded, extruded, machined, fabricated from an additive manufacturing process, or other suitable manufacturing process.

[0080] The corner protector 130 includes a recess 134 formed into the body 132. The recess 134 is sized to receive the corner 36 of the pane 20. The recess 134 separates the body 132 into a pair of spaced apart walls 136, interconnected by a pair of webs 138, 140. The recess 134 provides access to a pair of wall surfaces 142 provided within the recess 134, each on one of the walls 136. The wall surfaces 142 are spaced apart and sized to receive and contact the pane surfaces 24, 26 respectively, of the pane 20 therebetween. The wall surfaces 142 may each be generally flat within manufacturing tolerances, and generally parallel within manufacturing tolerances.

[0081] The recess 134 is formed to a depth, thereby leaving the webs 138, 140 angled relative to each other, and interconnecting the walls 136. For example, the webs 138, 140 are generally perpendicular to each other, within manufacturing tolerances. The webs 138, 140 each provide a web surface 144, 146 within the recess 134. The web surfaces 144, 146 may also be generally perpendicular to each other, within manufacturing tolerances. The wall surfaces 142 each intersect the first web surface 144 and the second web surface 146. The wall surfaces 142 are each generally perpendicular to each of the first web surface 144, and the second web surface 146 within manufacturing tolerances. The web surfaces 144, 146 are sized to receive two adjacent edge surfaces 28, 30 of the pane 20. Four corner protectors 130 can be assembled to the four corners 36 of the rectangular pane 20, as a pane assembly 148.

[0082] An aperture 150 is formed in the body 132 at a convergence of the first wall surface 142, the first web surface 144 and the second web surface 146, thereby preventing these three surfaces 142, 144, 146 from intersecting at a corner. The aperture 150 is formed through the body 132, and therefore extends through the second wall surface 142 as well, at a convergence with the first web surface 144 and the second web surface 146. The aperture 150 thereby prevents the second wall surface 142, the first web surface 144, and the second web surface 146 from intersecting at a corner. The aperture 150 is partially separated by the recess 134 thereby defining two separate apertures 150 through the walls 136. Although the aperture 150 is illustrated formed through both walls 136, the aperture 150 could be formed through one wall 136.

[0083] The aperture 150 defines a cavity 152 within the body 132, which provides a gap between the wall surfaces 142 of the body 132 and the pane surfaces 24, 26 of the pane 20 adjacent the corner 36 of the pane 20. The gap may be a suitable dimension to suspend the corner 36 within the body 132. The aperture 150 is formed through the walls 136 at an intersection of the wall surfaces 142 and the web surfaces 144, 146. Thus, the cavity 152 also provides a gap between the first web surface 144 and the first edge surface 28 of the pane 20. The gap between the first web surface 144 and the first edge surface 28 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 132. The cavity 152 also provides a gap between the second web surface 146 and the second edge surface 30 of the pane 20. The gap between the second web surface 146 and the second edge surface 30 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 132. Overall, the corner 36 is suspended from the body 132 along four surfaces 24, 26, 28, 30 of the pane 20.

[0084] By suspending the corner 36, loads applied to the corner protector 130 are distributed to the pane 20 along the pane surfaces 24, 26 and the edge surfaces 28, 30, away from the corner 36 to avoid shocks or stress directly upon the corner 36 or the edge formed along the corner 36. Therefore, loads are distributed to surfaces 24, 26, 28, 30 of the pane 20 that are less fragile than the corner 36.

[0085] The corner protector 130 optimizes structural integrity to support and protect the corner 36 of the pane 20. The walls 136 have exterior surfaces 154 to protect a region of the pane surfaces 24, 26 beyond the corner 36. Likewise, the webs 138, 140 also have external surfaces 156, 158 to protect a region of the edge surfaces 28, 30 beyond the corner 36. Structural ribs 160 are provided upon the external wall surfaces 154 to add structural enhancements and additional stiffness to the walls 136.

[0086] The aperture 150 is formed through the external wall surfaces 142 to provide a window 150 for viewing the corner 36. When the aperture 150 is formed through only one wall surface 142 according to an embodiment, the aperture 150 provides a window 150 for viewing the corner 36 through one side 142 of the corner protector 130. During unpackaging of the pane 20, an end user may employ the window 150 for visual inspection of the corner 36 to determine whether the pane 20 completed transit without damage. If so, the end user may proceed with unpackaging and installation of the pane 20. If the corner 36 of the pane 20 is damaged, the end user may repackage the pane 20 without removal of the corner protectors 130.

