Packaging system

Abstract

A packaging system for a pack of panels, in particular a pack of glass sheets, is described. The packaging system comprises a first cap for positioning over a first edge surface of the pack. The first cap comprises a body portion and a first extension portion extending from the body portion and is configured such that when the first cap is positioned over the first edge surface of the pack, the body portion faces the first edge surface of the pack and the first extension portion faces a second edge surface of the pack or a first major surface of the pack or a second major surface of the pack. At least one of the body portion and the first extension portion of the first cap comprises a polymer that is preferably reinforced with fibres.

Description

[0001] PACKAGING SYSTEM

[0002] The present invention relates to a packaging system for a pack of panels, in particular a pack of glass sheets.

[0003] It is known to make glass in sheet form using a manufacturing process such as a float process, a down draw process or a rolled process. Typically, flat glass sheets so produced are stacked in packs consisting of a plurality of sheets, each sheet having opposing major surfaces and a thickness defined by a minor surface connecting the major surfaces of the respective glass sheet. Often in the art a minor surface of a glass sheet connecting a first major surface of the glass sheet and a second opposing major surface of the glass sheet is simply referred to as an edge or an edge portion. For a rectangular glass sheet, there are four minor surfaces (and so four edges or four edge portions).

[0004] Typically, a pack containing a plurality of glass sheets has opposing major surfaces at opposite sides thereof defined by first and second glass sheets and a pack thickness defined by the combined thickness of the plurality of glass sheets in the pack. Typically, the pack of glass sheets has an edge surface defined by the edges of the glass sheets in the pack. For a pack of equal sized rectangular glass sheets, the pack has a left-hand edge surface, a right-hand edge surface, an upper edge surface and a lower edge surface. Each of the left-hand edge surface, right-hand edge surface, upper edge surface and lower edge surface connects the first and second major surfaces of the pack. Such a pack is configured as a rectangular prism. Other sheet-like material, or panels, may be stacked in packs.

[0005] When a pack of glass sheets is transported between locations, for example from an original despatch location to a glass processing facility, it is known to cover edge surfaces of the pack (and consequently the edges of the glass sheets forming the pack) to provide protection from damage. Usually at least two opposing edge surfaces of the pack of glass sheets are protected this way, although all edges surface of the pack may be protected with suitable covers.

[0006] Example packaging systems for packs of glass sheets are described in US2,811,249, US5,803,257, US5,908,808, US7,658,285 and US2011 / 0017616A1.

[0007] Packages for sheet material are described in US3,720,035.

[0008] Articles describing general package cushioning are available online at https: / / en.wikipedia.org / w / index.php?title=Package_cushioning&oldid=l 136151932. It is known in the art to use wooden crate-like covers to cover the edges of the glass sheets in the pack, and such covers are often known in the art as “end caps”. For example, a respective end cap is positioned over left and right ends of the pack.

[0009] However, wooden end caps may be damaged in transit, especially if the end caps are returned to be re-used with subsequent packs of glass sheets. Furthermore, to provide the pack of glass sheets with a desired level of protection from damage, the wooden end caps may become too heavy.

[0010] There is therefore a need for an improved packaging system for a pack of glass sheets that at least partially overcomes the problems identified above.

[0011] Accordingly, from a first aspect the present invention provides a packaging system for a pack of panels, the pack comprising a first major surface, a second opposing major surface, a first edge surface and a second edge surface; the pack further comprising at least a first panel and a second panel, the first and second panels each having respectively a first major surface, a second opposing major surface, a first edge portion and a second edge portion, wherein the first edge surface of the pack comprises the first edge portions of the first and second panels and the second edge surface of the pack comprises the second edge portions of the first and second panels; the packaging system comprising a first cap for positioning over the first edge surface of the pack, the first cap comprising a body portion and a first extension portion extending from the body portion, the first cap being configured such that when the first cap is positioned over the first edge surface of the pack, the body portion of the first cap faces the first edge surface of the pack and the first extension portion of the first cap faces the second edge surface of the pack, the first major surface of the pack or the second major surface of the pack, wherein at least one of the body portion and the first extension portion comprises a polymer.

[0012] Preferably the body portion of the first cap comprises a first polymer.

[0013] Preferably the first extension portion of the first cap comprises a second polymer.

[0014] Preferably the first polymer is the same as the second polymer. That is, the first polymer has a first polymer composition, and the second polymer has a second composition being the same as the first polymer composition. In such embodiments, reference to “the polymer” is reference to the first polymer and the second polymer.

[0015] When the body portion of the first cap comprises a first polymer having a first polymer composition and the first extension portion of the first cap comprises a second polymer having a second polymer composition different to the first polymer composition, reference to “the polymer” includes reference to the first polymer and the second polymer. For example, in such embodiments if it is preferred that the polymer is a polyamide having a polyamide composition, this includes embodiments wherein the first polymer is a polyamide, the second polymer is a polyamide, or both the first and second polymers are a polyamide.

[0016] When the first cap is positioned over the first edge surface face of the pack, the first edge portions of the first and second panels in the pack may be protected from damage by at least the body portion of the first cap.

[0017] The first edge surface of the pack may be defined as a minor surface of the pack that connects the first major surface of the pack to the second major surface of the pack.

[0018] The second edge surface of the pack may be defined as a minor surface of the pack that connects the first major surface of the pack to the second major surface of the pack.

[0019] The first edge surface of the pack is at an angle relative to the second edge surface of the pack. Preferably the first edge surface of the pack is at 90° relative to the second edge surface of the pack.

[0020] The first edge surface of the pack intersects with the second edge surface of the pack to form a first edge of the pack.

[0021] The first edge portion of the first panel may be defined as a first minor surface of the first panel that connects the first major surface of the first panel to the second major surface of the first panel.

[0022] The second edge portion of the first panel may be defined as a second minor surface of the first panel that connects the first major surface of the first panel to the second major surface of the first panel.

[0023] The first edge portion of the second panel may be defined as a first minor surface of the second panel that connects the first major surface of the second panel to the second major surface of the second panel.

[0024] The second edge portion of the second panel may be defined as a second minor surface of the second panel that connects the first major surface of the second panel to the second major surface of the second panel.

[0025] The first and / or second edge portions of the first and / or second panel may be flat or curved.

[0026] In general, an edge portion of a panel having a first major surface and a second opposing major surface may refer to a minor surface of the panel that connects the first major surface of the panel to the second major surface of the panel. The panel may comprise one or more edge portions. Each edge portion of the panel can be flat or curved. Preferably the body portion of the first cap has a first major surface, an opposing second major surface and a thickness.

[0027] Preferably the thickness of the body portion is at least 1mm, more preferably at least 2mm, even more preferably at least 3mm.

[0028] Preferably the body portion has a thickness less than 50mm.

[0029] Preferably the first extension portion of the first cap has a first major surface, an opposing second major surface and a thickness.

[0030] Preferably the thickness of the first extension portion of the first cap is the same as the thickness of the body portion of the first cap.

[0031] Preferably the thickness of the first extension portion of the first cap is at least 2mm, more preferably at least 3mm.

[0032] Preferably the first extension portion of the first cap has a thickness less than 50mm.

[0033] It is preferred that the body portion of the first cap has no holes in the first and / or second major surfaces thereof, but the body portion of the first cap may comprise at least a first hole extending between the first and second major surfaces of the body portion provided the desired level of protection is provided to the first edge portions of the first and / or second panels in the pack.

[0034] The body portion of the first cap has a length and a width.

[0035] Preferably the length of the body portion of the first cap is at least a length of the first edge portions of the first and / or second panels.

[0036] Preferably the width of the body portion of the first cap is at least sufficient to cover the first edge portion of the first and / or second panels.

[0037] Preferably the length of the body portion of the first cap extends along a first axis and the pack of panels has a thickness between the first and second major surfaces thereof, the thickness of the pack of panels extending along a second axis, wherein the first axis of the body portion of the first cap is preferably perpendicular to the second axis.

[0038] Preferably the first and / or second panel is a sheet of glass.

[0039] Preferably the first and / or second panel is a sheet of glass made using a float process, a rolled process or a downdraw process. Preferably the first and / or second panel is a sheet of glass having a soda-lime-silica glass composition.

