FIELD OF INVENTION

This invention relates to a plate edge protector. More particularly, this invention relates to a plate edge protector mountable to a plate acting as a cathode for metal relining.

BACKGROUND ART

The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion should not be assumed to relate to what is commonly or well known by the person skilled in the art, but to assist in the inventive process undertaken by the inventor(s) and in the understanding of the invention.

Plates are used as a cathode in refining metal out of a solution with fine metal particles or compounds with metal in them. Metal can build up on and near edges of the plates making it hard to remove the plates from a housing. Edge protectors are placed on the edges of the plates to stop build-up of the metal on or near the edges. Edge protectors have been described with structurally inadequate comers and insufficient sealing to stop the solution entering the region of and surrounding the edges.

An object of the present invention is to ameliorate one or more of the aforementioned disadvantages of the prior art or to at least provide a useful alternative thereto.

STATEMENT OF INVENTION

The invention according to one or more aspects may be as defined in the independent claims. Some optional and/or preferred features of the invention are defined in the dependent claims.

Accordingly, in one aspect of the invention there is provided:

An edge protector mountable to a cathode plate, the edge protector comprising a set of elongate channels, each elongate channel defining a slot, the set of elongate channels including a first and second channel adapted to receive and cover respective side edges of the cathode plate, and a third channel adapted to receive and cover a lower edge of the cathode plate, the first, second and third channels beings channels of a first, second and third body respectively, wherein: the edge protector further includes a first and a second insert, the first insert being adapted to be placed into or over a feature of a first end of the first body and a feature of a first end of the second body to form a first comer, the second insert being adapted to be placed into or over a feature of a second end of the second body and a feature of a first end of the third body to form a second comer; and the edge protector further includes first and second comer over mouldings adapted to seal the first and second comers, the first comer over moulding being separate to the second comer over moulding.

Edge protector

The edge protector may be made of materials including plastic, ceramic, rubber, metal, silicone and/or a composite. The edge protector may be made of materials including carbon fibre, fibre glass or other composite materials. The edge protector may be made of materials including glass, clay ceramic or other ceramic materials. Preferably, the edge protector is made of polymeric materials resistant to electrolytic solutions. The edge protector may be substantially made of polyvinyl chloride (PVC) or acrylonitrile-butadiene-styrene (ABS), or a composite of suitable polymers.

Cathode plate

The cathode plate may be made of materials including any metal. The cathode plate may be made of any metal with sufficiently unreactive properties in response to a solution for the cathode plate and to exposure to electric current. The cathode plate may be made substantially of any metal. Preferably the cathode plate is substantially made of either stainless steel or aluminium. The stainless steel or aluminium may have minimal impurities, such that the cathode plate is made substantially of pure stainless steel or aluminium. The cathode plate may be non-planar, such as curved. Preferably, the cathode plate is flat or planar on either facing surface. Preferably, the cathode plate is a thin plate. The cathode plate may be any thickness. Preferably, the cathode plate is between 2mm and 10mm thick. Most preferably, the cathode plate is between 2mm and 5mm thick. The cathode plate may be any width and length. Preferably, the cathode plate is between 500mm and 1000mm in width. Preferably, the cathode plate is between 500mm and 1500mm in length. The cathode plate is ideally polygonal, with at least three clear edges. Preferably, the cathode plate is rectangular, with two parallel side edges and a joining straight edge at right angles to the side edges.

The cathode plate may include holes, other cut outs and/or regions with different thicknesses. The cathode plate may include elbows or other shapes. Preferably, the cathode plate includes holes and other cut outs. The holes may be located along the edges of the cathode plate. Preferably, the holes are located along the side edges of the cathode plate. Preferably, the other cut outs include cuts outs on the sections of the plate which the first and second comers cover. Preferably, there are also cut outs on an upper edge of the cathode plate. Preferably, the cathode plate includes holes to receive bolts for attachment of the edge protector to the cathode plate. The cathode plate may include supports, handles or other devices attached to a main plate of the cathode plate.