[0087] The corner protector 130 is designed to optimize protection of the pane 20, while being compact enough for minimal packaging for transportation. Likewise, the corner protector 130 is sufficiently compact to protect the corner 36 during installation of the pane 20. The corner protector 130 can be removed after installation of the pane 20 is complete.

[0088] The corner protector 130 permits a manufacturer to ship panes 20 of shower door assemblies through a parcel shipment distribution chain to retailers or directly to an end user. The robustness of the corner protector 130 may be embodied in a variety of shapes, thicknesses, materials, etc., as applicable for a specific application.

[0089] The corner protector 130 is provided with generally triangular walls 136. By utilizing triangular walls 136, the corner protector 130 provides a triangular shape, thereby reducing material compared to the prior embodiments. The corner protector 130 creates the cavity 152 of a specific shape inside the body 132 of the corner protector 130. This internal geometry is designed to work with the required material type and thickness so that when placing the corner protector 130 on the pane 20, it will stop at a certain point to create a certain amount of spacing between the corner 36 of the product 20 and end of the corner protector 130. The corner protector 130 could be utilized with panes of glass, wood, metal, or any suitable material, and at any suitable thickness.

[0090] The cavity 152 of the corner protector 130 may or may not have a window 150 to see the corner 36 of the product for visibility of the state of the product 20 and that the corner protector 130 is properly installed. The thickness and material of the corner protector 130 is variable depending on product fragility and use case with embossed design criteria used for additional strength and/or branding opportunities. The corner protector 130 may embody an array of shapes depending on cost, level of protection, adherence to brand, etc.

[0091] FIG. 10 illustrates a corner protector 170 according to another embodiment. The corner protector 170 has a body, which may be formed from a polymeric material, such as polypropylene, polycarbonate compounds, or any suitable structural material. The corner protector 170 may be molded, extruded, machined, fabricated from an additive manufacturing process, or other suitable manufacturing process.

[0092] Four corner protectors 170 can be assembled to the four corners 36 of the rectangular pane 20, as a pane assembly 192.

[0093] By suspending the corner 36, loads applied to the corner protector 170 are distributed to the pane 20 along the pane surfaces 24, 26 and the edge surfaces 32, 34, away from the corner 36 to avoid shocks or stress directly upon the corner 36 or the edge formed along the corner 36. Therefore, loads are distributed to surfaces 24, 26, 28, 30 of the pane 20 that are less fragile than the corner 36.

[0094] The corner protector 170 optimizes structural integrity to support and protect the corner 36 of the pane 20. The walls have exterior surfaces to protect a region of the pane surfaces 24, 26 beyond the corner 36. Likewise, the webs also have external surfaces 202 to protect a region of the edge surfaces 32, 34 beyond the corner 36.

[0095] The corner protector 170 is designed to optimize protection of the pane 20, while being compact enough for minimal packaging for transportation. Likewise, the corner protector 170 is sufficiently compact to protect the corner 36 during installation of the pane 20. The corner protector 170 can be removed after installation of the pane 20 is complete.

[0096] The corner protector 170 permits a manufacturer to ship panes 20 of shower door assemblies through a parcel shipment distribution chain to retailers or directly to an end user. The robustness of the corner protector 170 may be embodied in a variety of shapes, thicknesses, materials, etc., as applicable for a specific application.

[0097] The thickness and material of the corner protector 170 is variable depending on product fragility and use case with embossed design criteria used for additional strength and/or branding opportunities. The corner protector 170 may embody an array of shapes depending on cost, level of protection, adherence to brand, etc.

[0098] FIGS. 9-10 illustrate a packaged pane assembly 208 for the pane assembly 192. As illustrated in FIG. 9, the packaged pane assembly 208 includes a carton or box 210, which may be formed from cardboard, or any suitable packaging material. The box 210 retains a pair of pane assemblies 192, for a shower door assembly that employs two panes 20. The packaged pane assembly 192 may employ any quantity of panes 20 for the applicable shower door enclosure. As illustrated in FIGS. 9 and 10, the pane assemblies 208 are stacked so that the corner protectors 170 are stacked directly upon each other with the structural ribs 206 of each corner protector 170 engaging the adjacent corner protector 170.

[0099] As illustrated in FIGS. 9 and 10, the packaged pane assembly 208 includes a plurality of foam side members 212 and a plurality of foam cross members 214. The foam members 212, 214 provide additional protection and damping to protect the pane assemblies 192 during transit. The side members 212 may include recesses 216 for clearance of the corner protectors 170 according to an embodiment. The lower corner protectors 170 are suspended within the foam members 212, 214 so that the lower corner protectors 170 rest directly within the carton 210. Alternatively, the recesses 216 may be omitted; and space may be provided in the box 210 due to a dimension between the corner protector 170 and the glass pane 20. According to another embodiment, the space in the box 210 may be filled with dunnage like corrugated cardboard or another packing material.