[0040] A typical soda-lime-silica glass composition is (by weight), SiO269 - 74 %; AI2O30 - 3 %; Na2O 10 - 16 %; K2O 0 - 5 %; MgO 0 - 6 %; CaO 5 - 14 %; SO30 - 2 %; Fe2O30.005 - 2 %. The glass may also contain other additives, for example, refining aids, which would normally be present in an amount of up to 2 %.

[0041] Preferably the first and / or second panel has a thickness between 0.3mm and 25mm.

[0042] The pack of panels has a thickness defined by the combined thicknesses of the panels in the pack.

[0043] Preferably the pack of panels has a thickness of between 100mm and 2000mm.

[0044] Preferably the pack of panels has a rectangular first major surface and an opposing rectangular second major surface.

[0045] Preferably the first edge surface of the pack of panels is a rectangular shape.

[0046] Preferably the second edge surface of the pack of panels is a rectangular shape.

[0047] Preferably the pack of panels has a third edge surface opposite the first edge surface of the pack of panels.

[0048] Preferably the pack of panels has a fourth edge surface opposite the second edge surface of the pack of panels.

[0049] Preferably the pack of panels has a third edge surface opposite the first edge surface of the pack of panels, and a fourth edge surface opposite the second edge surface of the pack of panels.

[0050] Preferably first the cap is self-supporting. By self-supporting, it is meant that the first cap having a first shape is able to maintain the first shape when standing upright. This is in contrast to a sheet of plastic having a thickness of 1mm or less.

[0051] Preferably the first cap comprises a cavity into which the first edge surface of the pack of panels may be received. Preferably an end of the pack of panels is a snug fit in the cavity.

[0052] Preferably the first extension portion of the first cap is integrally formed with the body portion of the first cap.

[0053] Preferably the polymer is a thermoplastic or a thermoset plastic. Preferably the polymer comprises at least one of polyester, vinylester, epoxy, phenolic resin, polyurethane resin, polyphenylene sulphide, polyurethane, polycaprolactone, polyamide, polysulfone, polyethylene, low density polyethylene, high density polyethylene, polycarbonate, polyphenylene ether, acrylonitrile butadiene styrene, polybutylene terephthalate, poly(butylene adipate), poly(lactic acid), polypropylene, polybutadiene, polyisoprene, poly chloroprene, polyethylene terephthalate, polystyrene, polyvinyl chloride, phenol formaldehyde resin, neoprene and polyacrylonitrile.

[0054] Preferably the polymer is reinforced with fibres. Such a polymer reinforced with fibres may be referred to as a fibre reinforced polymer.

[0055] Preferably the polymer has a density between 900 and 1400 kg / m3.

[0056] Preferably the polymer has a tensile strength measured according to DIN EN ISO 527-2 of between 5 and 120 MPa.

[0057] Preferably the polymer has a tensile modulus measured according to DIN EN ISO 527-2 of at least 0.12 GPa, preferably at least 0.13 GPa, or 0.14 GPa; or 0.15 GPa ; or 0.16 GPa; or 0.17 GPa .

[0058] Preferably the polymer has a tensile modulus measured according to DIN EN ISO 527-2 of less than 3.8GPa, preferably at less than 3.7GPa, more preferably less than 3.6 GPa, even more preferably less than 3.5 GPa, even more preferably less than 3.4GPa.

[0059] Preferably the polymer has a modulus of elasticity measured according to DIN EN ISO 527-2 of between 2 GPa and 10 GPa.

[0060] The body portion of the first cap and / or the first extension portion of the first cap may comprise other additives.

[0061] Additives and fillers may be added to the polymer used to form the body portion of the first cap and / or the first extension portion of the first cap. Suitable fillers may be used to reduce shrinkage, improve fire rating, and prevent cracking in polymer resins. Suitable fillers may improve hardness and creep performance, and fatigue and chemical resistance.

[0062] Preferably the polymer comprises between 10% and 30% by weight of a filler.

[0063] Additives may be used to provide the polymer with ultraviolet protection, fire resistance, shrinkage reduction, colour (via pigments and / or dyes), easier mould removal (when the polymer is moulded to provide a particular shape), and electrical and thermal insulation properties. The additives may be less than 5% of the polymer by weight, usually less than 3% by weight. In some embodiments the polymer comprises a polyamide. The polyamide has a polyamide composition. The polyamide composition may comprise one or more additive and / or one or more fdler.

[0064] Preferably the polyamide comprises polyamide-66. Polyamide-66 may be referred to as PA-66 or nylon 6, 6.

[0065] Preferably the polyamide comprises polyamide-6. Polyamide-6 may be referred to as PA-6 or nylon 6.

[0066] Preferably the polyamide comprises an aromatic polyamide.

[0067] Preferably the aromatic polyamide comprises aramid or polyphthalamide.

[0068] Polyamide compositions are described in W02020 / 115292A1.

[0069] In some embodiments the polymer comprises polyamide having a polyamide composition and at least one additive.

[0070] The additive may be any compound suitable for use with the polyamide composition.

[0071] Preferably the additive used in the polyamide composition includes at least one of a thermal stabiliser, a light stabiliser, an ultraviolet ray stabiliser, a lubricant, a nucleating agent, a colourant such as a pigment and / or a dye, a chain extender, an impact modifier, a flame retardant, a catalyst, an antioxidant, a plasticizer, and an antistatic agent.

[0072] In some embodiments the polymer comprises polyamide having a polyamide composition wherein the polyamide composition comprises at least one thermal stabiliser.

[0073] Preferably, the thermal stabiliser is present in the polyamide composition in an amount from 0.01 to 1.0 % by weight, more preferably from 0.05 to 0.5 % by weight, based on the total weight of the polyamide composition.

[0074] A thermal stabiliser is a material added to a polymer composition to improve thermal stability by preventing thermo-oxidative degradation during processing.

[0075] The thermal stabiliser is preferably selected from the group consisting of hindered phenol compounds, hindered amine compounds, phosphorous compounds, copper-containing compounds, and combinations thereof, preferably a combination of a hindered phenol compound and a phosphorous compound, more preferably copper-containing compounds. The term “hindered phenol compound” is used according to its usual meaning in the art and is intended to denote derivatives of ortho-substituted phenol, especially (but not limited to) di -tert-butyl- 1 -phenol derivatives, well known in the art.

[0076] The term “hindered amine compound” is used according to its customary meaning in the art and is intended to denote derivatives of 2,2,6,6-tetramethyl piperidine well known in the art. The hindered amine compound may either be of low or high molecular weight.

[0077] The hindered amine compounds of low molecular weight have typically a molecular weight of at most 900, preferably at most 800, more preferably of at most 700, still more preferably at most 600, and most preferably of at most 500 g / mol.

[0078] The hindered amine compounds of high molecular weight are typically polymeric and have typically a molecular weight of at least 1000, preferably at least 1100, more preferably of at least 1200, still more preferably at least 1300, and most preferably of at least 1400 g / mol.

[0079] The thermal stabiliser may be at least one phosphorous compound selected from the group consisting of an alkali or alkali earth metal hypophosphites, phosphite esters, phosphonites and mixtures thereof sodium and calcium hypophosphites are preferred alkali or alkali earth metal hypophosphites.

[0080] The copper-containing thermal stabiliser is further characterised as comprising a copper compound soluble in the polyamide and an alkali metal halide. Stabilizing formulations comprising copper (I) iodide and potassium iodide are well known and commercially available for use in stabilizing polyamides.

[0081] In some embodiments the polymer comprises a polyamide composition comprising at least one copper salt in an amount of 0.01 to 0.10 weight %, preferably 0.01 to 0.05 weight %, based on the total weight of the polyamide composition.

[0082] In some embodiments the polymer comprises a polyamide composition comprising at least one potassium salt in an amount of 0.05 to 0.50 weight %, preferably 0.1 to 0.3 weight %, based on the total weight of the polyamide composition.

[0083] In embodiments where the polymer comprises a polymer having a composition and an additive other than a thermal stabiliser, i.e. a light stabilisers, a lubricants, a nucleating agent, a colourant such as a pigment and / or a dye, a chain extender, an impact modifier, a flame retardant, a catalyst, an antioxidants, plasticizers, nucleating agents, antistatic agents, and any combinations thereof, preferably the additive other than a thermal stabiliser may typically be present in the polymer composition in an amount of 0.01 to 4.0 weight %, more preferably in an amount of 0.05 to 3.0 weight % and even more preferably in an amount of from 0.1 to 2.0 weight %, based on the total weight of the polymer composition.