The cathode plate, with the edge protector may be adapted for insertion into a solution or matrix. The solution may include metal ions, metal or compounds including metal. The metal may be any metal. The metal may be zinc or cobalt. Preferably, the compounds including metal include copper oxide and/or copper sulphate. Preferably, the cathode plate is adapted to be used as a cathode in that electrons are pumped into the cathode plate. Preferably, the cathode plate is adapted to be placed next to an anode plate. Preferably, electrons are pumped away from the anode plate. Preferably, the solution acts as an electrolyte. Preferably, the edge protector and cathode plate are adapted for use in electrorefining or electrolysis. Most preferably, the edge protector and cathode plate are adapted for use in copper, zinc or cobalt electrorefining. Preferably, the copper oxide and/or copper sulphate compounds are split to form in part copper ions. Preferably, the cathode plate and edge protector are adapted so that the copper ions are deposited onto the cathode plate in the electrorefining process. Preferably, the materials deposited onto the cathode plate form above 98% pure copper.

Elongate channels

The set of elongate channels (elongate channels) may be curved to follow a curved edge of the cathode plate. Preferably, the elongate channels are linear. The elongate channels may have the same cross-sectional profile along the length of each elongate channel. The elongate channels may include transverse holes or other features. Preferably, the elongate channels have the substantially the same cross-sectional profile along the length of each elongate channel. Substantially in that, preferably, the elongate channels also include transverse holes. The transverse holes may be any diameter. Preferably, the transverse holes are between 3mm and 15mm in diameter. Most preferably, the transverse holes are between 5mm and 9mm in diameter.

The elongate channels may include any transverse cross-sectional shape. The elongate channels may include transverse cross-sections with square or rectangular shapes. The elongate channels may include a substantially T-shaped transverse cross-section. Substantially in that the T-shaped transverse cross-section may also include features, holes, tapers and radiused comers. Preferably, the elongate channels include a substantially cruciform transverse cross-sectional shape. Substantially in that the cruciform shape may also include features, holes, tapered edges, radii and other features. Preferably, the elongate channels include a taper on a first end of the elongate channel. The first end of the elongate channel may be an open end of the elongate channel which the cathode plate is inserted into. Preferably, the taper is angled such that the elongate channel is thinner where the elongate channel is open compared to a region further into the elongate channel. The open end of the elongate channel may be between 0mm and 3mm thinner than the thickness of the cathode plate. The open end of the elongate channel may be between 0mm and 5mm thicker than the thickness of the cathode plate. The open end of the elongate channel may the same thickness as the thickness of the cathode plate. Preferably, internal edges of the transverse cross-sectional shape of the elongate channels have radii. The internal comers of the transverse cross-sectional shape of the elongate channels may include grooves shaped and adapted such that edges of the cathode plate do not contact the first, second and third bodies when the cathode plate has been inserted into the elongate channels. The grooves may include any shaped profile. The grooves may include square shaped, rectangular and circular profiles.

Preferably, the cruciform transverse cross-sectional shape of the elongate channels allows for retaining strips to be inserted in opposite outer slots of the elongate channels. Preferably, the opposite outer slots form two of four ends of the cruciform cross-sectional shape. Preferably, the opposite outer slots are adapted to extend outwards normal to large faces of the cathode plate when the cathode plate is inserted into the elongate channels. The opposite outer slots may form a channel which is any width and thickness. The large faces of the cathode plate may include a first large face and a second large face. Preferably, the sealing strips and opposite outer slots are positioned such that the sealing strips contact the first and second large face of the cathode plate and are adapted to prevent or limit the solution from contacting the side edges and lower edge of the cathode plate.

First, second and third channels and bodies

The first, second and third channels (channels) may include different transverse crosssections. The first and third channels may include the same transverse cross-sections which is different to the second channels transverse cross-section. Preferably, the first, second and third channels all have substantially the same transverse cross-section.

The edge protector may not be symmetrical. The edge protector may be symmetrical in that a first side edge of the cathode plate can be inserted into either the first channel or the third channel. The edge protector may be symmetrical about a transverse plane half way along the second channel. The edge protector may be symmetrical about a transverse plane half way along the second channel.