[0100] Referring now to FIG. 10, other shower door hardware may also be packaged in the packaged pane assembly 208. The additional hardware may include tracks 218, seals 220, and the like.

[0101] With reference to FIGS. 11-13, a corner protector 322 is illustrated according to another embodiment. Like the prior embodiments, the corner protector 322 is provided to suspend the corner 36 of the pane 20 within the corner protector 322 to further isolate the corner 36 to contact, and to distribute loading away from the corner 36, and away from the pane surfaces 24, 26 and the edge surfaces 28, 30, 32, 34 of the pane 20. The corner protector 322 has a body 338, which may be formed from a polymeric material, such as polypropylene, or any suitable structural material. The corner protector 322 may be molded, extruded, machined, fabricated from an additive manufacturing process, or other suitable manufacturing process.

[0102] The corner protector 322 includes a recess 340 or slot formed into the body 338 as illustrated in FIGS. 12 and 13. The recess 340 is sized to receive the corner 36 of the pane 20. Referring again to FIGS. 11-13, the recess 340 separates the body 338 into a pair of spaced apart walls 342, 344, interconnected by a pair of webs 346, 348. As depicted in FIGS. 12 and 13, the recess 340 provides access to a pair of wall surfaces 350, 352 provided within the recess 340, each on one of the walls 342, 344. The wall surfaces 350, 352 are spaced apart and sized to receive and contact the pane surfaces 24, 26 respectively, of the pane 20 therebetween. The wall surfaces 350, 352 may each be generally flat within manufacturing tolerances, and generally parallel within manufacturing tolerances.

[0103] The recess 340 is formed to a blind depth, thereby leaving the webs 346, 348 angled relative to each other, and interconnecting the walls 342, 344. For example, the webs 346, 348 are generally perpendicular to each other, within manufacturing tolerances. The webs 346, 348 each provide a web surface 354, 356 within the recess 340. The web surfaces 354, 356 may also be generally perpendicular to each other, within manufacturing tolerances. The wall surfaces 350, 352 each intersect the first web surface 354 and the second web surface 356. The wall surfaces 350, 352 are each generally perpendicular to each of the first web surface 354, and the second web surface 356 within manufacturing tolerances. The web surfaces 354, 356 are sized to receive two adjacent edge surfaces 28, 30 of the pane 20. Four corner protectors 322 can be assembled to the four corners 36 of the rectangular pane 20, as a pane assembly.

[0104] Referring again to FIGS. 11-13, a first aperture 360 is formed in the body 338 at a convergence of the first wall surface 350, the first web surface 354 and the second web surface 356, thereby preventing these three surfaces 350, 354, 356 from intersecting at a corner. The aperture 360 is formed through the first forward wall 342 of the body 338. The aperture 360 extends to a blind depth 362 within the second wall surface 352, at a convergence with the first web surface 354 and the second web surface 356. The aperture 360 is formed to the blind depth 362 with only one window to provide additional protection to avoid inadvertent contact with the corner 36. The first aperture 360 prevents the second wall surface 352, the first web surface 354, and the second web surface 356 from intersecting at a corner. The first aperture 360 is partially separated by the recess 340 thereby defining two separate apertures 360 through the walls 342, 344. Although the aperture 360 is illustrated formed into both walls 342, 344, the aperture 360 could be formed through one wall, such as the wall 342.

[0105] The aperture 360 defines a cavity 364 within the body 338, which provides a gap between the wall surfaces 350, 352 of the body 338 and the pane surfaces 24, 26 of the pane 20 adjacent the corner 36 of the pane 20. The gap may be a suitable dimension to suspend the corner 36 within the body 338. The aperture 360 is formed into the walls 342, 344 at an intersection of the wall surfaces 350, 352 and the web surfaces 354, 356. Thus, the cavity 364 also provides a gap between the first web surface 354 and the first edge surface 28 of the pane 20. The gap between the first web surface 354 and the first edge surface 28 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 338. The cavity 364 also provides a gap between the second web surface 356 and the second edge surface 30 of the pane 20. The gap between the second web surface 356 and the second edge surface 30 of the pane 20 may be a suitable dimension to suspend the corner 36 within the body 338. Overall, the corner 36 is suspended from the body 338 along four surfaces 24, 26, 28, 30 of the pane 20. The aperture 360 is formed as a pair of intersecting slots, or as an L-shape to align with the intersecting edge surfaces 28, 30 at the corner 36 of the pane 20.