[0084] Preferred light stabilisers include, among others, hindered amine light stabilisers (HALS), carbon black, benzotriazoles, hindered phenols, (inorganic) phosphites, ZnO, and combinations thereof.

[0085] Preferred lubricants include, among others, long chain fatty acids and their salts (such as stearic acid, Na stearate, Mg stearate, Al stearate, Ca stearate), long chain fatty acid amides such as ethylene bis(stearamide), montanic waxes, behenic waxes, or paraffins and oxidized paraffins, or combinations thereof.

[0086] Preferred nucleating agents include, among others, talc, polyamide 2.2, (inorganic) stearates, phenylphosphinic acid salts, etc., and combinations thereof.

[0087] Preferred colourants or dyes include, among others, carbon black, nigrosin chloridrate and nigrosine bas.

[0088] Preferred chain extenders include, among others, diepoxy resins, di-anhydrides, bis(oxazolines), styrene / maleic anhydride copolymers, ethylene / maleic anhydride copolymers, ethylene / (meth)acrylate / (glycidyl (meth)acrylate copolymers etc., and combinations thereof.

[0089] Preferred impact modifiers include among others, compounds such as grafted polyolefins like maleic anhydride grafted ethylene / propylene copolymers (EP-g-MA), maleic anhydride grafted ethylene / propylene / diene copolymers (EPDM-g-MA), maleic anhydride grafted styrene / ethylene / 1 - butene / styrene block copolymers (SEBS-g-MA), and others polyolefin copolymers such acrylic or methacrylic acid or acid salts.

[0090] Preferred flame retardants include, among others, compounds such as aluminium phosphinates, melamine polyphosphate (MPP), organophosphorus compounds, melamine cyanurate, red phosphorus, halogenated polystyrene, etc., and combinations thereof.

[0091] Preferred catalysts include, among others, compounds such as H3PO4, H3PO3, NaHPCf. etc., and combinations thereof.

[0092] Preferred antioxidants include, among others, compounds such as hindered phenols, semi aromatic amines or amides, organic phosphites, NaHPCf etc., and combinations thereof.

[0093] Any of the additives described above may be used with polymers having a polyamide composition, or with a polymer having a different composition, for example polyester, vinylester, epoxy, phenolic resin, polyurethane resin, polyphenylene sulphide , polyurethane, poly caprolactone, polysulfone, polyethylene, low density polyethylene, high density polyethylene, polycarbonate, polyphenylene ether, acrylonitrile butadiene styrene, polybutylene terephthalate, poly(butylene adipate), poly(lactic acid), polypropylene, polybutadiene, polyisoprene, polychloroprene, polyethylene terephthalate, polystyrene, polyvinyl chloride, phenol formaldehyde resin, neoprene and polyacrylonitrile. Other additives known in the art for use with the listed polymers may also be used in the present invention.

[0094] In some embodiments the polymer is reinforced with fibres.

[0095] Preferably the fibre is a synthetic fibre or a natural fibre.

[0096] Preferably the fibre comprises carbon fibre or aramid fibre or glass fibre.

[0097] Preferably the fibre has a coating thereon. The coating may be used to improve how the fibre is incorporated into the polymer.

[0098] Preferably the fibre comprises a first strand.

[0099] Preferably the fibre comprises a first strand and a second strand, each of the first and second strands having a respective composition that may be the same or different.

[0100] Preferably the fibre comprises a plurality of strands.

[0101] When the fibre comprises a plurality of strands, it is preferred that a first strand is between a second strand and a third strand. Preferably the first strand has a different composition compared to the second and / or third strand. Preferably the second strand has the same composition as the third strand.

[0102] When the fibre has a coating thereon, it is preferred that the coating is an organic or inorganic coating. Preferably the coating is a polymeric coating.

[0103] Preferably the polymeric coating has a composition the same as the polymer, or as one of the polymers previously described.

[0104] When the fibre has a coating thereon, and when the fibre comprises glass fibre, it is preferred that the coating is glass having a different composition compared to the composition of the glass fibre. Such a configuration is typical of an optical fibre, having a core and a cladding. In some embodiments the polymer is reinforced with fibres.

[0105] In some embodiments where the polymer is reinforced with fibres, preferably the fibres comprise glass having a composition. Such fibres are known as fibre glass. Preferably the fibre glass has a composition comprising (by weight) 50 - 60% SiCh, 10 - 20% A12O3, 2 - 15% B2O3, 0 - 6% MgO, 0 - 30% CaO, 0 - 3% K2O, 0 - 1% Fe2O3, 0 - 1% TiO2.

[0106] Preferably the fibre glass has a composition comprising (by weight) 51 - 58% SiCh, 11 - 18% AI2O3, 5 - 14% B2O3, 0 - 6% MgO, 5 - 25 CaO, 0 - 3% K2O, 0 - 1% Fe2O3, 0 - 1% TiO2.

[0107] Preferably the fibre glass has a composition comprising (by weight) 60 - 75% SiO2, 0 - 10% AI2O3, 0 - 10% B2O3, 0 - 6% MgO, 2 - 15% CaO, 0 - 6% ZnO and (Na2O + K2O) between 7% and 16%.

[0108] Preferably the fibre glass has a composition comprising (by weight) 65 - 74% SiO2, 1 - 10% AI2O3, 0 - 10% B2O3, 0 - 6% MgO, 3 - 14% CaO, 0 - 65 ZnO and (Na2O + K2O) between 8% and 15%.

[0109] Preferably the fibre glass has a composition comprising (by weight) 50 - 60% SiO2, 10 - 20% AI2O3, 3 - 15% B2O3, 0 - 10% MgO, 10 - 30% CaO, and (Na2O + K2O) between 0% and 5%.

[0110] Preferably the fibre glass has a composition comprising (by weight) 50 - 58% SiO2, 10 - 18% AI2O3, 3 - 15% B2O3, 0 - 8% MgO, 14 - 28% CaO, and (Na2O + K2O) between 0% and 3%.

[0111] Preferably the fibre glass has a composition comprising (by weight) 50 - 70% SiO2, 15 - 30% AI2O3, 0 - 10% B2O3, 5 - 25% MgO, 0 - 10% CaO, 0 - 3% K2O, 0 - 5% Fe2O3, 0 - 1% TiO2.

[0112] Preferably the fibres have a length between 0. 1 and 20mm.

[0113] In some embodiments the polymer is a fibre reinforced polymer, and the fibre is a short fibre having a length less than 2mm and preferably greater than 0. 1mm, preferably between 0.1mm and 1.0mm, even more preferably between 0.1mm and 0.5mm.

[0114] Preferably the fibre is less than 50% by weight of the volume of the polymer.

[0115] Preferably the short fibre is a short glass fibre.

[0116] In some embodiments the polymer is a fibre reinforced polymer, and the fibre is a medium fibre having a length less than 10mm and at least 2mm preferably between 2mm and 8mm, even more preferably between 2mm and 6mm.

[0117] Preferably the fibre is less than 50% by weight of the volume of the polymer.

[0118] Preferably the medium fibre is a medium glass fibre. In some embodiments the polymer is a fibre reinforced polymer, and the fibre is a long fibre having a length less than 50mm and at least 10mm preferably between 10mm and 40mm, even more preferably between 10mm and 30mm, even more preferably between 10mm and 20mm.

[0119] Preferably the fibre is less than 50% by weight of the volume of the polymer.

[0120] Preferably the long fibre is a long glass fibre.

[0121] In some embodiments the polymer is a fibre reinforced polymer having a tensile modulus measured according to DIN EN ISO 527-2 of at least IGPa.

[0122] Preferably the fibre reinforced polymer has a tensile modulus measured according to DIN EN ISO 527-2 of less than 20GPa, more preferably less than 17, 18 or 19 GPa.

[0123] In some embodiments the polymer is a fibre reinforced polymer having a tensile strength measured according to DIN EN ISO 527-2 of at least 50MPa.

[0124] In some embodiments the polymer is a fibre reinforced polymer having a tensile strength measured according to DIN EN ISO 527-2 of less than 300MPa.

[0125] In some embodiments the first extension portion of the first cap is connected to the body portion of the first pack. In such embodiments the first extension portion of the first cap is not integrally formed with the body portion of the first pack.