The longitudinal length of the first, second and third channels may be different. Preferably, the longitudinal length of the first and third channels are the same. Preferably, the longitudinal length of the first and third channels are different to the longitudinal length of the second channel. The longitudinal length of the first, second and third channels may be any length. The longitudinal length of the first, second and third channels may be between 100mm and 5 m. The longitudinal length of the first, second and third channels may be between 500mm and 2m. Preferably, the longitudinal length of the first and third channels is between 900mm and 1300mm. Preferably, the longitudinal length of the second channel is between 800mm and 1200mm. Preferably, the longitudinal length of the first, second and third channels is long enough to cover the side and lower edges of the cathode plate that is adapted to be exposed to the solution or matrix.

The first, second and third channel bodies (bodies) may be extruded bodies. The bodies may include a substantially uniform transverse cross-sectional shape along their length. Substantially in that the bodies may also include tapers, chamfers, radiused comers and holes.

The first and second ends of the first, second and third bodies may be substantially identical or different. Preferably, the first and second ends of the second body are the substantially identical. The features m the ends of the first, second and third bodies to receive inserts may include holes, extrusions and other shapes. Preferably, the first and third bodies each include an extrusion and/or hole in the first end of the first and third bodies which are adapted to receive the inserts. Most preferably, the first and third bodies each include a hole in the first end of the first and third bodies which are adapted to receive the inserts. Preferably, the second body includes an extrusion and/or hole in a first and second end of the second body which are adapted to receive the inserts. Most preferably, the second body includes a hole in a first and second end of the second body which are adapted to receive inserts.

Preferably, the holes in the ends of the first, second and third bodies have a transverse cross-section area larger than the channels. The holes may include substantially cylindrical holes, square/rectangular shaped holes, cruciform shaped holes, gear shaped holes or other shaped holes. Preferably, the holes include substantially cylindrical holes. Preferably, the inserts include cylindrical extrusions which are adapted to fit or press fit into the cylindrical holes. The features may include axial stubs or extrusions. The features may include cylindrical ring-shaped extrusions. The features may include other shaped extrusions.

Thicknesses of walls of the bodies may be adapted to be thin enough to allow open ends of the channels to act as movable cantilevered springs. The cantilevered springs may be adapted to be a stiffness which allows insertion of the cathode plate and also for the open ends of the channels to apply a force clamping down onto the cathode plate.

First and second inserts

Each of the first and second inserts (inserts) may be made of multiple pieces. Preferably, the first insert is made of a single piece and the second insert is made of a single piece. The inserts may be manufactured using a 3D printing method. The inserts may be manufactured using a machining process such as using a CNC (computer numerical control) machine. fhe inserts may be manufactured using a moulding process. The inserts may be made of materials including suitable plastic, ceramic and/or a composite. The inserts may be made of PVC or ABS.

The first and second inserts may be different. The first and second inserts may be substantially the same. Substantially being, they may have differences such as additional radii or tapers. Preferably, the first and second inserts are identical.

Preferably, the first insert is adapted to be placed into a feature of the first end of the first body and the feature of the first end of the second body to form the first comer. Preferably, the second insert is adapted to be placed into the feature of the second end of the second body and the feature of the first end of the third body to form the second comer.

The first insert may be adapted to be inserted into a feature of the first end of the first body and the feature of the first end of the second body to form the first comer. The second insert may be adapted to be inserted into the feature of the second end of the second body and the feature of the first end of the third body to form the second comer.