[0106] By suspending the corner 36, loads applied to the corner protector 322 are distributed to the pane 20 along the pane surfaces 24, 26 and the edge surfaces 28, 30, away from the corner 36 to avoid shocks or stress directly upon the corner 36 or the edge formed along the corner 36. Therefore, loads are distributed to surfaces 24, 26, 28, 30 of the pane 20 that are less fragile than the corner 36.

[0107] The corner protector 322 optimizes structural integrity to support and protect the corner 36 of the pane 20. The walls 342, 344 have exterior surfaces 366, 368 to protect a region of the pane surfaces 24, 26 beyond the corner 36. Likewise, the webs 346, 348 also have external surfaces 370, 372 to protect a region of the edge surfaces 28, 30 beyond the corner 36.

[0108] The aperture 360 is formed through the external wall surface 366 to provide a window 360 for viewing the corner 36, through one side 366 of the corner protector 322. During unpackaging of the pane 20, an end user may employ the window 360 for visual inspection of the corner 36 to determine whether the pane 20 completed transit without damage. If so, the end user may proceed with unpackaging and installation of the pane 20. If the corner 36 of the pane 20 is damaged, the end user may repackage the pane 20 without removal of the corner protectors 322.

[0109] A second aperture 374 is formed through the first wall 344 and into the recess 340. The second aperture 374 is spaced apart from the first aperture 360 and provides a window 374 to view the pane 20 during installation of the pane 20 into the recess 340 of the corner protector 322. The window 374 also provides a secondary viewpoint for inspection. The window 374 may be provided as a slot, as illustrated, offset from an inboard edge 376 of the corner protector 322. The second aperture 374 may be provided by other shapes and geometries.

[0110] The corner protector 322 is designed to optimize protection of the pane 20, while being compact enough for minimal packaging for transportation. Likewise, the corner protector 322 is sufficiently compact to protect the corner 36 during installation of the pane 20. The corner protector 322 can be removed after installation of the pane 20 is complete.

[0111] The corner protector 322 permits a manufacturer to ship panes 20 of shower door assemblies through a parcel shipment distribution chain to retailers or directly to an end user. The robustness of the corner protector 322 may be embodied in a variety of shapes, thicknesses, materials, etc., as applicable for a specific application.

[0112] The corner protector 322 is provided with the inboard edge 376 that is angled relative to the webs 346, 348 to provide generally chamfered walls 342, 344. By utilizing chamfered walls 342, 344, the corner protector 322 provides an overall chamfered, or near-triangular shape, thereby reducing material compared to the prior embodiments. The corner protectors 322 may be provided with the recess 340 of varying widths to receive panes 20 of varying thicknesses or varying materials. The corner protector 322 suspends the corner 36 of the pane 20 so that the corner 36 does not come in contact with the corner protector 322, other objects or surfaces, or other packaging. The thickness of the walls 342, 344 and the webs 346, 348 can vary depending on size, weight, fragility, designed transport, or design use of a particular pane 20. The corner protector 322 provides a streamlined appearance without additional bumpers associated with prior art corner protectors. The corner protector 322 can be embossed with company logos, text, or the like.

[0113] The corner protector 322 creates a cavity 364 of a specific shape inside the body 338 of the corner protector 322. This internal geometry is designed to work with the required material type and thickness so that when placing the corner protector 322 on the pane 20, it will stop at a certain point to create a certain amount of spacing between the corner 36 of the product 20 and end of the corner protector 322. The corner protector 322 could be utilized with mirrors, panes of glass, wood, metal, or any suitable material, and at any suitable thickness.

[0114] The cavity 364 of the corner protector 322 may or may not have a window 360 to see the corner 36 of the product for visibility of the state of the product 20 and that the corner protector 322 is properly installed. The thickness and material of the corner protector 322 is variable depending on product fragility and use case with embossed design criteria used for additional strength and/or branding opportunities. An area around the cavity 364 is solid to frame in the cavity 364 and help with protection for both the product 20 and the corner protector 322. This framing could be removed at an inward corner of the corner protector 322 to further expose the product 20 but still protect by transferring stresses to the edge surfaces 28, 30, 32, 34. The corner protector 322 may embody an array of shapes depending on cost, level of protection, adherence to brand, etc. Adhesive (tape, label 74, etc.) or the like may be used to keep the corner protector 322 attached to the product 20 for installation (if required).

[0115] While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.