[0126] Preferably the first extension portion of the first cap is connected to the body portion of the first pack by at least one of a mechanical fastener, an adhesive bond and a fusion bond.

[0127] In some embodiments the first cap further comprises a second extension portion extending from the body portion.

[0128] Preferably the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the second edge surface of the pack, and the second extension portion faces the first major surface of the pack or the second major surface of the pack.

[0129] Preferably the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the first or second major surface of the pack and the second extension portion faces the second edge surface of the pack.

[0130] Preferably the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the second edge surface of the pack and the second extension portion faces another edge surface of the pack, the another edge surface of the pack being at an opposite side of the pack than the second edge surface of the pack. Preferably the second extension portion is integrally formed with the body portion.

[0131] Preferably the second extension portion is integrally formed with the first extension portion.

[0132] Preferably the first and second extension portions are integrally formed with the body portion.

[0133] In some embodiments the first cap further comprises a second extension portion extending from the body portion and a third extension portion extending from the body portion.

[0134] Preferably the second extension portion is connected to the body portion of the first cap by at least one of a mechanical fastener, an adhesive bond and a fusion bond.

[0135] Preferably the second extension portion is connected to the first extension portion of the first cap by at least one of a mechanical fastener, an adhesive bond and a fusion bond.

[0136] In some embodiments the first cap further comprises a second extension portion extending from the body portion, a third extension portion extending from the body portion and a fourth extension portion extending from the body portion.

[0137] Preferably the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the first major surface of the pack, the second extension portion faces the second major surface of the pack, the third extension portion faces the second edge surface of the pack and the fourth extension portion faces a third edge surface of the pack, the third edge surface of the pack being at an opposite side of the pack than the second edge surface of the pack.

[0138] Preferably the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the second edge surface of the pack, the second extension portion faces the first major surface of the pack, and the third extension portion faces the second major surface of the pack and the fourth extension portion faces a third edge surface of the pack, the third edge surface of the pack being at an opposite side of the pack than the second edge surface of the pack.

[0139] Preferably the first, second, third and fourth extensions portions are configured as a cavity into which the first edge surface of the pack fits.

[0140] Preferably the second extension portion is integrally formed with the body portion.

[0141] Preferably the third extension portion is integrally formed with the body portion.

[0142] Preferably the fourth extension portion is integrally formed with the body portion.

[0143] Preferably the second extension portion is integrally formed with the first extension portion. Preferably the third extension portion is integrally formed with the first extension portion and / or second extension portion.

[0144] Preferably the fourth extension portion is integrally formed with at least one of the first extension portion, the second extension portion and the third extension portion.

[0145] Preferably the first, second, third and fourth extension portions are integrally formed with the body portion.

[0146] Preferably the body portion is integrally formed with at least one of the first extension portion, the second extension portion, the third extension portion and the fourth extension portion thereby forming a first interlocking member, and the remainder of the first extension portion, the second extension portion, the third extension portion and the fourth extension portion not integrally formed with the body portion are connectable with the first interlocking member.

[0147] Preferably two or more of the first extension portion, the second extension portion, the third extension portion and the fourth extension portion not integrally formed with the body portion, at least two of which are integrally formed to form a second interlocking member connectable with the first interlocking member.

[0148] In some embodiments the packaging system comprises a second cap configured in the same way as the first cap, the second cap being for positioning over a third edge surface of the pack, the third edge surface of the pack being at an opposite side of the pack to the first edge surface of the pack.

[0149] Preferably the packing system comprises at least a first strap or band for extending around the first and second caps to retain the first and second caps on the pack. Other suitable retaining means known in the art may be used, for example tape, cord and plastic film.

[0150] In some embodiments the packaging system comprises a first covering member for covering a portion of the second edge surface of the pack not covered by the first cap, or for covering at least a portion of another edge surface of the pack not covered by the first cap, preferably wherein the another edge surface of the pack is opposite the second edge surface of the pack.

[0151] In some embodiments the pack comprises a fourth edge surface opposite the second edge surface and the packaging system comprises a second covering member for covering a portion of the fourth edge surface of the pack.

[0152] In some embodiments the body portion of the first cap is connectable with the first extension portion of the first cap. Preferably the first extension portion of the first cap is connectable with the first extension portion of the first cap using a mechanical fastener.

[0153] Preferably the body portion comprises a male engaging portion and the first extension portion comprises a female engaging portion, and the body portion is connectable with the first extension portion by engaging the male engaging portion with the female engaging portion.

[0154] Preferably the body portion comprises a female engaging portion and the first extension portion comprises a male engaging portion, and the body portion is connectable with the first extension portion by engaging the male engaging portion with the female engaging portion.

[0155] In some embodiments the pack of panels comprises a pack of glass sheets comprising a plurality of glass sheets.

[0156] In some embodiments the pack of panels is a pack of glass sheets comprising a plurality of glass sheets.

[0157] In some embodiments the first cap is configured such that when the first cap is positioned over the first edge surface of the pack, the body portion of the first cap faces the first edge surface of the pack of panels and the first extension portion of the first cap faces the second edge surface of the pack of panels.

[0158] In some embodiments the first cap is configured such that when the first cap is positioned over the first edge surface of the pack, the body portion of the first cap faces the first edge surface of the pack of panels and the first extension portion of the first cap faces the first major surface of the pack of panels.

[0159] In some embodiments the first cap is configured such that when the first cap is positioned over the first edge surface of the pack, the body portion of the first cap faces the first edge surface of the pack of panels and the first extension portion of the first cap faces the second major surface of the pack of panels.

[0160] From another aspect the present invention also provides a method of making a first cap for a packaging system according to the first aspect of the present invention, wherein the polymer is injected into a first mould to form at least the body portion.

[0161] Preferably the first mould is also used to form the first extension portion.

[0162] Preferably the first extension portion is integrally formed with the body portion.

[0163] Preferably the entire first cap is injection moulded. In some embodiments the polymer is a fibre reinforced polymer.

[0164] In such embodiments, preferably the fibre is uncoated, but the method may include a coating step to provide the fibre with a suitable coating prior to the fibre being mixed with the polymer and prior to the fibre / polymer mixture being injected into the first mould.

[0165] When the method includes a fibre coating step, preferably the coating is a polymeric coating.

[0166] Preferably the polymeric coating has the same composition as the polymer.

[0167] When the polymer is reinforced with a fibre, preferably the method includes a step of mixing the fibre with the polymer before the step of injecting the polymer into the first mould.

[0168] From another aspect the present invention also provides a method of making a first cap for a packaging system according to the first aspect of the present invention, wherein the polymer is printed with a 3D printer to form at least the body portion.

[0169] In some embodiments of the second aspect of the present invention, the first extension portion is made from a polymer that is injected into a second mould to form the second extension portion.

[0170] In such embodiments, the first extension portion of the first cap is connectable with the body portion of the first cap.

[0171] The present invention also provides from another aspect use of a fibre reinforced polymer to make a first cap for a glass packaging system according to the first aspect of the present invention.

[0172] Preferably the first cap is primarily made from the fibre reinforced polymer.

[0173] Preferably the first cap is entirely made from the fibre reinforced polymer.

[0174] The present invention will now be described with reference to the following figures (not to scale) in which:

[0175] Figure 1 is a schematic isometric representation of a cap for a packaging system according to the present invention;

[0176] Figure 2 is an exploded view of the cap shown in figure 1;

[0177] Figure 3 is a schematic isometric representation of a pack of glass sheets and a packaging system according to the present invention prior to being positioned on the pack;

[0178] Figure 4 is a cross-sectional view along the plane B-B' of figure 3 when the packaging system is on the pack of glass sheets; Figure 5 is a view of the front of a pack of glass sheets positioned in a packaging system;

[0179] Figure 6 is a view of the front of a pack of glass sheets positioned in another packaging system;

[0180] Figure 7 is a schematic isometric representation of a pack of glass sheets and another packaging system according to the present invention prior to being positioned on the pack;

[0181] Figure 8 is a view of the front of a pack of glass sheets positioned in the packaging system shown in figure 7;

[0182] Figure 9 is a schematic isometric representation of another packaging system according to the present invention;

[0183] Figure 10 is a view of the front of a pack of glass sheets positioned in the packaging system shown in figure 9;

[0184] Figures 11 and 12 are schematic isometric representations of a two-component cap for use in a packaging system according to the present invention;

[0185] Figure 13 is a schematic isometric representation of another packaging system according to the present invention before being positioned on a pack of glass sheets;

[0186] Figure 14 is a plan view of the packaging system shown in figure 13 when positioned on a pack of glass sheets;

[0187] Figure 15 is a front view of the packaging system shown in figure 13 when positioned on a pack of glass sheets;

[0188] Figures 16 and 17 are schematic isometric representations of another two-component cap for use in a packaging system according to the present invention; and

[0189] Figures 18 and 19 are front view representations of another packaging system according to the present invention.