The first and second inserts may include a bend at any angle. The first and second inserts may include a bend between 80 and 100 degrees. Preferably, the first and second inserts may include a 90 degree bend. The first and second inserts may include insert slots. Each of the first and second inserts may include a first and second slot (slots). Preferably, a longitudinal axis of the first slot may be orientated at 90 degrees to a longitudinal axis of the second slot. Preferably, the first and second slot meet to form an elbow slot. A transverse cross-section of the slots may include the same transverse cross-section as the first, second and/or third channels. Preferably, the transverse cross-section of the slots is different to the transverse cross-section of the first, second and/or third channels. Preferably , the transverse cross-section of the slots is substantially rectangular. Preferably, a first end of the transverse cross-section of the slots is enclosed and a second end is open. Preferably, the first and second slots are adapted so that the cathode plate is inserted into the open second end of the slots. Preferably, the first and second slots are slots of a first and second arm respectively. An end of each of the first and second arms may include features, such as extrusions and tapers. The extrusions may include any shape. The extrusions may include cylinders, T-shaped extrusions and/or cruciform extrusions. Preferably, the end of each of the first and second arms include cy linder shaped extrusions. Preferably, the cylinder-shaped extrusions have a larger diameter than the dimensions of the slots in the inserts. Preferably, the cylinder-shaped extrusions are adapted to fit or press fit into the holes in the ends of the first, second and third channels with holes. The holes in the end of the first and second arms may be any shaped holes. The holes in the end of the first and second arms may be T-shaped, cruciform and/or cylindrical. The holes may be shaped and sized to fit or press fit onto the features on the ends of the first, second and third bodies. Extrusion features of the bodies may be inserted into holes in the first and second arms.

First and second corners

Preferably, the process of over moulding the first and second comers may include use of a frame. Preferably, the process of overmoulding the first and second comers includes installing a temporary brace (the frame) to hold the comers at right angles and the slots of the first and second inserts aligned with the first, second and third channels. Preferably, the process further includes placing the frame and/or the first and second comers into at least one mould (which may include dies and inserts). Preferably, then using methods including injection moulding and/or other moulding processes to overmould the first and second comers.

Alternatively, the process of overmoulding the first and second comers may include placing composite materials such as fibre glass or carbon fibre with a glue such as epoxy over the first and second comers. This alternate process may include a vacuum forming method.

The material which is overmoulded on the first and second comers may be plastic or a composite such as fibre glass. The plastic may be any suitable plastic. The plastic maybe PVC or ABS. The material which is overmoulded on the first and second comers may be the same material which the first, second and third bodies are substantially made of. The material which is overmoulded on the first and second comers may be the same material which the first and second inserts are made of.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

Figure 1 is a front exploded view of an edge protector and a cathode plate according to any one of a first, second, third and fourth embodiment of the invention.

Figure 2 is a front assembled view of the edge protector mounted to the cathode plate according to any one of the first, second, third and fourth embodiment of the invention.

Figure 3 is a front view of a first and third body according to any one of the first, second, third and fourth embodiment of the invention.

Figure 4 is an end cross-sectional view of a first end of the first body, first and second end of a second body and first end of the third body according to the first or second embodiment of the invention.

Figure 5 is an end cross-sectional view of a second end of the first body or a second end of the third body according to the first or second embodiment of the invention.

Figure 6 is a front cross-sectional view of a first and second insert according to the first or third embodiment of the invention.

Figure 7 is a front view of the first and second insert according to the first or third embodiment of the invention.

Figure 8 is a perspective view of the first and second insert according to the first or third embodiment of the invention.

Figure 9 is a front view of overmoulded first and second comers according to any one of the first, second, third and fourth embodiment of the invention.

Figure 10 is an upper perspective view of the overmoulded first and second comers according to any one of the first, second, third and fourth embodiment of the invention.

Figure 11 is a lower perspective view of the overmoulded first and second comers according to any one of the first, second, third and fourth embodiment of the invention.

Figure 12 is a perspective view of the first and second comers according to any one of the first, second, third and fourth embodiment of the invention.

Figure 13 is a side view of a first and second insert according to either the second or fourth embodiment of the invention.

Figure 14 is an end cross-sectional view of the second end of the first body or a second end of the third body according to either a third or fourth embodiment of the invention. Figure 15 is an end cross-sectional view of the first end of the first body, the first and second end of the second body and the first end of the third body according to either a third or fourth embodiment of the invention;

Figure 16 is an illustration of a brace moulding plate slotted into an edge protector according to one embodiment;

Figure 17 is a sectional perspective view of a comer section according to one embodiment; and

Figure 18 is an illustration of a front view of a brace moulding plate according to the embodiment shown in Fig. 16.

DETAILED DESCRIPTION OF THE DRAWINGS

Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention.

An edge protector 1 mountable to a cathode plate 2, the edge protector 1 , 101, 201, 301 comprising a set of elongate channels 3, 103. Each elongate channel 10, 20, 30, 110, 120, 130 defining a slot. The set of elongate channels 3 including a first and second channel 10, 20, 110, 120 adapted to receive and cover respective side edges 4a, 4c of the cathode plate 2, and a third channel 30, 130 adapted to receive and cover a lower edge 4b of the cathode plate 2. The first, second and third channels 10, 20, 30, 110, 120, 130 being channels of a first, second and third body 12, 22, 32, 112, 122, 132 respectively. Wherein, the edge protector 1 further includes a first and second insert 40a-b, 140a-b. The first insert 40a, 140a being adapted to be placed into or over a feature 14 of a first end 16a of the first body 12, 112 and a feature 24a of a first end 26a of the second body 22, 122 to form a first comer 6a. The second insert 40b being adapted to be placed into or over a feature 24b of a second end 26b of the second body 22, 122 and a feature 34 of a first end 36a of the third body 32, 132 to form a second comer 6b. The first and second comers 6a-b are overmoulded with a first and second mouldable material respectively. The first comer 6a being separately overmoulded to the second comer 6b.

Like features may be referenced with the same reference number. For example, the first and second comers 6a-b in each of a first, second, third and fourth embodiment are slightly different in some embodiments but are all referenced 6a-b. Furthermore, like features may be referenced with like reference numbers. A first, second, third and fourth embodiment of the invention include combinations of two versions of the first, second and third channels 10, 20, 30, 110, 120, 130 (channels) and two versions of the first and second inserts 40a-b, 140a-b (inserts). The first embodiment of the invention includes a first version version of the channels 10, 20, 30 shown in Fig. 4 and 5 with a first version of the inserts 40a-b shown in Figs. 6 to 8. The second embodiment of the invention includes the first version of the channels 10, 20, 30 with a second version of the inserts 140a-b shown in Fig. 13. The third embodiment of the invention includes a second version of the channels 110, 120, 130 shown in Fig. 14 and 15 with the first version of the inserts 40a-b. The fourth embodiment of the invention includes the second version of the channels 110, 120, 130 with the second version of the inserts 140a-b.

The following passages refer to any one of a first, second, third or fourth embodiment of the invention. The first and third bodies 12, 32, 1 12, 132 are identical. The first, second and third channels 10, 20, 30, 110, 120, 130 are substantially the same. The channels 10, 20, 30, 110, 120, 130 have an inner transverse cross-section which is substantially cruciform shape 10a, 110a (as seen in Fig. 4 to 5 and Fig. 14 to 15). Substantially in that the cruciform shape also includes radii and tapers.

The following passages refer to either the first or second embodiment of the invention. The cruciform shape includes four ends; a top end 10b, two side ends lOc-d and a bottom end lOe. The top end 10b includes tapers lOf angled outwards from a smaller width base lObi of the top end 10b to a larger width top lObii of the top end 10b. The larger width top lObii of the top end 10b includes radiused edges 10g. The two side ends lOc-d include radiused upper edges lOh with larger radii and radiused lower edges lOi with smaller radii. Furthermore, lowers faces lOj of the two side ends lOc-d include tapers lOn. The tapers lOn extend inwards from a smaller width inner side lOci of each of the two side ends lOc-d to a larger width outer side lOcii of the two side ends lOc-d. The top end 10b and two side ends lOc-d are enclosed. The bottom end lOe is open or not enclosed by the first, second and third bodies. The bottom end lOe includes tapered faces 10k extending from a smaller width base lOei of the bottom end 10c to a larger width top lOcii of the bottom end 10c. The tapered faces 10k of the bottom end lOe include edges 10m on the smaller width base lOei which are adapted to contact the large faces of the cathode plate 2 when the cathode plate 2 is inserted into the channels 10, 20, 30. The edges 10m limit the flow of a solution into the channels 10, 20, 30.