[0190] Figure 1 shows an isometric representation of a cap for use in a packaging system according to the present invention. To help with the description of the cap shown in figure 1, an exploded representation thereof is shown in figure 2.

[0191] With reference to figures 1 and 2, the cap 1 comprises a body portion 3 and four extension portions 5a, 5b, 5c and 5d.

[0192] The extension portions 5a, 5b, 5c, 5d and the body portion 3 form a cavity 7 which is sized to receive an edge surface of a pack of panels such as sheets of glass. In the glass field, such caps are used to cover the end of a pack of glass sheets and are often referred to as “end caps”. The particular dimensions of the end cap depend upon the particular size of the pack of glass sheets, the end of which is being covered by the end cap.

[0193] The cavity 7 has a length 2a, a width 2b and a depth 2c. In this example the length 2a is 800mm, the width 2b is 670mm and the depth 2c is 50mm.

[0194] The thickness 5a’ of the first extension portion 5a may be at least 50mm and the thickness 4 of the body portion 3 and extension portions 5b, 5c and 5d may be 2mm or more.

[0195] In this example the cap 1 is made of fibre reinforced polyamide and is of a unitary construction. The polyamide is PA66 and the glass fibres are E-glass having a composition (in percent by weight) of 54% SiCE, 14% AI2O3, 20% CaO, 3% MgO, 9% B2O3. As is known in the art, E-glass usually has Na2O+K2O less than 2% by weight.

[0196] The fibres have a length of about 0.3 - 0.4mm and a fibre weight to volume ratio of about 20% but may be in the range of 5 - 50%.

[0197] The cap 1 may be made using known processes in the art for forming polymer objects, such as an injection moulding process, a 3-d printing process or a pultrusion process.

[0198] The body portion 3 has a first side 3 a for facing the edge surface of the pack when said end portion is received in the cavity 7, and an opposing second side 3b. The spacing of the first and second sides 3a, 3b defines the thickness 4 of the body portion 3. The thickness 4 of the body portion 3 in this example is 3mm but may be less than 25mm, for example in the range 1mm - 25mm. The extension portions 5b, 5c and 5d may have the same thickness as the body portion 3. The extension portion 5a has a thickness 5a’ which may be greater than the thickness 4 in order to support the weight of the pack of panels when received in the cavity 7 and when the extension portion 5a is a base portion for supporting a portion of the pack of glass sheets thereon.

[0199] On the second side 3b of the body portion 3 is a lifting member 9 configured such that the cap 1 may be lifted using a suitable lifting mechanism, for example by engaging a suitable lifting means (not shown) such as a fork or tine of a forklift truck with the lifting member 9.

[0200] Although in this example the cap 1 has a unitary construction with four extension portions 5a, 5b, 5c and 5d, in an alternative example the cap only includes the body portion 3 and up to any three of the extension portions 5a, 5b, 5c, 5d. Such a cap may also be of unitary construction. For example, in such embodiments the cap may have a body portion 3, a first extension portion 5 a and a second extension portion 5b. In an alternative such embodiment, the cap may have a body portion 3 and only a first extension portion 5a. This is described in more detail with reference to figures 18 and 19.

[0201] In an embodiment the cap has a body portion 3 and integrally formed therewith a lower extension portion 5a. Such a cap may be provided with one or both side extensions 5b, 5c by suitably coupling to the body portion 3, for example using an adhesive or by a locking arrangement. A locking arrangement may allow the end cap to be disassembled and re-assembled, for example the locking arrangement may comprise a slot in the first side 3a of the body portion 3 into which an end 5c’ of the side extension 5c can fit. Such an end cap may be provided with an upper extension portion 5d. The locking arrangement may be configured such that one of the side extensions 5b, 5c is a snap fit to the body portion 3. A snap fit is a convenient form of mechanical fastener.

[0202] In another embodiment the body portion 3 is made of two or more portions that are connectable together by a suitable interlocking arrangement and / or an adhesive bond and / or a fusion bond.

[0203] As discussed above, in the example described in relation to figures 1 and 2, the cap is of a unitary construction. Whilst it is preferred to have a cap of unitary construction because only one part needs to be manufactured (for example by injection moulding), it may also be desirable to have a cap made of various separate components, which in use, are suitably connected or coupled together. This allows the individual component parts to be connected or coupled together to make a cap having a different size. For example, with reference to figures 1 and 2, the extension portions 5a, 5c may be used with 1 different sized body portion such that a cavity having a different width 2b may be provided. Furthermore, two or more body portions 3 may be coupled together to provide a body portion for a cap having a wider cavity. Such coupling may be by a snap fit.

[0204] The individual components may be connected together using at least one of a mechanical fastener, an adhesive or welding.

[0205] In other embodiments, the cavity 7 has a length 2a between 0.5m and 4m, preferably between 0.5m and 3m.

[0206] In other embodiments the cavity has a width 2b between 0.1m and Im, preferably between 0.1m and 0.9m.

[0207] In other embodiments the cavity has a depth 2c is less than 500mm, preferably less than 400mm, more preferably less than 300mm.

[0208] Figure 3 shows two caps 1, 21 before being positioned over opposing edge surfaces of a pack of glass sheets 30. The cap 21 is configured in the same way as the cap 1 previously described but may be made of a different material than the cap 1. For example, the cap 21 may be a conventional end cap made from wood, but this is not preferred. The cap 1 may be made of a first polymer and the cap 21 may be made from a second polymer different to the first polymer.

[0209] The cap 21 may have a different configuration to the cap 1, but this is not preferred.

[0210] The pack of glass sheets 30 comprises a plurality of glass sheets each having a respective first major surface and opposing second major surface, The pack of glass sheets 30 has a first major surface 32 and an opposing second major surface (not labelled).

[0211] Connecting the first major surface 32 of the pack of glass sheets and the second opposing major surface of the pack of glass sheets is, on a first side of the pack, a first edge surface portion 24 and on a second side of the pack opposite the first side of the pack, is a second edge surface portion 26.

[0212] The first cap 1 is positioned over the first edge surface portion 24 by moving the first cap 1 in the direction of arrow 34 towards the edge surface portion 24 of the pack of glass sheets 30. The second cap 21 is positioned over the second edge surface portion 26 by moving the second cap 21 in the direction of arrow 36 towards the edge surface portion 26 of the pack of glass sheets 20.

[0213] Also shown in figure 3 are first and second covers 41, 51.

[0214] The first cover 41 is of unitary construction and has a U-shaped profile in cross-section i.e., when viewed along the plane A-A The first cover 41 is made from the same material as the body portion 3, although in some embodiments the first cover may be made from a different polymer or a different material such as cardboard or wood.

[0215] The first cover 41 is channel-shaped and configured to be positioned over an upper edge surface portion 27 of the pack of glass sheets 30 by moving in the direction of arrow 37. The first cover 41 has a body portion 41a and at opposing lateral sides thereof a first extension portion 41b and a second extension portion 41c. Once positioned on the upper edge surface portion 27, the body portion 41a covers a portion of the upper edge surface portion 27, the first extension portion 41b covers a portion of the first major surface 32 of the pack 30 and the second extension portion 41c covers a portion of the second major surface of the pack 30.

[0216] The second cover 51 is configured in the same way as the first cover 41 and is arranged to be positioned on the lower edge surface portion 29 of the pack of glass sheets 30 by moving in the direction of arrow 39.

[0217] In an alternative embodiment, the first and / or second cover 41, 51 is made of two or more interlocking members. In another alternative embodiment, the first and / or second cover 41, 51 is flat having only a respective body portion to cover a portion of the respective edge surface portion 27, 29. Figure 4 shows the caps 1, 21 and covers 41, 51 in position in relation to the glass pack 30 when viewed along a cross-sectional plane in the direction B-B' shown in figure 3. The cover 41 may be a snug fit over the upper edge surface portion 27. The cover 51 may be a snug fit over the lower edge surface portion 29.

[0218] As shown in figure 4, the first extension portions of the first and second end caps are configured to engage with the ground and the thickness 5a’ is suitably sized to provide adequate support.

[0219] The lifting members 9, 29 are horizontally aligned when position on the respective edge faces of the pack and may be used to lift the pack with the packaging system thereon from a first location to a second location by engaging the lifting members 9, 29 with a suitable lifting means.

[0220] Figure 5 shows another embodiment viewed in the direction of arrow 60 of figure 3 when caps 1’, 21’ and are in position relative to the pack 30’. The caps 1’, 21’ are configured in the same way as the cap 1. The pack 30’ is similar to the pack 30.

[0221] Suitable banding 70, 80 is used to retain the caps 1’, 21’ in position over the respective edge surface portions of the pack 30’. Suitable banding material may include any conventional material used for such banding applications, for example metal and / or plastic. Instead of banding (or as well as) other known strapping means may be used to retain the caps 1 ’, 21 ’ in position over the respective edge surface portions of the pack 30’.

[0222] The cap 1’ has a first external extension member 2’ and a second external extension member 4’. The end cap 21’ has a first external extension member 22’ and a second external extension member 24’. The banding 70 is positioned over the first external extension members 2’, 22’ and the banding 80 is positioned over the second external extension members 4’, 24’.

[0223] Figure 6 shows another embodiment viewed in the direction of arrow 60 of figure 3 and is similar to the embodiment shown in figure 5 except that in addition to the caps 1 ’, 21 ’, there are also flat covers 41’, 51’ in position relative to the pack 30’.

[0224] The flat covers 41 ’, 51 ’ may extend into the cavity of the cap 1 ’ and / or the cavity of the cap 21’. Alternatively, or in addition to, there may be additional banding used to retain the cover 41 ’ over the lower edge surface portion of the pack 30’ and the cover 51 ’ over the upper edge surface portion of the pack 30’.

[0225] Figure 7 shows another packaging system before positioning over the end faces of a pack of glass sheets 30. In this example there is a first cap 1 configured as previously described and a second cap 61. The second cap 61 is made from two interlocking parts 61a, 61b.

[0226] The interlocking part 61a is made from a fibre reinforced polyamide, which in this example is PA66 reinforced with glass fibres having an E-glass composition with a fibre length of 2.5mm and a fibre weight per volume ratio of about 35%.

[0227] The interlocking part 6 lb is made of the same material but may be made of a different polymer. For example, the interlocking part 61b may be made of a polymer than is not as hard as the polymer used to make the interlocking part 61a such that there is less risk of surface damage to the major surfaces of the pack of glass sheets 30.

[0228] The interlocking parts 61a, 61b are made using an injection moulding process.

[0229] The first interlocking part 61a has a body portion 63 and an extension portion 65a. The body portion 63 is similar to the body portion 3 of the first cap 1. The extension portion 65a is integrally formed with the body portion 63 and in this example is a hollow cuboid, although reinforcing members may be provided in the interior space of the cuboid. The dotted line is included for illustration purposes only to demarcate the body portion 63 and the first extension portion 65a.

[0230] At an upper end of the body portion 63 is a lifting member 69 which is similar to the lifting members 9, 29 previously described.

[0231] The second interlocking part 61b has two spaced apart wall sections 67, 67’ having an inverted “L” shape, being joined together at an upper end thereof by an upper wall section 68. The second interlocking part 61b can interlock with the first interlocking part by moving in the direction of arrow 62. The first and second interlocking parts may be connected together by at least one of a suitable mechanical fastener, adhesive bonding or welding. Advantageously, the first and second interlocking parts can be coupled and decoupled as required. For example, the upper end 63a of the body portion 63 may be provided with a pair of studs (shown in phantom as studs 70a, 70b) and the underside of the upper wall 68 may be provided with a pair of openings into which the studs may be a snug fit. The first interlocking part 61b may then be decoupled from the first interlocking part 61a by pulling the two parts away from each other such that the studs are removed from the openings.

[0232] The packaging system also includes a cover 41 ” for positioning over a lower edge surface portion of the pack 30. In this example the cover 41” is made of cardboard but may be made of a polymer such as fibre reinforced polyamide-6. Being formed of cardboard, the cover 41’ may be suitably bent to shape, whereas when made of a polymer the cover 41 ’ may be formed by injection moulding. Figure 8 shows a front view of the pack of glass sheets 30 in the packaging system shown in figure 7 viewed in the direction of arrow 60’. The first cap 1 is over a first edge surface portion of the pack 30 and the second cap 61 is over a second edge surface portion of the pack 30, the second edge surface portion of the pack being at an opposite side of the pack relative to the first edge surface portion of the pack. With reference to figure 1, the first edge surface portion is that part of the pack 30 labelled 24, and the second edge surface portion is that part of the pack labelled 26.

[0233] The upper wall 68 also covers a portion of the upper edge surface of the pack of glass sheets. Part of the walls 67 covers a portion of the first major surface 32 of the pack of glass sheets 30. A part of the wall 67’ covers a portion of the other major surface of the pack of glass sheets 30.

[0234] A cover 41 ” is used to cover the lower edge of the pack of glass sheets. Suitable banding straps 71, 73 are used to hold the caps 1, 61 on the respective ends of the pack of glass sheets 30.

[0235] Figure 9 shows another packaging system for a pack of glass sheets comprising a first cap 61 and a second cap 81. The first cap 61 is as described with reference to the cap 61 shown in figures 7 and 8 and has two component parts 61a. 61b that are connected together in use (as shown).

[0236] The second cap 81 is made from a fibre reinforced polymer resin reinforced with fibres. In this example the polymer is a thermosetting polymer resin such as polyester and the fibres are carbon, glass or aramid. A particular composition for the glass fibre is (in % by weight) 65 - 72% SiO2, 1 - 7% A12O3, 4 - 11% CaO, 0 - 8% B2O3, 0 - 6% ZnO and 9 - 13% (Na2O + K2O). This is typical of a C -glass composition.

[0237] The second cap 81 has a unitary construction having been made using an injection moulding process well known in the art.

[0238] The second cap 81 is ‘L’-shaped and has a first ‘L’-shaped sidewall 81a spaced apart from a second ‘L’-shaped sidewall 81b joined at the bottom by a base portion 81c and at the top by an upper wall 8 Id. The spaced apart sidewalls 81a, 81b define a channel 82 sized to receive an edge surface portion of a pack of glass sheets (not shown). The channel 82 has a closed end where the body portion 83 is located. A lifting member 89 is position on the outer face of the body portion 83 as previously described.

[0239] The cap 61 and the cap 81 may be positioned over opposing edges faces of a pack of glass sheets by moving in the direction of arrow 85. In an alternative embodiment, the base portion 81c includes a lug 87 for engaging with a suitable opening (not shown) in the first part 61a of the cap 61.

[0240] Figure 10 shows a front view of the packaging system shown in figure 9 in use when position over the edge faces of a pack of glass sheets 30. Suitable banding 71’, 73’ is used to retain the caps 61, 81 on the ends of the pack 30. Figure 11 shows another cap for use in a packing system in accordance with the present invention. The cap 91 comprises two parts 92a and 92b.

[0241] The part 92a comprises a body portion 93 and a first extension portion 95a. The second portion 92b comprises two parallel spaced apart sidewalls 94a, 94b joined at an upper end thereof by an upper wall 96. Each part 92a, 92b is of a unitary construction and each is made from the same polymer. In this example, each part 92a, 92b was made by injection moulding. In another embodiment, the first part 92a is made by injection moulding a first polymer (which may or may not be reinforced with fibres), and the second part 92b is made by 3d-printing or injection moulding a second polymer, which may or may not be reinforced with fibres.

[0242] The first part 92a may be used without the second part 92b as will be described hereinafter, although in this example, in use the cap 91 includes the first and second parts 92a, 92b coupled together, as shown in figure 12. The first and second parts 92a, 92b may be coupled together using mechanical fasteners and / or adhesive bonding and / or welding. It is preferred that the first and second parts 92a, 92b are coupled together such that the cap 91 may be disassembled for easier transportation and / or storage when not being used.