The following passages refer to either the third or fourth embodiment of the invention. The cruciform shape includes four ends; a top end 110b, two side ends 1 lOc-d and a bottom end HOe. The top end 110b includes cylindrical slots 11 Of cut into two upper comers 11 Obi of the top end 110b. The top end 110b is adapted such that edges 4a-c of the cathode plate 4a-c do not contact the bodies 112, 122, 132 when the cathode plate 2 is inserted into the edge protector 1. The adaptions include the cylindrical slots 1 lOf. The top end 110b includes a top 1 lObii. The bottom end 1 lOe includes tapered faces 110k extending from a smaller width base 11 Oei of the bottom end 11 Oe to a larger width top 1 lOeii of the bottom end 1 lOe. The tapered faces 110k of the bottom end 11 Oe include edges 110m on the smaller width base 11 Oei which are adapted to contact the large faces of the cathode plate 2 when the cathode plate 2 is inserted into the channels 1 10, 120, 130. The edges 110m limit the flow of a solution into the channels 110, 120, 130. The two side ends 1 lOc-d are substantially rectangular slots. Unless otherwise stated, the following passages refer to any of the first, second, third and fourth embodiments of the invention. The edge protector 1, 101, 201, 301 and cathode plate 2 are adapted for insertion into the solution. The solution may include any metal. Preferably, the solution includes either copper, zinc or cobalt. The copper, zinc or cobalt may be in an oxidised form or in the form of another compound including copper, zinc or cobalt. A plate portion 2a of the cathode plate is made of either stainless steel or aluminium. The tapers 10k, lOn described above may also include curved faces and curved tapers.

The features 14, 24a-b, 34 of the first, second and third bodies 12, 22, 32, 112, 122, 132 (bodies) are substantially identical. The features 14, 24a-b, 34 of the first or second embodiment of the invention are shown in Fig. 4. The features 14, 24a-b, 34 of the second and third embodiment of the invention are shown in Fig. 15. The features 14, 24a-b, 34 include a cylindrical hole 18 with a longitudinal axis aligned substantially parallel with a longitudinal axis of the first, second and third channels 10, 20, 30, 110, 120, 130. The cylindrical holes 18 only extend part way into the bodies 12, 22, 32, 112, 122, 132. Preferably, the cylindrical holes 18 extend between 0mm and 5mm further than the distance the inserts 40a-c extend into the cylindrical holes 18. The cylindrical holes 18 may include tapers, radius edges and chamfered edges. Preferably, the cylindrical holes 18 are in the shape of a regular cylinder. Preferably, the diameter of the cylindrical holes 18 is between 5mm smaller and 5mm larger than the diameter of features on the first and second inserts 40a-b, 140a-b which are adapted for insertion into the cylindrical holes 18. The first and second inserts 40a- b, 140a-b may be a press fit into the cylindrical holes 18. The cylindrical holes 18 may be any diameter. The cylindrical holes 18 may be between 5mm and 30mm in diameter. Preferably, the cylindrical holes 18 are between 13mm and 19mm in diameter.

End faces 11 of the ends of the bodies 10, 20, 30, 110, 120, 130 are substantially flat. The bodies 12, 22, 32, 112, 122, 132 further include holes 72 in the ends of the channels 10, 20, 30, 110, 120, 130 without the features 14, 24a-b, 34. The holes 72 are located in the the second end 16b of the first body 12, 112 and second end 36b of the third body 32, 132. Outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132 are rounded. A transverse cross-section of the outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132 are in the shape of a rectangle with rounded comers.