[0243] Figure 13 shows another packaging system in accordance with the present invention. The packaging system is used when transporting a pack of panels such as glass sheets and is used to protect the edges thereof.

[0244] In this example the packaging system includes caps 101, 111. Each cap is of a unitary construction and made of fibre reinforced polymer such a short fibre reinforced polyamide-66. The fibres are glass fibres and may have an E-glass composition or a C-glass composition.

[0245] In this example the caps 101, 111 are configured to cover edge surface portions of a pack of glass sheets 30 by moving each cap 101, 111 toward a respective major surface of the pack of glass sheets 30. The cap 101 may be moved in the direction of arrow 102 to towards the first major surface 32 of the pack of glass sheets 30 to cover the part of edge surface portions 24, 26, 27, 29. The cap 111 is moved in the direction of arrow 103 towards the major surface of the pack of glass sheets opposite the major surface 32 to cover other parts of edge surface portions 24, 26, 27, 29.

[0246] Each cap 101, 111 is configured in the same way so only a description of cap 101 is provided. The cap 101 has a first body portion 104 for covering a portion of the edge surface portion 26, a second body portion 105a for covering a portion of the edge surface portion 27, a third body portion 105b for covering a portion of the edge surface portion 24 and a fourth body portion 105c for covering a portion of the edge surface portion 29. The first and fourth body portions 105a, 105c are equivalent to extension portions. An extension portion 106 connects all the body portions 104, 105a, 105b, 105c and is rectangular shaped with an opening therein. The outer perimeter of the extension portion is sufficiently sized to cover the outer perimeter of the major surface 32 of the pack of glass sheets 30.

[0247] At an upper end of the first body portion 104 is a first lifting support member 107 and on the third body portion 105b is a second lifting support member 107’. The cap 111 has corresponding lifting support members 117, 117’.

[0248] When both caps 101, 111 are positioned on the pack of glass sheets 30, the pack of glass sheets 30 is essentially enclosed in a cavity defined by the inner surfaces of the caps 101, 111. The cavity is open-ended and the major surfaces of the pack of glass sheets 30 ae accessible when the caps are positioned thereon, but this is not essential and the extension portion 106 may not have an opening therein.

[0249] A view in the direction of arrow 108 when the caps 101, 111 are positioned on the pack of glass sheets 30 is shown in figure 14. The lifting support members 107, 117 align to form a first lifting member 109’ and the lifting support members 107’, 117’ align to form a second lifting member 109”. End portions of the lifting support members 107, 117 (or 107’, 117’) may have engaging portions to help with the rigidity of the first lifting members 109’ (or 109”) and / or there may be additional members coupled thereto to increase strength.

[0250] A view in the direction of arrow 109 is shown in figure 15.

[0251] Figures 16 shows a schematic isometric representation of another cap 121 configured in a similar way to the caps 101, 111 except that the cap 121 consists of two component parts that engage together. This is shown in figure 17.

[0252] With reference to figures 16 and 17, the cap 121 has a first component part 121a and a second component part 121b. Each component part 121a, 121b is of unitary construction and is made of glass fibre reinforced polyamide-66. The glass fibre has a C-glass composition as previously described but may have an E-glass composition. The glass fibres have a length of 0.3 - 0.4mm. Each component part 121a, 121b is made using an injection moulding process.

[0253] The first component part 121a has a body portion 124 and extending therefrom an upper extension portion 125a and a lower extension portion 125b. The body portion 124, the upper extension portion 125a and the lower extension portion 125b are connected together by another extension portion 126. Each extension portion is substantially flat having opposed parallel major surfaces. As can be seen in figure 17, the extension portion 126 has a “C”-shaped perimeter.

[0254] At an upper end of the body portion 124 is a lifting support member 127 which is the same as the lifting support member 107 previously described. The second component part 121 is configured in a similar way.

[0255] In order to connect the first and second component parts 121a, 121b together (as shown in figure 16), the first and second component parts 121a, 121b have engaging portions to allow a mechanical fastening of the parts. Whilst adhesive bonding and / or fusion bonding may be used instead of a mechanical fastener, it is preferred to not form a permanent bond between the two components parts 121a, 121b so that the cap 121 may be easily disassembled.

[0256] The mechanical fastener is provided as follows.

[0257] The upper extension portion 125a’ of the second component part 121b has three lugs 127a’ at the end thereof (only one of which is labelled) configured for engaging with a respective opening 127a (only one of which is labelled) in the end of the upper extension portion 125a of the first component part 121a.

[0258] Similarly, the lower extension portion 125a’ of the second component part 121b has three lugs 126a’ at the end thereof (only one of which is labelled) configured for engaging with a respective opening 126a (only one of which is labelled) in the end of the upper extension portion 125a of the first component part 121a.

[0259] The first and second component parts 121a, 121b may be connected to each other by moving one towards the other. Disconnection is achieved by move one away from the other one. Arrow 128 is used to illustrate this.

[0260] When used as a part of a packaging system, the cap 121 is used in the same way as either of the caps 101, 111 shown in figures 13 - 15.

[0261] Figure 18 shows a view of another packaging system according to the present invention. In the example the packaging system comprises two caps 131, 141. The first cap 131 is configured in the same way as the second cap 141. Both caps 131, 141 have a unitary construction and are made of glass fibre reinforced polyamide-66. The glass fibre has an E-glass composition but may be a C-glass composition. Instead of glass fibre, carbon fibre may be used to reinforce the polyamide-66. Other synthetic or natural fibres may be used. The fibre length was between 0.3 mm and 0.4mm.

[0262] The caps 131, 141 are each made by an injection moulding process.

[0263] There are similarities between the caps 131, 141 and the cap 1 shown in figures 1 and 2. However, in this example each cap 131, 141 only has respectively a body portion, an extension portion and a lifting member. However, to help with the description of figures 18 and 19, reference is also made to figures 1 and 2. The first cap 131 has a body portion 133 being a rectangular prism having an upper end 131’ and a lower end 131”, a first major surface 133a and a second opposing major surface 33b. The extension member 135 is at the lower end 131” of the body portion 133 and the lifting member 139 is near the upper end 131 ’ of the body portion 133. With reference to figure 2, the cap 131 consists of the body portion 3, the first extension portion 5 a and the lifting member 9.

[0264] The second cap 141 is configured the same way and has a body portion 143, an extension member 145 and a lifting member 149.

[0265] Also shown in figures 18 and 19 is a pack of glass sheets 150, which is similar to the pack of glass sheets 30 shown in figure 3. The pack 150 has a first major surface 152, a first edge surface portion 154 and a second edge surface portion 156 at an opposite side of the pack to the first edge surface portion 154. Figure 18 is a view towards the first major surface 152 being at an angle of 90° thereto.

[0266] Figure 18 shows the configuration before the caps 131, 141 are placed overthe edge surface portions 154, 156 of the pack 150.

[0267] The first cap 131 is used to cover the first edge surface portion 154 of the pack 150 by moving towards the pack in the direction of arrow 138. Similarly, the second cap 141 is used to cover the second edge surface portion 156 of the pack 150 by moving towards the pack in the direction of arrow 148.

[0268] Figure 19 shows the first and second caps 131, 141 covering the respective edge surface portions 154, 156. Two nylon straps 161, 162 are used to retain the caps 131, 141 in position by securing the caps on the respective ends of the pack of glass sheets 150. Due to the body portion 133 having a first major surface 133a that has a width that is at least as wide as a width of the first edge surface portion 154, the straps do not contact the pack comers, for example where the first edge surface portion 154 intersects with the first major surface 152. The second cap 141 is configured the same way in relation to the how the second edge surface portion 154 is covered.

[0269] To move the pack of glass sheets 150 when positioned in the packaging system as shown in figure 19 between locations, the lifting members 139, 149 may be connected to a suitable hoist or the fork of a fork-lift truck or the like.

[0270] The pack of glass sheets 150 in the packaging system may then be transported to a different location where the packing system is then removed from the pack of glass sheets. The caps 131, 141 may be re-used and / or returned to the original despatch location.