The following refers to the first and second inserts 40a-b according to the first and third embodiments of the invention. The first and second inserts 40a-b (inserts) are in the shape of a 90 degree elbow. The first and second inserts 40a-b are identical. The inserts 40a-b each include a slot 41. The slot 41 is a rectangular slot with a closed end 42a and an open end 42b. The open end 42b is adapted to receive the cathode plate 2. The slot 41 is within 20% of the thickness of the top end 10b and bottom end lOe of the first, second and third channels 10, 20, 30, 110, 120, 130. The inserts 40a-b are adapted such that when they are inserted into the first, second and third channels 10, 20, 30, 110, 120, 130 a top 42ai of the closed end 42a of the slot 41 is within 5mm of lining up with the top lObii, 1 lObii of the top end 10b, 110b of the first, second and third channels 10, 20, 30, 110, 120, 130. Preferably, within 2mm of lining up. The closed end 42a of the slots 41 of the inserts 40a-b have radiused edges. The slots 41 include a 90 degree bend. The slots 41 are adapted to be aligned with the top and bottom ends 10b, lOe, 110b, I lOe of the channels 10, 20, 30, 110, 120, 130 when the inserts 40a-b are inserted into the bodies 12, 22, 32, 112, 122, 132.

The 90 degree elbow of the inserts 40a-b include two arms 43a-b. The two arms 43a-b orientated at 90 degrees to each other. Each of the two arms 43a-b include a feature 44a-b (insert feature). The features 44a-b are in the form of cylinders 44a-b. The cylinders 44a-b are adapted for insertion into the features 14, 24a, 24b, 34 of the bodies 12, 22, 32, 112, 122, 132. At inner ends 48a-b of the cylinders 44a-b the inserts 40a-b include a surface 49a-b which is adapted to contact the ends of the bodies 12, 22, 32, 112, 122, 132 when the inserts 40a-b are inserted into the features 14, 24a, 24b, 34 of the bodies 12, 22, 32, 112, 122, 132.

Fig. 1 shows an exploded view of the components of the edge protector 1 and the cathode plate 2. The moulded bodies 50, 60 shown in Fig. 1 are adapted not the be separated from the other components of the edge protector 1 and are only shown in the exploded view for clarity. All the components of the edge protector 1 are made of either PVC or ABS. The assembly of the components of the edge protector 1 , 101, 201, 301 is as follows. A first cylinder 44a of the first insert 40a is inserted into the feature 14 of the first end 16a of the first body 12, 1 12. A second cylinder 44b of the first insert 40a is then inserted into the feature 24a of the first end 26a of the second body 22, 122. This completes the first corner 6a.

A first cylinder 44b of a second insert 40b is then inserted into the feature 24b of the second end 26b of the second body 22, 122. A second cylinder of the second insert 40b is then inserted into the feature 34 of the first end of the third body 32, 132. This completes the second comer 6b.

A brace 80 is then inserted into the channels 10, 20, 30, 110, 120, 130 and slots 41 as seen in Figs. 16 and 17. The regions 80a of the brace 80 which are inserted into the channels 10, 20, 30, 110, 120, 130 have the same thickness as the cathode plate 2. The thickness of the cathode plate is 2.7mm. The brace 80 is made of steel plate. The brace 80 holds a longitudinal axis of the first body 12, 112 at 90 degrees to a longitudinal axis of the second body 22, 122 and the longitudinal axis of the second body 22, 122 at 90 degrees to a longitudinal axis of the third body 32, 132 while the first and second comers 6a-b are overmoulded. The brace 80 may also prevent the first and second mouldable materials from entering the channels 10, 20, 30, 110, 120, 130 and the slots 41 . The first comer 6a is then placed in between two halves of a mould. A suitable plastic, such as PVC or ABS, is injected into spaces between the two halves of the mould and the first comer 6a in an overmoulding process forming a first moulded body 50. The plastic injected melts outer surfaces 70 of the bodies 12, 22, 112, 122, therefore fixing the bodies 12, 22, 112, 122 to the first insert 40a rotationally and axially. In the same process the second comer 6b is placed in between two halves of a mould or the mould. A suitable thermoplastic material, such as PVC or ABS, is injected into spaces between the two halves of the mould and the second comer 6b in an overmoulding process forming a second moulded body 60. The plastic injected melts outer surfaces 70 of the bodies 22, 32, 122, 132 and therefore fixes the bodies 22, 32, 122, 132 to the second insert 40b rotationally and axially. The brace 80 is then removed from the channels 10, 20, 30, 110, 120, 130 and slots 41.