[0271] In an alternative embodiment to that described with reference to figures 18 and 19, at least one of the caps has a two or more component part structure. Each of the component parts may be made by injection moulding and each component of a respective cap is coupled together using at least one of a mechanical faster, an adhesive or welding to make the cap. For example, the body portion 133 and the lifting member 139 may be unitary formed using an injection moulding process. The extension member may also be unitary formed using an injection moulding process and the cap 131 may be formed by coupling the extension member 135 to the lower end of the body portion 133. When returning such a cap back to a previous location i.e., an original despatch location, the extension member 135 may be decoupled from the body portion 133 thereby reducing the return volume. Furthermore, the extension member 135 may be made of a different polymer compared to the body portion 133. This may be desirable to improve the strength of certain portions of the cap and / or to reduce potential for damage to portions of the pack of panels that may contact certain parts of the packing system.

[0272] Accordingly, a packaging system for a pack of panels, in particular a pack of glass sheets, is described. The packaging system comprises a first cap for positioning over a first edge surface of the pack. The first cap comprises a body portion and a first extension portion extending from the body portion and is configured such that when the first cap is positioned over the first edge surface of the pack, the body portion faces the first edge surface of the pack and the first extension portion faces a second edge surface of the pack or a first major surface of the pack or a second major surface of the pack. At least one of the body portion and the first extension portion of the first cap comprises a polymer that is preferably reinforced with fibres.

Claims

CLAIMS1. A packaging system for a pack of panels, the pack comprising a first major surface, a second opposing major surface, a first edge surface and a second edge surface; the pack further comprising: at least a first panel and a second panel, the first and second panels each having respectively a first major surface, a second opposing major surface, a first edge portion and a second edge portion, wherein the first edge surface of the pack comprises the first face edge portions of the first and second panels and the second edge surface of the pack comprises the second edge portions of the first and second panels; the packaging system comprising: a first cap for positioning over the first edge surface of the pack, the first cap comprising a body portion and a first extension portion extending from the body portion, the first cap being configured such that when the first cap is positioned over the first edge surface of the pack, the body portion faces the first edge surface of the pack and the first extension portion faces the second edge surface of the pack, the first major surface of the pack or the second major surface of the pack, wherein at least one of the body portion and the first extension portion comprises a polymer.

2. A packaging system according to claim 1, wherein the body portion comprises a first polymer and the first extension portion comprises a second polymer, preferably wherein the first polymer is the same as the second polymer.

3. A packaging system according to claim 1 or claim 2, wherein the first extension portion is integrally formed with the body portion.

4. A packaging system according to claim 1 or claim 2, wherein the first extension portion is connected to the body portion, preferably by at least one of a mechanical fastener, an adhesive bond and a fusion bond.

5. A packaging system according to any of the preceding claims, wherein the first cap is self- supporting.

6. A packaging system according to any of the preceding claims, wherein the polymer comprises at least one of polyester, vinylester, epoxy, phenolic resin, polyurethane resin, polyphenylene sulphide, polyurethane, polycaprolactone, polyamide, polysulfone, polyethylene, low density polyethylene, high density polyethylene, polycarbonate, polyphenylene ether, acrylonitrile butadiene styrene, polybutylene terephthalate, poly(butylene adipate), poly(lactic acid), polypropylene, polybutadiene, polyisoprene, polychloroprene, polyethylene terephthalate, polystyrene, polyvinyl chloride, phenol formaldehyde resin, neoprene and polyacrylonitrile.

7. A packaging system according to any of the preceding claims, wherein the polymer is reinforced with fibres.

8. A packaging system according to claim 7, wherein the fibre is a synthetic fibre or a natural fibre; or wherein the fibre comprises carbon fibre or aramid fibre.

9. A packaging system according to claim 7, wherein the fibre comprises glass having a composition.

10. A packaging system according to claim 9, wherein the glass has a composition comprising (by weight) 50 - 60% SiO2, 10 - 20% A12O3, 2 - 15% B2O3, 0 - 6% MgO, 0 - 30% CaO, 0 - 3% K2O, 0 - 1% Fe2O3, 0 - 1% TiO2; or wherein the glass has a composition comprising (by weight) 60 - 75% SiO2, 0 - 10% A12O3, 0 - 10% B2O3, 0 - 6% MgO, 2 - 15% CaO, 0 - 6% ZnO and (Na2O + K2O) between 7% and 16%; or wherein the glass has a composition comprising (by weight) 50 - 60% SiO2, 10 - 20% A12O3, 3 - 15% B2O3, 0 - 10% MgO, 10 - 30% CaO, and (Na2O + K2O) between 0% and 5%; or wherein the glass has a composition comprising (by weight) 50 - 70% SiO2, 15 - 30% A12O3, 0 - 10% B2O3, 5 - 25% MgO, 0 - 10% CaO, 0 - 3% K2O, 0 - 5% Fe2O3, 0 - 1% TiO2.

11. A packaging system according to any of the claims 7 to 10, wherein the fibre comprises at least a first strand, preferably at least a first strand and a second strand, each strand having a respective composition that may be the same or different.

12. A packaging system according to any of the claims 7 to 11, wherein the fibre comprises a coating thereon13. A packaging system according to any of the claims 7 to 12, wherein the fibres have a length between 0.1 and 20mm.

14. A packaging system according to any of the claims 7 to 13, wherein the fibre is a short fibre having a length less than 2mm and preferably greater than 0.1mm, preferably between 0. 1mm and 1.0mm, even more preferably between 0. 1mm and 0.5mm ; or wherein the fibre is a medium fibre having a length less than 10mm and at least 2mm preferably between 2mm and 8mm, even more preferably between 2mm and 6mm; or wherein the fibre is a long fibre having a length less than 50mm and at least 10mm preferably between 10mm and 40mm, even more preferably between 10mm and 30mm, even more preferably between 10mm and 20mm.

15. A packaging system according to any of the preceding claims, wherein the polymer has a tensile modulus measured according to DIN EN ISO 527-2 of at least 1 GPa and / or at most 20 GPa; and / or wherein the polymer has a tensile strength measured according to DIN EN ISO 527-2 of at least 50 MPa and / or at most 300 MPa16. A packaging system according to any of the preceding claims, wherein the polymer has a polymer composition and the polymer composition comprises at least a first additive and / or at least one filler to modify a property of the polymer.

17. A packaging system according to claim 16, wherein the first additive includes at least one of a thermal stabiliser, a light stabiliser, an ultraviolet ray stabiliser, a lubricant, a nucleating agent, a colourant such as a pigment and / or a dye, a chain extender, an impact modifier, a flame retardant, a catalyst, an antioxidant, a plasticizer, and an antistatic agent.

18. A packaging system according to any of the preceding claims, wherein the first cap comprises a second extension portion extending from the body portion19. A packaging system according to claim 18, wherein the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the second edge surface of the pack and the second extension portion faces the first major surface of the pack or the second major surface of the pack; or wherein the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the first or second major surface of the pack and the second extension portion faces the second edge surface of the pack; or wherein the first cap is configured such that when the first cap is over the first edge surface of the pack, the first extension portion faces the second edge surface of the pack and the second extension portion faces another edge surface of the pack, the another edge surface of the pack being at an opposite side of the pack than the second edge surface of the pack.

20. A packaging system according to claim 18 or claim 19, wherein the second extension portion is integrally formed with the body portion and / or wherein the second extension portion is integrally formed with the first extension portion.

21. A packaging system according to any of the preceding claims, further comprising a second cap configured the same as the first cap for positioning over a third edge surface of the pack, the third edge surface of the pack being at an opposite side of the pack than the first edge surface of the pack, preferably further comprising at least a first retaining means for extending around the first and second caps for retaining the first and second caps on the respective sides of the pack.

22. A packaging system according to claim 21, wherein the second cap is made from a polymer or comprises wood.

23. A packaging system according to any of the preceding claims, further comprising a first covering member for covering a portion of the second edge surface of the pack not covered by the first cap, or for covering at least a portion of another edge surface of the pack not covered by the first cap, preferably wherein the another edge surface of the pack is opposite the second edge surface of the pack.

24. A method of making a first cap for a packaging system according to any of the preceding claims, wherein the polymer is injected into a first mould to form at least the body portion and preferably to also form the first extension portion when the first extension portion is integrally formed with the body portion.

25. Use of a fibre reinforced polymer to make a first cap for a glass packaging system according to any of the claims 1 to 23.

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