Therefore, the first and second mouldable materials may be a suitable plastic, such as PVC or ABS. The first and second mouldable materials may be different materials. Preferably, the first and second mouldable materials are the same material.

The first and second moulded bodies 50, 60 (moulded bodies) are substantially in the form of a 90 degree elbow. The moulded bodies 50, 60 cover substantially all of an outer surface 7a-b of the first and second comers 6a-b. The moulded bodies 50, 60 each include a slot 52, 62 aligned with the open end 42b of the slots 41 of the inserts 40a-b and the top end 10b of the channels 10, 20, 30, 110, 120, 130 as seen in Fig. 10. The moulded bodies 50, 60 provide structural support to the first and second comers 6a-b. The moulded bodies 50, 60 increase the moment required to break the first and second comers 6a-b. The moulded bodies 50, 60 include tapers 54, 64 onto outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132. Outer surfaces 56, 66 of the moulded bodies 50, 60 include rounded corners 58, 68. Outer surfaces 56, 66 of the moulded bodies 50, 60 largely follow the contours of the outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132.

The first body 12, 112 further includes a hole 72 in a second end 16b of the first body 12, 112. The third body 32, 132 further includes a hole 72 in a second end 36b of the third body 12, 1 12. The holes 72 may have a diameter of between 3mm and 11mm. Preferably, the holes 72 have a diameter of between 5mm and 9mm. The cathode plate 2 is adapted for inserting into the edge protector 1, 101, 201, 301. The cathode plate 2 includes holes 82 on a top end 83 a of the cathode plate 2. After the cathode plate 2 is inserted into the edge protector 1, 101, 201, 301, bolts are inserted through the holes 72 in the first and third bodies 12, 32, 112, 132 and through the holes 82 in the cathode plate 2. These bolts fix the edge protector 1, 101, 201, 301 to the cathode plate 2. The edge protector 1, 101, 201, 301 further includes four retainers 90a-d. The retainers 90a-d are inserted into the two side ends 1 Oc-d of the first and third channels 10, 30. The retainers 90a-d are adapted for insertion into the two side ends lOc-d of the first and third channels 10, 30 before or after the cathode plate 2 is inserted into the edge protector 1, 101, 201, 302. The retainers 90a-d apply additional force and friction from the bodies 12, 22, 32, 112, 122, 132 onto the plate portion 2a of the cathode plate 2 to keep the cathode plate 2 from moving relative to the edge protector 1, 101, 201, 301.

The cathode plate 2 further includes rectangular shaped cut outs 85a-b in the cathode plates 2 lower comers 86a-b. The cut outs 85a-b ensure the comers 86a-b of the cathode plate 2 can be inserted into the edge protector 1, 101, 201, 301 without interference by build up of material in comers 41a of the slots 41 of the inserts 40a-b.

The following passage refers to inserts 140a-b included in the second and fourth embodiments of the invention. Fig. 13 shows inserts 140a-b according to the second and fourth embodiments of the invention. The inserts 140a-b includes tapers 144c on cylinders 144a-b of two arms 143a-b of the inserts 140a-b. The tapers 144c extend outwards from the cylinders 144a-b to a larger diameter edge 144d. The tapers 144c create an interference or press fit between the inserts 144a-b and the features 14, 24a, 24b, 34 of the bodies 12, 22, 32, 1 12, 122, 132. The press fit may assist in keeping the inserts 144a-b in the same position relative to the bodies 12, 22, 32, 112, 122, 132 when the comers 6a-b are being overmoulded.

Throughout the specification and claims the word “substantially” refers to greater than 80% by mass. Throughout the specification and claims the word “comprise” and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word “comprise” and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.

In the present specification, terms such as “apparatus”, “means”, “device” and “member” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an “apparatus”, “means”, “device” or “member” or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the tenn, and similarly, where an “apparatus”, “assembly”, “means”, “device” or “member” is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise.

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the second body 22,122 lowermost.

It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention.