CARGO COVER FOR A LOAD ON A PALLET OR ROLL CAGE, BUCKLE AND FASTENER

Field of the Invention

The present invention relates to a cover, sheath or sleeve for a cargo or load on a pallet or roll cage for transportation. The cargo cover comprises at least a main panel and a plurality of side panels, the main panel and plurality of side panels comprising a selfreinforced polymer.

Background to the Invention

Cargo or freight is often transported whilst loaded on pallets or in roll cages. Each pallet or roll cage provide a unit of freight, which is easily moveable between shipping containers, distribution vehicles, or for delivery to customers. Typically, once a load is placed on the pallet or inside a roll cage, it can be secured in place using a suitable cargo cover or net. The covering can serve as a binding or fastening for the load to the pallet or inside the roll cage, and may also provide a protective, insulative or waterproof layer for the load.

A variety of cargo covers are known. A simple form of pallet cover may be a tarpaulin or plastic sheet, covering the load and fastened to the pallet or roll cage. More sophisticated reusable fabric covers are also known, for instance having a panel over the top of a load, and wings arranged to hang down the side of a load, fixed with lashing straps or other fasteners. However, such covers may be easily damaged, and do not provide a great deal of protection from impacts or penetration during transit.

Thus, there is a need for an improved cargo cover for a pallet or roll cage providing increased protection to the goods or the load on the pallet or roll cage.

Summary of the Invention

There is described a cover (“cargo cover”) for a load on a pallet or in a roll cage. The cover is formed of self-reinforced polymer. Self-reinforced polymer provides a material that is hard-wearing and durable, that is resistant to tearing and penetration, and that is waterproof and lightweight. Therefore, a pallet or roll cage cover made from this material can be reused many times, and may provide superior protection for a load. The described cargo cover may be flexible (in the manner of a tarpaulin), or may be rigid (in the manner of a box or casing). The flexibility or rigidity of the cargo cover can be adapted by the selection of an appropriate thickness of self-reinforced polymer material for the cargo cover, or the layering of the self-reinforced polymer material with other materials. Use of self-reinforced polymer material of sufficient thickness can provide a rigidity to the cover that potentially allows covered pallets and loads to be stacked.

The described pallet or roll cage cover comprises at least a main panel and a plurality of side panels. In use, the main panel overlies, or is arranged on top of, the load, and the side panels are arranged to cover and protect the sides of the load. The main and side panels are fastened together to cause the pallet or roll cage cover to enclose the top and side of the load. In some cases, the pallet or roll cage cover extends to cover the complete sides of the pallet or roll cage, so that the side panels extend almost to the surface on which the pallet or roll cage stands.

Many configurations for the cargo cover are possible. The cover may be formed from a single piece of self-reinforced polymer, wherein the main and side panels are divided by hinges or folds. Alternatively, the main and side panels may be entirely separate entities, joined when the pallet or roll cage cover is in use by one or more fastener, or joined prior to use by one or more permanent seams. In some examples, reinforcement panels are provided to overlap (and reinforce) the side panels of the pallet or roll cage cover. This can improve the rigidity of the pallet or roll cage cover and/or the protection it provides to a load therein. Beneficially, the pallet or roll cage cover is collapsible, and when not in use can be folded or the separate panels stacked, so as to take up a relatively small volume for storage or transportation.

According to a first aspect there is a cargo cover for a pallet or roll cage comprising: a main panel and a plurality of side panels, the main panel configured to overlie a cargo on the pallet or roll cage when the cargo cover is in use, and the side panels configured to cover a side of the cargo on the pallet or roll cage when the cargo cover is in use; wherein each of the main panel and the plurality of side panels comprise a layer of self-reinforced polymer.

The cargo cover is a cover for a load or cargo mounted on or held in a pallet or roll cage. The roll cage will typically have a regular shape and volume, and often a load on a pallet will also be arranged to have a regular shape and volume (to conform to common transportation and shipping practices and vehicles). Similarly, a pallet will typically be of a standard size and construction. The load may be any type of goods, which are carried on a pallet or in a roll cage, the pallet or roll cage improving ease of lifting and transportation. The cargo cover looks to provide protection from impacts or damage to the load, to provide a waterproof layer over the load, and also to contain and secure the load.

In use, the main panel of the cargo cover may be on top of, or overlie, the load. The side panels may be arranged to cover the sides of the load. In some configurations, the side panels are separate panels which are reversibly connectable to the main panel when the cover is in use. In other configurations, at least some of the side panels may extend from and be permanently connected to the main panel. When the main panel is arranged to overlie the loads, one or more of the side panels in this configuration hang down from the main panel (as one or more ‘wing’ to the main panel). The side panels may then be secured around the load using fasteners. Advantageously, when not in use either configuration of the cargo cover is collapsible, and can be folded (or the panels stacked) into a smaller volume.

All of the panels are formed from or comprise self-reinforced polymer material (also known as self-reinforced polymer composite). This material and its characteristics are discussed in detail below. Beneficially, this material provides a highly durable and impact resistant panel, which has superior protective properties for a given weight or thickness of material. Depending on the thickness of the material panel, the panels may be rigid or may be flexible. The self-reinforced polymer material may be layered with other materials as part of the panel, to provide extra rigidity or additional properties (thermal insulation, for instance). In some examples, the self-reinforced polymer is self-reinforced polypropylene.

Optionally, each of the main and/or side panels may comprise a fold extending across the panel, in order to assist a user in carrying the panel, and/or assist a user in arranging the cargo cover on a load.

Preferably, each side panel extends directly from a different side of a perimeter edge of the main panel. In other words, each side panel is connected to the perimeter edge of the main panel, so that in use the side panels hang down the side of the load when the main panel overlies the load.

Optionally, the main panel and the plurality of side panels are separate pieces, and the main panel and the plurality of side panels are connected via a hinge. For instance, a hinge panel could be bonded to each of the side panels and the main panel, to provide a bridge or connection therebetween. This provides a hinge between the main panel and each side panel. The hinge panel could be formed of self-reinforced polymer, and may be formed of self-reinforced polymer having a greater thickness than the main panel or side panel. Alternatively, separate main and side panels can be joined directly at a seam (for instance via stitching, ultrasonic welding, or heat welding). Use of separate main panel and side panels allows each panel to be formed from different thicknesses of self-reinforced polymer. For instance, the main panel may be made of a thicker (and so stiffer) selfreinforced polymer than compared to the side panels.

Optionally, the main panel and the plurality of side panels may be formed from a single piece of self-reinforced polymer, wherein hinges formed in the single piece divide the main panel and the plurality of side panels. In other words, the main and side panels of the cargo cover are cut as a net from a single sheet or piece of self-reinforced polymer. The main and side panels may be defined in the net by formation of folds or hinges in the net. This may avoid the need for fasteners or seams to be formed to connect each panel of material, thus making manufacture of the cover easier. When the cover is provided as a single entity in this way, it may be easier to transport and store by users.

Preferably, the cargo cover comprises at least four side panels, each side panel extending directly from a different side of a perimeter edge of the main panel. The main panel may be substantially planar and square or rectangular. However, the cargo cover may comprise any number of side panels, each side panel extending directly from a different portion of the perimeter edge of the main panel. In this way, the side panels are connected to and extend from the main panel like ‘wings’.

Preferably, the cargo cover comprises at least four side panels, wherein at least a first two side panels of the plurality of side panels each extend directly from a different side of a perimeter edge of the main panel, and at least a second two side panels of the plurality of side panels each extend directly from a side of a perimeter edge of a different one of the first two side panels. In other words, a first two of the side panels extend from the main panel, each in an opposite direction, like ‘wings’. A further side panel then extends from each of the first two side panels. The different configurations for the side panels compared to the main panel allows different access to a load when the cargo cover is in use (for instance, the configuration may define if a side panel has to be lifted as a flap from the main panel, when the panel overlies the load, or if the side panel is hinged to another side panel in the manner of a door).

Preferably, one or more of the side panels of the plurality of side panels has a reinforcement panel extending therefrom, the reinforcement panel hingedly connected to the side panel from which it extends, such that when the cargo cover is in use the hinge is arranged so that one of the side panels of the plurality of side panels overlaps the reinforcement panel. In use, the reinforcement panel may overlap the side panel to which it is connected, or another side panel. The reinforcement panels are further panels of self- reinforced polymer, which may be separate panels that are joined to the side panels, or which may be cut from the same single piece of self-reinforced polymer as the main and side panels. The reinforcement panels are arranged so as to provide a second panel parallel to, and overlapping with, each side panel when the cover is in use (by, for instance, having a reinforcement panel inside and facing the side panel when the cover is in use). This means that the sides of the load are protected by two layers - a side panel and a reinforcement panel. Advantageously, this improves protection to the load. The reinforcement panels can also provide additional stiffness and rigidity to the cargo cover, without requiring use of thicker and stiffer self-reinforced polymer material for the individual panels. This may reduce manufacturing cost.

Self-reinforced polymer sheets may be formed of a plurality of thermo-compressed, or consolidated, layers of self-reinforced polymer, as discussed below. In an example, the main panel, plurality of side panels and the reinforcement panels (if using) may be formed from two consolidated layers of self-reinforced polymer, three consolidated layers of selfreinforced polymer, four or fewer consolidated layers of self-reinforced polymer or six or fewer consolidated layers of self-reinforced polymer. This may provide panels with the best balance of rigidity, flexibility and weight considerations. However, a different number of layers could be used, either to increase the flexibility of the panels (by reducing the number of layers) or increasing the rigidity of the panels (by increasing the number of layers). Increasing the number of layers also increases the weight of the panels (and cargo cover overall). For some cargo covers according to the invention, it may be appropriate to reduce the number of layers of self-reinforced polymer from which the panels are formed to increase flexibility of the walls of the cover. For some cargo covers according to the invention, the self-reinforced polymer material may be layered with other types of material (such as foam), to improve the rigidity of the pallet cover without to significantly the increasing weight of the cover.

Optionally, the main panel and plurality of side panels (and if used, the reinforcement panels) are formed from a self-reinforced polymer sheet having a thickness of less than 5 mm, less than 4 mm, less than 3 mm, or less than 2 mm, or less than 1 mm. Thicker material will increase the stiffness of the panel, with thinner material offering greater flexibility and less weight.

Optionally, the main panel and plurality of side panels comprise a layer of flexible self-reinforced polymer. Where a flexible main panel and side panel are required, the thickness of the self-reinforced polymer material forming the main panel and side panel comprise a layer of self-reinforced polymer having a thickness of less than 1 mm, and more preferably less than 0.6 mm. The layer of self-reinforced polymer may be 0.12 mm to 1 mm thick, and more preferably 0.25mm to 0.6mm thick. A flexible main panel and side panel may comprise 1 to 6 consolidated layers of self-reinforced polymer, and more preferably 2 to 4 consolidated layers of self-reinforced polymer. In other words, a flexible main panel and side panel may comprise six or fewer thermo-compressed, consolidated layers of selfreinforced polymer and more preferably four or fewer thermo-compressed, consolidated layers of self-reinforced polymer. In a specific example, the main panel and side panel is around 0.25 to 0.3 mm thick and comprises two consolidated layers of self-reinforced polymer.

Preferably, the cargo cover may comprise at least one tab, hingedly connected to at least one side panel or the main panel, and configured to slot into a portion of the pallet or roll cage, or between the cargo and the pallet or roll cage, or for alignment with another panel, when the cargo cover is in use. The tab may be considered a flap or stub which can be held or trapped underneath the load in order to lock the cargo cover around the load by virtue of the load’s weight. The tab may extend across the width of the cargo cover, or only part of the width of the cargo cover.

Preferably, the tab comprises a portion of rigid self-reinforced polymer. The tab may be formed of a thicker self-reinforced polymer sheet than the main, side and reinforcement panels. This increases the comparative stiffness of the tab. The tab may be hingedly connected to the side panel, to allow the tab to be folded out of the way if not required. The tab may be formed as part of a single piece of self-reinforced polymer material with a side panel, but have applied additional laminated layers to increase its thickness compared to the side panel.

Optionally, the tab may be formed from a self-reinforced polymer sheet having a thickness of greater than 0.5 mm, greater than 0.8 mm, greater than 1 mm, greater than 2mm, or even greater than 3mm. Thus, the tab is a relatively stiff material, and may be more rigid than compared to a more flexible main, side and (if used) reinforcement panels. The tab may formed from a self-reinforced polymer sheet having a thickness that is at least 150%, or even 180% or more, of the thickness of the self-reinforced polymer layer comprised within the main panel and plurality of side panels. In an example, the tab may be formed from five or more consolidated layers of self-reinforced polymer, or eight or more consolidated layers of self-reinforced polymer, or even ten or more consolidated layers of self-reinforced polymer to achieve the preferred stiffness.

The cargo cover may further comprise a fastener, configured to secure the one or more side panel of the plurality of side panels in place so that they cover a side of the cargo on the pallet or roll cage when the cargo cover is in use. The fastener may connect or join each side panel to an adjacent side panel, or to an adjacent edge of the main panel. When the cargo cover is in use the fastener is connected or closed, which may help to improve the rigidity and structural integrity of the cover.

The fastener may be a strap, possibly in conjunction with a buckle. The buckle and/or may be in the form described in the aspects below. In a particular example, a strap may be provided that encircles the side walls of the cargo cover, and when tightened ensures the side walls are tightly secured around the load. The strap may be passed through cooperating apertures or eyelets in the side panels (and/or, if appropriate, the main panel). Alternatively, separate straps and/or buckles may be used at each join between panels. For instance, the straps may be used at each corner edge of the cargo cover. In some examples, a strap may be used to bind the side panels to a portion of the pallet or roll cage on which the load is mounted. Advantageously, the strap and/or buckle may itself be formed from a self-reinforced polymer.

Preferably, at least one of the side panels of the plurality of side panels comprises one or more aperture or loop through which a strap can be passed when the cargo cover is in use. This may anchor or attach the strap to the cargo cover.

Preferably, the fastener is configured to reversibly connect at least one side panel of the plurality of side panels to at least one other side panel of the plurality of side panels. The at least one fastener may be of any appropriate type, including one selected from a group comprising: a hoop and loop fastener, a zip fastener, a strap and buckle (for instance, as described as particular aspects below), one or more press stud closures. The type of fastener may be selected with a view to ease of use, the number of times for expected reuse by opening and closing etc. A mixture of types of fastener could be used within a particular cargo cover. Although a number of the specific examples described below show the use of hook-and-loop fastener or zip fastener to connect the at least one side panel, it will be understood the fastener may be of the type described in particular aspects below.

The cargo cover may further comprise one or more bracing panel, arranged to cover the hinge at the join between the main panel and each of the plurality of side panels. A different bracing panel may be used to cover each hinge, or the same bracing panel may be one piece that extends to cover all the of the hinges between the main panel and plurality of side panels. The bracing panel may comprise a further layer of self-reinforcing polymer to reinforce or cover the hinge. In an example, the bracing panel may be 0.35 mm to 1 .2 mm thick, and may comprise 3 to 8 consolidated layers of self-reinforced polymer. The bracing panel may be bonded to the side and/or main panel by stitching, by heat and compression, by heat welding or by ultrasonic welding. The bracing panel may be scored at the pivot point of the hinge, to improve the flexibility of the bracing panel. The bracing panel may be formed having a permanent bend or angle at the pivot point of the hinge, in order to provide some structure and support at the corners of the main panel when overlying the load. The bracing panels may be formed of self-reinforced polymer woven composite, to prevent delamination of the panel. Optionally the bracing panel may be a hinge panel connecting the main panel to the plurality of side panels.

In an alternative configuration for the cargo cover, the main panel and the side panels (and reinforcement panels, if used) are formed as separate panels, rather than as a net from a single sheet of self-reinforced polymer. The separate panels are still formed from, or comprise a layer of, self-reinforced polymer, however. In this case, the cargo cover further comprises at least one fastener at a perimeter edge of the main panel, the at least one fastener for connecting the main panel to each one of the plurality of side panels.

This alternative configuration may offer a number of benefits. For instance, the main panel and side panels may be interchangeable, to closely match loads (or pallets or roll cages) of different sizes and dimensions. Said interchangeability also allows different combinations of weights and rigidity for the panels, according to requirements. The separate panels can be entirely separated when the cargo cover is not in use, and the panels can be collapsed and stacked for storage.

In an example, the main panel can be formed separately to the side panels, but the plurality of side panels are formed out of a single self-reinforced polymer piece.

The cargo cover, having separate main panel and side panels, may further comprise at least one fastener at a portion of a perimeter edge of each of the plurality of side panels, the at least one fastener for connecting each of the side panels to the main panel and/or to at least one adjacent side panel. In other words, fasteners (of the same or different types) may be provided at each edge of each of the side or main panel required to be connected to another panel for forming the cargo cover around the load.

The fasteners may be of any appropriate type, including by not limited to: hoop and loop fastener, zip fastener, strap and buckle, one or more press stud closures. The fastener may be the buckle and/or strap formed from self-reinforced polymer, as described in particular aspects below.

For this configuration (having separate main and side panels), the main panel and the side panels may preferably be rigid, so as to maintain a planar form that can be less readily bent or flexed. This causes the cargo cover to be relatively rigid around the load when in use, which may be useful for cargo loads that need to be stacked for efficient transportation.

To provide a rigid main panel and plurality of side panels, the panels may comprise a thicker layer of the self-reinforced polymer. In an example, the main and side panels of this configuration may be formed from a self-reinforced polymer sheet having a thickness of greater than 0.8 mm, greater than 1 mm, greater than 2 mm, greater than 3 mm, greater than 5 mm, or even greater than 8 mm of self-reinforced polymer material.

Alternatively, the main panel and plurality of side panels may be rigid and have a layered structure, comprising one or more layers of self-reinforced polymer and/or one or more layers of foam or another material. In the layered structure, the one or more layers of self-reinforced polymer may each be thinner, for instance between 0.25 and 1 .2 mm, as discussed below.

As in the earlier described configuration, the configuration for the cargo cover having separate main and side panels may further comprise at least one tab, hingedly connected to at least one side panel and configured to slot into a portion of the pallet or roll cage, or between the cargo and the pallet or roll cage, when the cargo cover is in use. The tabs can be inserted under the weight of the load, in order to lock the side panels into position.

The cargo cover (of any configuration) may further comprise a security seal extending across a join between the main panel and one or more side panels, and/or between two adjacent side panels. Said seal could be heat welded onto a mounting plate, and then attached to the panel via stitching or riveting through the mounting plate. Said seal could be heat welded to an outer surface of the panel. The seal may itself be injection moulded from polymer material (including self-reinforced polymer material) together with the mounting plate. The seal may be of a type that must be broken to separate the join between panels across which it is mounted, so that tampering to the cargo cover becomes evident.

In relation to any of the configurations for the cargo cover, any one or more of the main panel, the plurality of side panels, or the reinforcement panels described may comprise a laminated structure, always incorporating a layer of the self-reinforced polymer material. For instance, the panels may comprise a layer of self-reinforced polymer together with a foam layer. In this case, one or more of the main panel and/or plurality of side panels may further comprise a foam layer extending across an inner surface.

Preferably, one or more of the main panel and/or plurality of side panels further comprise a laminated structure having a first self-reinforced polymer layer, a foam layer, and a second self-reinforced polymer layer, wherein the foam layer is arranged between the first and second self-reinforced polymer layers. The first and second layer may have a thickness of 0.25 mm to 1 .2 mm, comprising 2 to 8 consolidated layers of self-reinforced polymer. The foam layer may have a thickness of 4mm to 12 mm, and a density of between 25 kgrrr ³ and 50 kgrrr ³ grams per cubic metre. The first self-reinforced polymer layer, foam layer, and second self-reinforced polymer layer may be bonded together across the whole of their contacting surfaces

Preferably, one or more of the main panel and/or plurality of side panels further comprise a third and fourth layer of self-reinforced polymer, wherein the first self-reinforced polymer layer, foam layer, and second self-reinforced polymer layer are arranged between the third and the fourth self-reinforced polymer layer. The third and fourth layer may have a thickness of 0.12 mm to 0.9 mm, comprising 1 layer or 2 to 8 consolidated layers of selfreinforced polymer. In this configuration, the third and fourth self-reinforced polymer layer may only be bonded to the first self-reinforced polymer layer, foam layer, and second selfreinforced polymer layer by stitching or welding at the perimeter of the layered panel, or at specific seams across the planar surface of the panel.

Alternatively or additionally, one or more of the main panel and/or plurality of side panels may further comprise a thermal insulation layer extending across a surface of each panel comprising self-reinforced polymer, preferably an inner surface. The thermal insulation layer may be a layer of foam, or a thermal blanket (such as a reflective foil layer), for instance. Alternatively or additionally, one or more of the main panel and/or plurality of side panels may further comprise a velour layer extending across a surface of each panel comprising self-reinforced polymer, preferably an inner surface. The velour may be applied as a spray coating to a surface of the panel. Alternatively or additionally, one or more of the main panel and/or plurality of side panels may further comprise a fire retardant layer extending across a surface of each panel comprising self-reinforced polymer, preferably an inner surface. Such additional layers can provide improved properties for the cargo cover, including thermal insulation, or a soft protective inner layer. The outer surface of the cargo cover (i.e. normally the outer surface of the main panel and side panels) can be printed with a design or logo. A hydro dipping technique may be used for this purpose.

Alternatively or additionally, one or more of the main panel and/or plurality of side panels may further comprise a reflective or blocking layer extending across a surface of each panel comprising self-reinforced polymer, preferably an inner surface. Such a layer may block scanning or X-ray of a load housed within the cargo cover. Additives may be included within the self-reinforced polymer material. For instance, the self-reinforced polymer may further comprise a fire retardant additive. This may improve the safety of the cargo cover, and may be necessary to conform to certain safety standards. Additionally or alternatively, the self-reinforced polymer may further comprise an infra-red filter additive or a disrupting infra-red additive, being an additive for disrupting infra-red signal. Such additives can include titanium oxide (TiOs) or black carbon nanoparticles. This can disrupt the infra-red signal from the polymer used in the cargo cover.

In any of the configurations for the cargo cover described above, fasteners may be connected to the main or side panels. Preferably, the fasteners may be attached via stitching, heat welding or sonic welding. For manufacture of the cargo cover, the main panel and plurality of side panels (and reinforcement panels, if used) may be cut from a sheet of self-reinforced polymer using laser cutting, stamping or water jet cutting.

Optionally, straps may be attached to a perimeter edge of each side panel so that, in use, the straps pass through the body of a pallet (on which a load the cargo cover is covering is mounted) and connect to a strap at an opposite or adjacent side panel. In this way, the cargo cover can be secured in place over the load on the pallet. The straps may be a self-reinforced polymer strap, and may include a buckle formed using self-reinforced polymer as described in aspects below.

In a further aspect, there is described a method of manufacture for a cargo cover, as described herein.

In a still further aspect, there is a cargo cover for protection of a cargo on a pallet or roll cage, the cargo cover comprising: a panel, comprising two or more side panels, the side panels configured to wrap around a side of the cargo on the pallet or roll cage when the cargo cover is in use; wherein the panel comprises a layer of self-reinforced polymer.

The cargo cover can be considered as a ‘wrap’ for a load on a pallet or in a roll cage. The panel is a self-reinforced polymer panel, which is arranged to wrap around the outer surfaces at the side of the cargo load, in order to protect the load and help prevent movement of the load.

The self-reinforced polymer material (also known as self-reinforced polymer composite, and which may be a self-reinforced polymer woven composite) is discussed in more detail below. This material provides a highly durable and impact resistant panel for the cargo cover, which has superior protective properties for a given weight or thickness of material. Depending on the thickness of the material in the panel, the panel may be rigid or may be flexible. The self-reinforced polymer material may be layered with other materials (for instance, polymer foam) as part of the panel, to provide extra rigidity or additional properties (thermal insulation, for instance). In some examples, the self-reinforced polymer is self-reinforced polypropylene or self-reinforced polyethylene.

Preferably, the panel comprises the layer of self-reinforced polymer having a thickness of less than 1 mm, and more preferably less than 0.6 mm. A thinner layer of selfreinforced polymer provides a layer that is more flexible and lightweight, yet still provides a good level of protection. A thicker layer of self-reinforced polymer is stiffer, and more rigid. A thicker layer may also have heat reflection and insulation properties that are more efficient than thinner layers. It will be understood that the thickness of the self-reinforced polymer layer can be selected based on the purpose of the cargo cover and the load to be protected by it.

Preferably, the panel comprises a layer of self-reinforced polymer comprising ten or fewer thermo-compressed, consolidated layers of self-reinforced polymer, and more preferably six or fewer thermo-compressed, consolidated layers of self-reinforced polymer, and more preferably four or fewer thermo-compressed, consolidated layers of selfreinforced polymer. The panel may comprise a single layer of self-reinforced polymer. The fewer layers of the self-reinforced polymer, then the less the thickness of the material. The thickness has consequences for the relative rigidity or flexibility of the self-reinforced polymer, as discussed above.

Preferably, one or more folds are arranged between each side panel (and the folds may define the side panels). In other words, each of the side panels is separated by one or more folds. At least one fold is arranged between each side panel, but in some cases a plurality of folds may be arranged between each side panel, to accommodate different sizes of pallet as discussed below. The folds are arranged so that, once the cargo cover is in use, the folds align with the corners of a load on the pallet or in roll cage. In most cases, the fold also will be arranged to align with the corners of the pallet or roll cage itself.

Preferably, the panel is formed from a single piece of self-reinforced polymer, wherein the folds are folds in the single piece. Alternatively, the panel is formed by joining a plurality of separate pieces, each separate piece being a side panel, and wherein the folds comprise joins between each separate piece. Use of a single piece for the panel may reduce manufacturing costs, for instance, although use of separate pieces may simplify the cutting stages for the cargo cover.

Preferably, the cargo cover further comprises a reinforcement panel arranged at each fold, the reinforcement panel(s) comprising a layer of self-reinforced polymer. The reinforcement panel(s) may be used to cover a portion of the planar face of the panel, wherein that portion extends across each of the one or more folds between each side panel. The reinforcement panel can add stiffness and structure to the cargo cover, and also increases the robustness of the cover. In particular, the reinforcement panels can avoid destruction of the cargo cover through wear and tear at the portions of the cover which undergo regular bending and folding. Finally, the reinforcement panel provided additional protection for the corners of a load on a pallet or for the corners of a roll cage when the cargo cover is in use.

Preferably, the reinforcement panel comprises a layer of self-reinforced polymer having a thickness of less than 1 mm, and more preferably less than 0.6 mm. Preferably, the panel comprises a layer of self-reinforced polymer comprising ten or fewer thermocompressed, consolidated layers of self-reinforced polymer, and more preferably six or fewer thermo-compressed, consolidated layers of self-reinforced polymer, and more preferably four or fewer thermo-compressed, consolidated layers of self-reinforced polymer. Preferably, the reinforcement panel comprises a layer of self-reinforced polymer being a single layer of self-reinforced polymer. As discussed above, the number of layers (and consequent thickness) for the self-reinforced material may be selected according to need for protection and or reinforcement of the folds and corners of the cargo cover.

Preferably, the reinforcement panel may be connected or attached to the panel by heat and compression, by stitching or by riveting. The connection may be by any reasonable means to secure the reinforcement panel at the planar face of the panel.

Preferably, the dimensions of each side panel correspond to the dimensions of a standard pallet. In other words, the spacing of folds either side of a side panel can be chosen so that the cargo cover fits a pallet of a given size.

In an example, a plurality of folds may be arranged between each side panel, wherein a first fold between each of a first pair of side panels may be spaced apart from a first fold between a different, second pair of side panels, so that the spacing equates to a length or width of a UK standard pallet. A second fold between the second pair of side panels may be spaced apart from the first fold between the first pair of side panels so that the distance between the first fold of the first pair and the second fold of the second pair equates to a length or width of a European standard pallet. Similarly, a third fold between the second pair of side panels may be spaced apart from the first fold between the first pair of side panels so that the distance between the first fold of the first pair and the third fold of the second pair equates to a length or width of a North American standard pallet. It will be understood that a UK, European and North American standard pallet may each vary in dimensions by between 200 to 400 mm. In this way, the cargo cover can be used with different sizes of standard pallet. A given reinforcement panel may be of sufficient size to cover all of the folds between each of the pairs of the side panels

The height of the cargo cover can be configured to wrap around the full height of any cargo to be carried on a pallet. In some circumstances, the load or cargo is approximately cuboid, with a length, width and height that is similar to the length and width of the pallet. In these cases, the cargo cover is arranged to extend to cover this height of the load. In some cases, two such cuboid loads can be stacked on a single pallet, in which case the height of the cargo cover can be changed to cover the full height of the double load.

Preferably, the cargo cover further comprises a fastener, configured to secure the two or more side panels to be wrapped around the sides of the cargo on the pallet or roll cage when the cargo cover is in use. The fastener may be a strap and/or buckle, in which case the strap may be an elasticated strap, and/or the strap and/or buckle may comprise or be formed from self-reinforced polymer. The fastener may be arranged to connect two opposing ends of the strap or panel when the panel is wrapped around a load on a pallet or in a roll cage. The strap could be formed of self-reinforced polymer, and may be secured by the self-reinforced polymer buckle, for instance as described in aspects below. The fastener could equally be push poppers, hook and loop fasteners, a zipper or other type of fastener.

Preferably, the cargo cover further comprises a lid panel connectable to the two or more side panels so that, when the cargo cover is in use, the lid panel is configured to overlie a cargo on the pallet or roll cage. The cargo cover may further comprise a base panel connectable to the two or more side panels so that, when the cargo cover is in use, the base panel is configured to underlie a cargo on the pallet or roll cage. Preferably, the lid panel and/or the base panel comprise a layer of self-reinforced polymer.

As before, the lid and/or base panel may comprise a layer of self-reinforced polymer having a thickness of less than 1 mm, and more preferably less than 0.6 mm. The lid and/or base panel may comprise a layer of self-reinforced polymer comprising ten or fewer thermo-compressed, consolidated layers of self-reinforced polymer, and more preferably six or fewer thermo-compressed, consolidated layers of self-reinforced polymer, and more preferably four or fewer thermo-compressed, consolidated layers of self-reinforced polymer. In some case, the lid and/or base panel may comprise a single layer of selfreinforced polymer. The thickness of the self-reinforced polymer layer (which may be determined by the number of layers) may be selected to provide the correct balance of stiffness, weight and protection required by the user for the base or lid portion of the cargo cover. In some cases, the base and/or lid panel may be stiffer (i.e. formed of a thicker selfreinforced polymer material) than the panel to be wrapped around the sides of the cargo load. Lid and/or base panels may be interchangeable with different panel or side portions of a cargo covers, according to the requirement for stiffness or weight of each part.

Preferably, the lid panel and/or base panel are connectable using a fastener. In one example, the fastener is hook and loop fastener. In another example, the fastener is straps and/or buckles (for instance, this may be a strap and buckle fastener as described elsewhere in this disclosure). In a still further example, the fastener is by push popper fastenings. In each case the fastener is reversible, by which is meant it can easily connect or disconnect the lid panel and/or the base panel to the panel.

Preferably, the cargo cover further comprises a connector or fastener, for connecting the cargo cover to the pallet or roll cage when in use. For instance, the cargo cover may comprise a strap or tether to go under or through the pallet or roll cage, in order to hold the cargo cover in place.

In yet another aspect, there is described a method of manufacture for a cargo cover, as described herein.

In a still further aspect, there is a buckle, for connecting an end of a strap to an anchor loop, the buckle comprising: a body portion, comprising self-reinforced polymer, wherein the body portion is configured having a hook portion for hooking to the anchor loop, and two spaced-apart and parallel elongate openings arranged in the body portion, the elongate openings extending in a direction orthogonal to a direction of extension of the strap, wherein, in use, the end of the strap is retained in the buckle by passing in a first direction through a first of the elongate openings, and passing in a second direction through a second of the elongate openings, the first direction being opposite to the second direction, and wherein the buckle is connectable to the anchor loop by passing the hook portion through the anchor loop.

The buckle is made or formed from self-reinforced polymer, a material which is described in detail elsewhere in this disclosure. The self-reinforced polymer may be of a standard, layered construction, or may be a self-reinforced polymer woven composite. In an example, the self-reinforced polymer may be self-reinforced polypropylene or selfreinforced polyethylene. Beneficially, when the buckle formed of self-reinforced polymer is used together with the described cargo cover which is formed of the same type of polymer, end of life recycling for the cargo cover is more straightforward, as less separation of components is required to undertake recycling.

The strap is retained at or connected to the buckle as a result of being passed through the elongate openings therein. The openings are configured to allow the strap to pass, having a width greater than the width of the strap and a depth greater than the thickness of the strap.

In use, the body portion of the buckle provides a relatively rigid frame for the strap to be threaded therethrough. The rigidity of the body portion also allows the hook to be connected to the anchor loop and subsequently stay in position. The strap may be connected to a first element, and the anchor loop may be connected to a second element, wherein the first and second element are parts to be connected by use of the strap and buckle fastener.

The body portion may be planar. In other words, the body portion may be cut from a panel of self-reinforced polymer. This reduces the complexity of manufacturing the buckle.

Said panel may have a thickness of at least 1 mm. The thickness of self-reinforced polymer affects its rigidity. A self-reinforced polymer panel of 1 mm or more is relatively stiff or rigid. In some examples, the panel may be at least 1 .2 mm, or at least 1 .5 mm.

Said panel may comprise four or more consolidated layers of self-reinforced polymer. The thickness of self-reinforced polymer may be adjusted by forming a panel of laminated and thermo-compressed layers of the self-reinforced polymer. The laminated layers are heated whilst under pressure, causing at least a portion of the material in each layer to melt and intermingle, thereby consolidating the laminated layers. Use of four or more consolidated layers of self-reinforced polymer in the panel from which the body portion of the buckle is cut out causes the body portion to be relatively rigid or stiff. In some examples, the panel may comprise six or more consolidated layers of self-reinforced polymer, or even eight or more layers of self-reinforced polymer.

In another aspect there is a fastener for joining a first element to a second element, comprising: a strap, attached to the first element; an anchor loop, attached to the second element; and a buckle according to the description above.

For instance, the buckle may have a body portion configured having a hook portion and two spaced-apart and parallel elongate openings, as described above. The fastener may be used within the cargo cover as described elsewhere in this disclosure. The strap may comprise self-reinforced polymer. In other words, the strap may be formed of self-reinforced polymer as well as the buckle to which the strap is attached. Again, this improves end of life recyclability because it avoids the need for the strap and buckle components to be separated before recycling. Instead, both components, being made of the same material, can be recycled together.

The self-reinforced polymer of the strap may have a thickness of 0.8 mm or less. As noted above, the thickness of self-reinforced polymer may affect how rigid or stiff is the material. Ideally, the strap is relatively bendable and lacking in rigidity. Therefore, the strap may be formed from a relatively thin self-reinforced polymer material, for instance being less than 0.8 mm, being 0.6 mm or less, or being 0.4 mm or less in thickness.

The self-reinforced polymer of the strap may comprise three or fewer consolidated layers of self-reinforced polymer. As noted above, the self-reinforced polymer may be formed from laminated and thermo-compressed layers of the self-reinforced polymer, in order to adjust the thickness of the self-reinforced polymer material. In order for the strap to be relatively bendable it may be formed from self-reinforced polymer having three or fewer consolidated layers, two or fewer consolidated layers, or even a single layer of selfreinforced polymer.

The anchor loop may comprise a looped strap formed from self-reinforced polymer. Alternatively, the anchor loop may comprise a planar, stiff portion of self-reinforced polymer having an opening therethrough, through which the hook portion of the buckle may be passed.

Where the anchor loop is a looped strap the self-reinforced polymer of the anchor loop may have a thickness of 0.8 mm or less, or 0.6 mm or less, or even of 0.4 mm or less. In this case, the self-reinforced polymer of the anchor loop may comprise three or fewer consolidated layers of self-reinforced polymer, two or fewer consolidated layers, or even a single layer. Where the anchor loop comprises a planar, stiff portion, the self-reinforced polymer may be more than 0.6 mm, more than 0.8 mm or more than 1 mm thick, in order to provide the required stiffness.

The anchor loop may be mounted to a rotating anchor plate, the rotating anchor plate arranged to rotate compared to the second element. In other words, the anchor loop is arranged to rotate compared to the element or panel to which it is directly connected. The rotation allows the fastener to be more easily manipulated by a user during fastening or unfastening. Alternatively, the strap, at an end opposite to the end to which the buckle is connected, may be mounted to a rotating strap plate, the rotating strap plate arranged to rotate compared to the first element.

The first and the second element may be a first and second side panel of the cargo cover as described elsewhere in this disclosure. The fastener may be used to join one or more panel of the cargo cover for a pallet or roll cage described above or below. The one or more panel may be a first and a second side panel of the cargo cover. The fastener as described may be used for securing panels around a load.

In another aspect there is a buckle, for connecting a first strap end to a second strap end, the buckle comprising: a first portion and a second portion that are discrete and separable, each of the first and the second portion comprising self-reinforced polymer, and wherein the first portion is connected to the first strap end, and the second portion is connected to the second strap end; the first portion comprising an opening, and the second portion comprising an engagement member, the engagement member for insertion through the opening to connect the first and the second portions; wherein each of the first portion and the second portion further comprise two spaced-apart and parallel elongate openings, the elongate openings extending in a direction orthogonal to a direction of extension of the strap connected to the respective first or second portion; wherein, in use, the first strap end is retained in the first portion by passing in a first direction through a first of the elongate openings in the first portion, and passing in a second direction through a second of the elongate openings in the first portion, the first direction being opposite to the second direction, and wherein, in use, the second strap end is retained in the second portion by passing in a third direction through a first of the elongate openings in the second portion, and passing in a fourth direction through a second of the elongate openings in the second portion, the third direction being opposite to the fourth direction; wherein, in use, the first and second portions are connectable by insertion of the engagement member at the second portion through the opening in the first portion.

The first strap end and the second strap end may be opposing ends of the same strap or may be an end of a first strap and an end of a second strap, respectively.

The engagement member in the second portion may be arranged so as to be barbed, similar to a barbed arrow. This means that once the engagement member is passed through the opening in the first portion, it is difficult to release or remove unless sufficient slack is present in the straps.

The engagement member may protrude from a body portion of the second portion, wherein the engagement member may have a head portion and a trunk portion, the trunk portion extending in an extension direction between the head portion and the body portion; wherein, at a point of connection to the head portion, the width of the trunk portion in a direction perpendicular to the extension direction is less than the width of the head portion at the same point and in the direction perpendicular to the extension direction. The trunk portion may connect the body portion to the head portion. Typically, the body portion and the head portion are wider than the trunk portion, for example being more than twice the width of the trunk portion.

The width of the head portion in the direction perpendicular to the extension direction may be greater than the opening in the first portion in at least one direction. The width of the head portion in the direction perpendicular to the extension direction may be less than the opening in the first portion in at least another direction. The at least one direction may be perpendicular to the at least another direction. In other words, the opening may be large in once dimension than in another, perpendicular direction. The opening may be configured so as to be narrower than the head portion of the engagement member when the first and second portion are connected and aligned such that a strap extends from each of the first and second portion in opposite directions.

Each of the first and the second portion may be planar, and cut-out from a panel of self-reinforced polymer. The panel may have a thickness of 1 mm or more, of 1 .2 mm or more, or even 1 .5 mm or more. The panel may comprise four or more consolidated layers of self-reinforced polymer, may comprise six or more consolidated layers of self-reinforced polymer, or may comprise eight or more consolidated layers of self-reinforced polymer. The thickness (or number of layers) will be selected to ensure sufficient rigidity for each of the first and second portions to allow operation and fastening of the buckle, whilst keeping overall weight to a minimum.

In a yet still further aspect there is a fastener for joining a first element to a second element, comprising: a buckle, as described above having a first and a second portion, a first strap, having a first end retained within the first portion of the buckle and attached at a second, opposing end to the first element; and a second strap, having a first end retained within the second portion of the buckle and attached at a second, opposing end to the second element. The first and second element may be a first and second side panel of a cargo cover, for instance.

The first and/or second strap may comprise self-reinforced polymer. Ideally, the straps, the buckle and connected elements (such as panels of the cargo cover) will be formed of the same type of polymer. This allows for easier end of life recycling.

The self-reinforced polymer may have a thickness of 0.8 mm or less, of 0.6 mm or less, or 0.4 mm or less. The thickness is selected to allow for sufficient bendability or lack of stiffness in the strap, so as to make the strap easy to use.

The self-reinforced polymer may comprise three or fewer consolidated layers of self-reinforced polymer, may comprise two or fewer consolidated layers of self-reinforced polymer, or may comprise a single layer of self-reinforced polymer. The number of layers may be selected to give an appropriate thickness of self-reinforced polymer material.

The first strap may be mounted to a first rotating anchor plate at the first element, the first rotating anchor plate arranged to rotate compared to the first element; and/or the second strap may be mounted to a second rotating anchor plate at the second element, the second rotating anchor plate arranged to rotate compared to the second element. Each rotating anchor plate may be as described above, with respect to an earlier aspect.

The first and the second element may be respectively a first and second side panel of the cargo cover as described elsewhere in this disclosure. The fastener may be used to join one or more panel of the cargo cover for a pallet or roll cage described above or below. The one or more panel may be a first and a second side panel.

The cargo cover as described in any of the aspects above may comprise the buckle or the fastener as described in any of the aspects above.

List of Figures

The disclosure will now be put into practice in a number of ways, and preferred embodiments will now be described by way of example only and with reference to the accompanying drawings, in which:

FIGURE 1 (a) and 1 (b) show schematic views of a cargo cover according to a first configuration;

FIGURE 2(a) and 2(b) show schematic views view of a cargo cover according to a second configuration; FIGURE 3(a) and 3(b) show schematic views of a cargo cover according to a third configuration;

FIGURE 4(a) and 4(b) show schematic views of a cargo cover according to a fourth configuration;

FIGURE 5(a) and 5(b) show schematic views of a cargo cover according to a fifth configuration;

FIGURE 6(a) and 6(b) show schematic views of a cargo cover according to a sixth configuration;

FIGURE 7 shows a series of photographs providing an example of the folding of a cargo cover according to the sixth configuration;

FIGURE 8(a) and 8(b) show schematic views of a cargo cover according to a seventh configuration;

FIGURE 9(a) and 9(b) show schematic views of a cargo cover according to an eighth configuration;

FIGURE 10 show a photograph of a cargo cover according to the eighth configuration, in use;

FIGURE 1 1 (a) and 1 1 (b) show a cross-sectional view of a wall of a rigid cargo cover;

FIGURE 12(a) and 12(b) show cross-sectional views of a cargo cover according to a ninth configuration;

FIGURE 13 shows a schematic view of a cargo cover according to the ninth configuration;

FIGURE 13A shows a schematic view of a fastener or catch for connecting panels of the cargo cover;

FIGURE 13B shows photographs of the fastener in use;

FIGURE 14 shows a schematic view of a cargo cover according to a tenth configuration;

FIGURE 15 shows a cross-sectional view of a cargo cover according to the tenth configuration;

FIGURE 16 is a photograph showing the cargo cover according to the tenth configuration, in use;

FIGURE 17 is a photograph showing a side panel of the cargo cover according to the tenth configuration;

FIGURE 18(a) and 18(b) are photographs showing the main panel of the cargo cover according to the tenth configuration; FIGURE 19(a), 19(b), 19(c) and 19(d) are photographs showing aspects of the the cargo cover according to the tenth configuration;

FIGURE 20(a) and 20(b) are photographs showing a strap or connector at the foot of a pallet cover according to the tenth configuration;

FIGURE 21 shows a schematic diagram of a first configuration of a pallet wrap;

FIGURE 22 shows a schematic diagram of a second configuration of a pallet wrap;

FIGURE 23 shows a schematic diagram of a third configuration of a pallet wrap;

FIGURE 24 shows a photograph of a pallet wrap in a rolled configuration;

FIGURE 25(a) and 25(b) shows photographs of different views of a strap and buckle at the pallet wrap;

FIGURE 26 shows a photograph of a plurality of straps and buckles at the pallet wrap;

FIGURE 27 shows a photograph of a first view of a third configuration of a pallet wrap;

FIGURE 28 shows a photograph of a second view of the third configuration of a pallet wrap;

FIGURE 29 shows a photograph of a third view of the third configuration of a pallet wrap;

FIGURE 30 shows a schematic diagram of a first example of a buckle formed from self-reinforced polymer;

FIGURE 31 shows a schematic diagram of the first example of the buckle having a rotating anchor point;

FIGURE 32 shows photographs of a buckle according to the first example;

FIGURE 33 shows further photographs of the buckle according to the first example;

FIGURE 34 shows a schematic diagram of a second example of a buckle formed from self-reinforced polymer;

FIGURE 35 shows photographs of a buckle according to the second example;

FIGURE 36 shows a schematic diagram of a third example of a buckle formed from self-reinforced polymer; and

FIGURE 37 shows photographs of a buckle according to the third example.

In the figures, like parts are denoted by like reference numerals. The figures are not drawn to scale. Detailed description of preferred embodiments

FIGURE 1 (a) and 1 (b) show a cargo cover suitable for covering a load on a pallet 10 or roll cage (not shown). The cargo cover comprises a main (or central) panel 12 and four side (or wing) panels 14a, 14b, 14c, 14d. Each of the side panels extends from the main panel 12, at a different side or portion of the perimeter edge of the main panel 12. The main 12 and side panels 14a, 14b, 14c, 14d are formed as a net in a single sheet or piece of self-reinforced polymer material. The main 12 and side panels 14a, 14b, 14c, 14d are defined by hinges (or folds) 16 formed in the net, to divide the net into the separate panels. A fastener 18 (in FIGURE 1 (a) and 1 (b) being a zip fastener) is arranged at adjoining edges of each adjacent side panel.

In FIGURE 1 (a) a tab 20 is shown extending from the an edge of each side panel 14a, 14b, 14c, 14d, distal from the main panel 12. The tab 20 is hingedly connected to the side panel 14a, 14b, 14c, 14d. The tab 20 may be formed from the same sheet or piece of the self-reinforced polymer material as the main 12 and side panels 14a, 14b, 14c, 14d, or may be formed from separate sections that are then connected to the side panels 14a, 14b, 14c, 14d (for instance by stitching). It will be understood that the tabs 20 shown in FIGURE 1 (a) are a beneficial, but not essential, feature of the cargo cover.

In use, the main panel 12 of the cargo cover can be placed on top of a load arranged on a pallet 10 or inside a roll cage. The main panel 12 thereby overlies the load or cargo. The side panels 14a, 14b, 14c, 14d are then folded to hang down the sides of the load or cargo. The fasteners 18 at the edges of adjacent side panels 14a, 14b, 14c, 14d can be connected, in order to join the edges of the side panels 14a, 14b, 14c, 14d, and enclose the load within the cargo cover. The tabs 20 are folded and inserted beneath the load, to engage and secure the cargo cover around the load.

In the example of FIGURE 1 (a) and 1 (b) a further fastener is used to secure the cargo cover to the pallet. For instance, the cargo cover of FIGURE 1 (a) and 1 (b) has loops 22 arranged on an outer surface of each side panel 14a, 14b, 14c, 14d, through which a strap 24 can be threaded and subsequently passed around a portion of the body of the pallet or roll cage before tying or securing (for example, with the aid of a knot or buckle).

In FIGURE 1 (a) and 1 (b), the main panel 12 and four side panels 14a, 14b, 14c, 14d are shown as being of approximately equal size. However, it will be understood that different sizes of panel could be used, providing that the edges join to form a full cover for a load on a pallet 10 or in a roll cage when in use. In the particular example of FIGURE 1 (b), the side panels 14a, 14b, 14c, 14d are shown as extending down the full depth of the load to the upper surface of a pallet 14a, 14b, 14c, 14d. It will be understood that the side panels 14a, 14b, 14c, 14d may extend beyond the side of the load (not shown), to also extend down the sides of the pallet 10 to the base of the pallet. In this case, cut-outs at an edge of the side panel distal the main panel may be introduced, in order to allow access for the fork of a fork-lift truck into the recesses in the main body of the pallet. Preferably, these cut-outs may also be used to provide the hingedly attached tabs 20 described above.

Beneficially, when the cargo cover is not in use, the side panels 14a, 14b, 14c, 14d may be folded down at the hinges 16 (so as to overlap and cover the main panel 12). Thus the cargo cover can be folded or collapsed into a small volume for easier storage.

As noted above, the main panel 12, the side panels 14a, 14b, 14c, 14d and, if used as described below, reinforcement panels, may be formed of a self-reinforced polymer. Self-reinforced polymers (or polyolefins) are a particular family of thermocomposite materials in which both the reinforcing fibre and the polymer matrix are formed from the same polymer family. The fibres are manufactured as stretched, highly molecularly orientated form of the same polymer as the matrix. Self-reinforced polymeric composite materials possess many advantages including thermoformability, high stiffness, high tensile strength, and outstanding impact resistance at low density. Self-reinforced polymer materials are particularly impact resistant for a given weight or density of material. This may allow thinner sheets of material to be used, thereby reducing the overall weight of the cargo cover compared to manufacture from other materials providing equal protection. Furthermore the material can be melted and recycled, thus fulfilling requirements for use of more sustainable materials. Moreover, the self-reinforced material is waterproof.

It will be understood that, although the term ‘polymer’ and ‘self-reinforced polymer’ are used within this description, this could refer to any self-reinforced thermoplastic composite material. It could refer to any self-reinforced polymer or self-reinforced polymer composite or self-reinforced polyolefin. Particular examples of materials that could be used include self-reinforced polypropylene, or self-reinforced polyethylene.

Two main methods can be used for processing and production of self-reinforced polymer composites. In a first method, hot compaction is used, in which stretched fibres or strands of the polymer are aligned and layered, an then compressed together and heated to a precise temperature. This heating results in melting of only the outer layer or ‘skin’ of each strand or fibre, which has a lower melting point than the core of the strand or fibre. Heating causes around 10% of the strand or fibre to melt (at its outermost surface), and the applied pressure causes the molten polymer to flow around and between the fibres to form a continuous matrix. Once cooled, the polymer material of the matrix solidifies, and contains the strands or fibres.

A second method that can be used is co-extrusion. In this process, fibres or strands of the polymer in a highly-oriented form can be formed by extrusion. In addition, another grade of the same polymer can be extruded or coated on the surface of each fibre or strand. The polymer used for coating each strand is a lower melting point grade of the polymer than the higher melting point grade of the same polymer used for the fibres. As such, this results in coated stands of the same polymer material, which can be aligned and thermo-compressed together. Thermo-compression (heating and compression) causes the outer coating of each strand or fibre (comprising the lower-melting point type of the same polymer) to melt, but the core of each strand to remain solid. Compression during heating again causes the melted polymer of the outer coating to flow, and form a matrix in which the strands of the polymer are contained.

In some cases, sheets or panels of the self-reinforced polymer material may be built up by layering of self-reinforced polymer tapes formed in this way (in other words, lamination of multiple tapes), followed by compressing the layers of tapes under heat and pressure (i.e. thermo-compression of the laminated tapes). Sheets or panels of selfreinforced polymer formed in this way have many uses, as they provide a highly durable and strong material, which is lightweight. The thickness of such sheets or panels can easily be modified or adapted by layering and compression together of different numbers of layers of tapes of self-reinforced polymer.

A further composition of the self-reinforced polymer material has recently been developed. This is known as self-reinforced polymer woven composite. This makes use of yarns or threads formed of the fibres of the self-reinforced polymer materials as described above. The yarns or threads can be woven into a fabric or textile of the self-reinforced polymer material. For instance, the yarns or threads can be interlaced using a weave in a similar manner to standard textile or fabric formation. The woven yarns or threads can then be heated and compressed, in order to form bonds between the yarns or threads. In some cases, before weaving of said yarns or threads, multiple strands of the yarns or threads can be twisted or braided together to form a stronger, thicker yarn or thread (in the manner of forming a rope). The density and thickness of the self-reinforced polymer woven composite can be adapted by changing the thickness of the individual yarns and threads (by increasing the number of braided strands), or by changing the number of interlacing threads within a given unit area (in other words, changing the number of weaves per unit area, or pics per unit area). An example of self-reinforced polymer woven composite material is Dewforge™ by James Dewhurst™, which is a self-reinforced polypropylene woven composite (see https://www.jamesdewhurst.eom/2020/11/19/dewforge-james- dewhursts-easy-to-forge-srpp-woven-composite/, accessed 25 October 2021 )..

Both types of self-reinforced polymer (layered, and woven composite) may be used to form the main panel 12, side panels 14a, 14b, 14c, 14d or reinforcement panels of the cargo cover as described in the present application. Both types of self-reinforced polymer provides various the benefits, including a very high strength-to-weight ratio, being very durable but lightweight, even when provided as a thin sheet. Both types of self-reinforced polymer have high resistance to perforations, and do not retain and are not damaged by water (waterproof). Both are recyclable. However, the woven material has an added benefit of avoiding delamination that can sometimes be seen at exposed edges of typical, layered self-reinforced polymer materials sheets, in view of interlaced structure of the polymer threads or yarns. In contrast, use of a larger number of consolidated layers of the self-reinforced polymer material allows formation of thicker, stiffer panels of the selfreinforced polymer.

For the cargo cover described herein, the thickness and other properties of the selfreinforced polymer material may be chosen so that the main panel 12 and plurality of side panels 14a, 14b, 14c, 14d (and if used, the reinforcement panels in relation to certain embodiments below) are formed from a flexible self-reinforced polymer. Alternatively, the thickness and other properties of the self-reinforced material may be chosen to provide a main panel 12 and plurality of side panels 14a, 14b, 14c, 14d (and if used, reinforcement panels) that are stiff and rigid. In this case, the panels can be bent or warped, but are resilient and elastic, and so will be substantially planar when any deforming force is removed. The rigid panels may be preferable if the cargo cover is to be stacked.

Where, the main panel 12 and side panels 14a, 14b, 14c, 14d (and if used, reinforcement panels in relation to certain embodiments below) are formed as a net in a single piece of self-reinforced polymer (as in the cargo cover of FIGURE 1 (a)), the panels are separated by the formation of hinges or folds 16. The hinges 16 may be formed by applying heat and/or pressure to at least one area on the surface of the net shape formed of the self-reinforced polymer. The heat and/or pressure is applied only at the required position of the pivot of the hinge. Preferably, when forming the hinges 16 the polymer material surrounding the one or more reinforcing fibres of the self-reinforced polymer are heated, ideally to a temperature above or equal to its melting point, and then allowed to cool. As an alternative, hinges 16 could be formed by a region of stitching in the net forming the cargo cover.

FIGURE 2(a) and 2(b) shows an alternative configuration for a cargo cover. Once again, the cargo cover comprises a main panel 12 and four side panels 14a, 14b, 14c, 14d. The panels are provided as a net cut from a single sheet or piece of self-reinforced polymer. In this example, a first 14a and second 14b of the side panels each extend from opposing sides of the perimeter edge of the main panel 12, wherein the main panel 12 is separated from each of the first 14a and the second 14b of the side panels by a hinge or fold 16. A third 14c and fourth 14d side panels are then each attached to one of the first 14a and second 14b side panels, respectively. For example, the third side panel 14c extends from a portion of the perimeter edge of the first side panel 14a, such that the third side panel 14c extends in a direction perpendicular to the extension of the first side panel 14a from the main panel 12.

Fasteners 18 are arranged at certain edges of the main panel 12 and side panels 14a, 14b, 14c, 14d, as described further below. In this example, the fasteners 18 are zip fasteners.

Tabs 20 are shown in FIGURE 2(a) and 2(b), extending from the first 14a and the second 14b side panels that are directly connected to the main panel 12, at an edge of the given side panel 14a, 14b that is distal from the main panel 12. It will be understood that such tabs 20 are beneficial but not essential. The tabs 20 are hingedly connected to the respective side panel 14a, 14b.

In use, the main panel 12 of the cargo cover can be placed on top of a load arranged on a pallet 10 or inside a roll cage. The main panel 12 thereby overlies the load or cargo. The first 14a and second 14b side panels hang down opposing sides of the load, akin to wings from the main panel 12. Each of the third 14c and fourth 14d side panels may then be folded around the remaining sides of the load, in the manner of a door hinged to the respective first 14a or second 14b side panel.

Once the side panels 14a, 14b, 14c, 14d have been folded into position around a load, an edge of the main panel 12 is adjacent an edge of the third side panel 14c, and another edge of the main panel 12 is adjacent an edge of the fourth side panel 14d. A fastener 18 at these edges (here a zip fastener, although a hoop-and-loop fastener or press studs, for instance, could also be used) can be joined to connect these edges. Moreover, when the cargo cover in used to surround or enclose a load, an edge of the third side panel 14c is adjacent an edge of the second side panel 14b, and an edge of the fourth side panel 14d is adjacent an edge of the first side panel 14a. These edges can be secured together by the coupling of a further fastener 19 (here a zip fastener, although other types of fastener could be used). Thus the described cargo cover surrounds five sides or faces of the cubic load arranged on the pallet 10 as shown in FIGURE 2(b) (with the sixth face of the load being in contact with the pallet). It will be understood that an equivalent configuration of the cargo cover could be arranged around a roll cage.

FIGURE 2(a) and 2(b) show optional loops 22 attached to the outer surface of the side panels 14a, 14b, 14c, 14d. As in the example of FIGURE 1 (a) and 1 (b), such loops 22 can be used to allow a strap 24 to be threaded through the loops 22 and then the body of the pallet 10 on which the load is mounted. This secures the cargo cover into place.

It will be understood that when not in use, the cargo cover can be folded at the described hinges 16 so that each of the main panel 12 and side panels 14a, 14b, 14c, 14d overlap each other. Thus the cargo cover can be collapsed for easy storage until reuse.

FIGURE 3(a) and 3(b) shows a further example for a cargo cover for a load on a pallet 10 or in a roll cage. In this example, the arrangement of the main panels 12 and side panels 14a, 14b, 14c, 14d are similar to that described with respect to the example cargo cover in FIGURE 1 (a) and 1 (b). However, the fasteners at adjacent edges of the side panels 14a, 14b, 14c, 14d in this example comprise a flap 28 at an edge with a hook and look fastener, connecting to another cooperating hook and look fastener 26 on the surface of an adjoining side panel 14a, 14b, 14c, 14d. The main 12 and side panels 14a, 14b, 14c, 14d are formed as a net in a single sheet or piece of self-reinforced polymer material.

Furthermore, the example at FIGURE 3(a) and 3(b) includes reinforcement panels 30a, 30b, 30c, 30d. A reinforcement panel 30a, 30b, 30c, 30d is connected to extend from each side panel 14a, 14b, 14c, 14d, at an edge that is distal from the main panel 12. The reinforcement panels 30a, 30b, 30c, 30d are cut from the same sheet of self-reinforced polymer as the main 12 and the side panels 14a, 14b, 14c, 14d, with the reinforcement panels 30a, 30b, 30c, 30d separated from an adjoining side panel by a fold or hinge 16.

In use, as before with respect to the example of FIGURE 1 (a) and 1 (b), the main panel 12 of the cargo cover can be placed on top of a load arranged on a pallet 10 or inside a roll cage. The main panel 12 thereby overlies the load or cargo. The side panels 14a, 14b, 14c, 14d are then arranged to hang down the sides of the load or cargo. However, in the configuration of the cargo cover shown in FIGURE 3(a) and 3(b), the hinge 16 between each side panel 14a, 14b, 14c, 14d and adjoining reinforcement panel 30a, 30b, 30c, 30d is bent before securing the side panels 14a, 14b, 14c, 14d around the load, so that each reinforcement panel 30a, 30b, 30c, 30d is bent back to overlap respective, joined side panel 14a, 14b, 14c, 14d (in other words, so that the reinforcement panel 14a, 14b, 14c, 14d folds inside and is arranged parallel to and facing the side panel 30a, 30b, 30c, 30d).

Once each of the side panels 14a, 14b, 14c, 14d and reinforcement panels 30a, 30b, 30c, 30d have been arranged as described, the side panels may be secured to each other using the fastener at adjoining edges. Here, a hoop-and-loop fastener at the flap 28 on the edge of a particular side panel may attach to a cooperating hoop-and-loop fastener 26 at the outer surface of an adjoining side panel. In this way, the cargo cover is securely closed around the load, with the reinforcement panels 30a, 30b, 30c, 30d tucked under each side panel 14a, 14b, 14c, 14d.

Accordingly, the described reinforcement panels 30a, 30b, 30c, 30d each provide a second layer for the respective side panel 14a, 14b, 14c, 14d, to provide additional protection from penetration and damage to the goods within the cargo cover. Moreover, the overall structure of the cargo cover (once the side panels are fastened together) is provided with greater rigidity as a result of the reinforcement panels 30a, 30b, 30c, 30d, but without increasing the thickness and stiffness of each side panel individually (which would be less advantageous for collapsing or folding the cargo cover when not in use). Increasing the rigidity of the cargo cover when in use may allow stacking of pallets enclosed by the pallet covers, for instance, without crushing of the load protected by the cover.

Although not shown, the example of FIGURE 3(a) and 3(b) may include loops at the outer surface of the side panels 14a, 14b, 14c, 14d for use with a strap to secure the cargo cover to a pallet or roll cage. Alternatively, other types of fastener could be used.

Optional tabs 20 are shown in FIGURE 3(a) and 3(b), In this example, said tabs 20 can be provided as cut outs from the reinforcement panels 30a, 30b, 30c, 30d. The tabs 20 provide a function as described above, to slot into a portion of the pallet or roll cage, or under the load to secure the cargo cover. Tabs 20 provided as cut outs in this way may be reinforced by application of a further layer of self-reinforced polymer on their surface, in order to stiffen the tab and the hinged connection of the tab to the side panel 14a, 14b, 14c, 14d.

FIGURE 4(a) and 4(b) shows a still further example of the configuration of the cargo cover. In this example, the arrangement of the main panel 12 and side panels 14a, 14b, 14c, 14d are similar to that described with respect to the example cargo cover in FIGURE 2(a) and 2(b). However, in this example, the fasteners between adjacent edges of the side panels, when the cargo cover is in use, are zip fasteners 18, but the main panel 12 connects to an adjacent edge of the side panel 14a, 14b, 14c, 14d, when the cargo cover is in use, by way of a flap 40 and buckles 32.

Moreover, the example of FIGURE 4(a) and 4(b) comprises four reinforcement panels 30a, 30b, 30c, 30d. The main panel 12, side panels 14a, 14b, 14c, 14d and reinforcement panels 30a, 30b, 30c, 30d are formed as a net in a single sheet or piece of self-reinforced polymer material. Each reinforcement panel 30a, 30b, 30c, 30d is hingedly connected to an edge of a side panel 14a, 14b, 14c, 14d, and to an edge of an adjacent reinforcement panel, so that a pair of reinforcement panels are connected to pairs of adjacent side panels. When the cargo cover is in use, the reinforcement panels 30a, 30b, 30c, 30d fold over to be aligned with the adjacent side panels 14a, 14b, 14c, 14d. When the side panels are secured to each other around the load on the pallet or roll cage, a given reinforcement panel 30a, 30b, 30c, 30d is then folded inside and parallel to the inner face of a respective side panel 14a, 14b, 14c, 14d.

Once again, use of reinforcement panels 30a, 30b, 30c, 30d in this way provides a cargo cover that offers greater protection. Moreover, the cover is highly durable and resilient to penetration and impacts, thus avoiding damage to loads under the pallet cover during transportation.

Optionally, a further fastener (not shown in FIGURE 4(a) or 4(b)) could be used to secure the cargo cover, when in use, to the body of the pallet or roll cage.

FIGURE 5(a) and 5(b) show a yet still further example of the configuration of the cargo cover. In this example, the arrangement of the main panel 12 and side panels 14a, 14b, 14c, 14d are similar to that described with respect to the example cargo cover in FIGURE 2(a) and 2(b), being formed in a single piece of self-reinforced polymer. No specific fasteners are shown in FIGURE 5(a) and 5(b) to connect adjacent edges of the side panels when the cargo cover is in use. However, it will be understood that any suitable fastener may be used for this purpose.

Compared to the example cargo cover of FIGURE 2(a) and 2(b), the cargo cover of FIGURE 5(a) and 5(b) further comprises four reinforcement panels 30a, 30b, 30c, 30d, also formed in the self-reinforced polymer. A first 30a and a second 30b reinforcement panel extend from the first 14a and the second 14b side panel connected directly to the main panel 12. In particular, each of the first 30a and second 30b reinforcement panels extend from the edge of the given side panel 14a, 14b so that it is distal the main panel 12. A third 30c and fourth 30d reinforcement panel extend from the same first 14a and second 14b side panels, from the edge of the first 14a and second 14b side panel distal the connected respective third 14c or fourth 14d side panel. In use, the first 30a and the second 30b reinforcement panel are folded to overlap the respective first 14a or second 14b side panel connected to the main panel 12. The third 30c and fourth 30d reinforcement panels then wrap around the load on the pallet or in the roll cage, to overlap with the third 14c or the fourth 14d side panel attached to the opposite side of the main panel 12. In this way, the third and fourth reinforcement panel 14c and respective side panel 30c create “doors” hinged at opposing sides of a face of the pallet or roll cage. This may be useful for access to a load arranged on a pallet or in a roll cage, and that is covered by the cargo cover.

FIGURE 6(a) and 6(b) shows another example configuration for the cargo cover, formed as a net in a single piece of self-reinforced polymer. In this example, the arrangement of the main panel 12 and side panels 14a, 14b, 14c, 14d are similar to that described with respect to the example cargo cover in FIGURE 1 (a) and 1 (b). However, in this example, four reinforcement panels 30a, 30b, 30c, 30d are provided. A first 30a and a fourth 30d reinforcement panel extend from opposite edges of a first 14a of the side panels connected to the main panel 12. A third 30c and a second 30b reinforcement panel extend from opposite edges of a second side panel 14b, the second side panel 14b extending from the main panel 12 opposite to the direction of extension of the first side panel 14a. In each case, the reinforcement panels 30a, 30b, 30c, 30d extend from the side panels 14a, 14b in a direction perpendicular to the extension from the main panel 12 of the side panel 14a, 14b to which they are attached. As such, the first 30a and second 30b, and the third 30c and fourth 30d reinforcement panels provide ‘wings’ to the first 14a and second 14b side panel respectively.

In use, as before with respect to the example of FIGURE 1 (a) and 1 (b), the main panel 12 of the cargo cover can be placed on top of a load arranged on a pallet or inside a roll cage. The main panel 12 thereby overlies the load or cargo. The side panels 14a, 14b, 14c, 14d are then folded to hang down the sides of the load or cargo. However, in this example, the reinforcement panels 30a, 30b, 30c, 30d extending from the first 14a and second 14b side panel are each folded, either back over the side panel to which they are attached, or around the adjacent face of the load, so as to overlap with one of the side panels.

In the particular example shown in FIGURE 6(a) and 6(b), the side panels 14a, 14b, 14c, 14d are held around the load using a lashing or strap 38. However, other types of fastener could be used. In the example of FIGURE 6(a) and 6(b), apertures or holes 36 are provided in the side panels 14a, 14b, 14c, 14d, through which a strap 38 can be threaded. As illustrated in FIGURE 6(b), the strap 38 can extend around the whole load, passing through the apertures 36 at each side panel 14a, 14b, 14c, 14d. When tightened (for instance, by use of a buckle (not shown)), the strap 38 securely pulls the side panels 14a, 14b, 14c, 14d closely around the load. In an alternative, the apertures 36 could be used to receive separate straps at each corner of the load.

Although a number of specific configurations are described above for the main panel 12, the plurality of side panels 14a, 14b, 14c, 14d and in some cases the plurality of reinforcement panels 30a, 30b, 30c, 30d, it will be understood that still other configurations for the panels are possible. Ideally, in configurations including reinforcement panels 30a, 30b, 30c, 30d, each reinforcement panel is configured to overlap a different side panel 14a, 14b, 14c, 14d when the cargo cover is in use. This may be beneficial for providing greater protection for a load, as well as a more rigid cargo cover.

FIGURE 7 shows a series of photographs of a prototype model of the cargo cover in the example of FIGURE 6(a) and 6(b). The series of photographs show the way in which the cargo cover can be folded, when not in use to cover a load. The folded cargo cover reduces to a small volume for storage or transportation.

FIGURE 8(a) and 8(b) shows another example configuration for the cargo cover. The configuration for the cargo cover shown in FIGURE 8(a) and 8(b) is similar to the configuration of the cargo cover of FIGURE 1 (a) and 1 (b). In particular, the configuration for the cargo cover in FIGURE 8(a) and 8(b) comprises a main (or central) panel 12 and four side (or wing) panels 14a, 14b, 14c, 14d. Each of the side panels 14a, 14b, 14c, 14d extends from the main panel 12, at a different side or portion of the perimeter edge of the main panel 12. The main 12 and side panels 14a, 14b, 14c, 14d are formed as a net in a single sheet or piece of self-reinforced polymer material. The main 12 and side panels 14a, 14b, 14c, 14d are defined by hinges (or folds) 16 formed in the net, to divide the net into the separate panels.

Compared to the example shown in FIGURE 1 (a) and 1 (b), the configuration in FIGURE 8(a) and 8(b) additionally includes flaps 80 at a portion of the perimeter edge of each of the side panels 14a, 14b, 14c, 14d. The flaps 80 are arranged at the edge of a side panel 14a, 14b, 14c, 14d that will be adjacent to and parallel with another side panel 14a, 14b, 14c, 14d when the cargo cover is in use to cover a load. In use, the flaps 80 are arranged to wrap around the corner of the load, to overlap (underneath or over the top of) the adjacent side panel 14a, 14b, 14c, 14d. This avoids gaps in the cargo cover, when in use, at the vertical corners of the load.

The embodiment of FIGURE 8(a) and 8(b) further shows an additional portion or layer of self-reinforced polymer (known as a bracing panel 82) over each hinge 16 connecting the main panel 12 to the side panels 14a, 14b, 14c, 14d. One or more bracing panel 82 can be used to connect the main panel 12 to each side panel 14a, 14b, 14c, 14d, in a configuration of the cargo cover in which the main panel 12 and side panels 14a, 14b, 14c, 14d are formed from separate portions or sheet of self-reinforcing polymer. However, a bracing panel 82 can still be applied to cover the hinge 16, even if the main panel 12 and side panels 14a, 14b, 14c, 14d are formed from a single piece of self-reinforced polymer. In both cases, the bracing panel 82 acts to stiffen and provide shape to the region of the cargo cover at the hinge or corner portions. This, in turn, has been found to make the cargo cover easier to attach to and cover a load, as well as providing protection for the corner regions of the cargo cover which are more susceptible to wear and impact in use. The bracing panel also aids the alignment of the cargo cover over a load as the cargo cover is being applied to the load.

The bracing panels 82 in FIGURE 8(a) and 8(b) are shown as strips covering each hinge 16 and an adjacent portion of the main panel 12 and the side panels 14a, 14b, 14c, 14d. However, it will be understood that a single bracing panel 82 could be used that covers the whole of the main panel 12, each of the hinges 16, and a portion of each side panel 14a, 14b, 14c, 14d. In this case, the main panel 12 and bracing panel 82 could represent one and the same panel, having greater stiffness compared to the side panels 14a, 14b, 14c, 14d, and to which the side panels are attached.

The embodiment of FIGURE 8(a) and 8(b) also shows a different type of fastener than the embodiment of FIGURE 1 (a) and 1 (b). The embodiment of FIGURE 8(a) and 8(b) shows straps 84 and buckles 86, connected to the tabs 80 at each of two opposing side panels 14a, 14b, 14c, 14d. In use, connection of the buckles 86 and tightening of the straps 84 allows the cargo cover to be pulled tightly around the load, as shown in FIGURE 8(b).

FIGURE 9(a) and 9(b) shows another example configuration for the cargo cover. The configuration for the cargo cover shown in FIGURE 9(a) and 9(b) is similar to the configuration of the cargo cover of FIGURE 8(a) and 8(b). In particular, the configuration for the cargo cover in FIGURE 9(a) and 9(b) comprises a main (or central) panel 12 and four side (or wing) panels 14a, 14b, 14c, 14d. Each of the side panels 14a, 14b, 14c, 14d extends from the main panel 12, at a different side or portion of the perimeter edge of the main panel 12. The main 12 and side panels 14a, 14b, 14c, 14d are formed as a net in a single sheet or piece of self-reinforced polymer material. The main 12 and side panels 14a, 14b, 14c, 14d are defined by hinges (or folds) 16 formed in the net, to divide the net into the separate panels. The embodiment of the cargo cover shown in FIGURE 9(a) and 9(b) has a bracing panel 82. In this embodiment, the bracing panel 82 extends across the whole planar surface of the main panel 12, over the hinges 16, and over a portion of the surface of each side panel. Again, the bracing panel 82 acts to stiffen and provide shape to the hinges 16, and in this case also to stiffen the main panel 12. This type of bracing panel has been found to improve the usability of the cargo wrap, making it easier to wrap a load. Moreover, the bracing panel 82 provides protection to the corners of the cargo wrap covering a load, which can be prone to abrasion.

It should be noted that the main panel 12 and bracing panel 82 may be the same panel, such that the main panel 12 is formed from a stiffer self-reinforcing polymer than the side panels, and the main panel 12 has wings extending over the hinges 16 to be connected to the side panels 14a, 14b, 14c, 14d at a seam 92. The seam 92 could be formed by stitching, sonic welding or heat welding. If by stitching, the seam 92 can be covered by a polymer glue in order to waterproof the seam.

Similar to FIGURE 8(a) and 8(b), in the embodiment of FIGURE 9(a) and 9(b) the side panels 14a, 14b, 14c, 14d comprises flaps 80 extending from a portion of the perimeter edge which is adjacent another side panel 14a, 14b, 14c, 14d, when the cargo cover is in use. When the cargo cover is in use the flaps 80 wrap around the corner of the load, to overlap the adjacent side panel 14a, 14b, 14c, 14d. Each flap 80 comprises a strengthening panel 90 extending along its length. The strengthening panel 90 may be connected to either the outer or inner face of the tab 80. The strengthening panel may help to disperse the tension created by a fastener (such as buckles 86 and straps 84) when fastening the cargo cover over the load.

FIGURE 10 shows a photograph of the embodiment of the cargo cover of FIGURE 9(a) and 9(b) when in use.

It will be understood that the bracing panels 82 described in respect of FIGURE 8(a), 8(b), 9(a), 9(b) and 10, could be applied to any of the embodiments discussed with respect to FIGURES 1 (a) to 7. In particular, the bracing panels 82 strengthen and reinforce the hinge 16 between the main panel 12 and each of the side panels 14a, 14b, 14c, 14d. In every case, the configurations for the cargo cover discussed with respect to FIGURES 1 (a) to 7, above, could be formed by separate main panel 12 and side panels 14a, 14b, 14c, 14d, wherein the main panel 12 comprises a thicker, stiffer panel than the side panels 14a, 14b, 14c, 14d, and wherein the main panel 12 is the bracing panel 82 covering the whole of the top surface of the load when in use. As noted above, the thickness of self-reinforcing polymer material used for the main panel 12, side panels 14a, 14b, 14c, 14d and any reinforcing panels 30a, 30b, 30c may be selected to provide appropriate flexibility. In specific examples of the configurations shown in FIGURE 1 (a) to FIGURE 10, the self-reinforcing polymer may have a thickness of between 0.12 and 1 mm. In some cases, the self-reinforced polymer may comprise one, two, three or more consolidated layers of the self-reinforced polymer material. The tabs 20 attached to the side panels 14a, 14b, 14c, 14d may be formed from a thicker self-reinforced polymer having thicknesses of around 0.5 mm to 2 mm, and may comprise 4 to 8 consolidated layers of self-reinforced polymer. The bracing panel 82, as described with respect to the embodiments of FIGURE 8(a) and 8(b), and FIGURE 9(a) and 9(b) may be formed of self-reinforced polymer having a thickness of 0.3 mm to 1 .5 mm, and formed of 2 to 8 consolidated layers of self reinforced polymer. For every element, the self-reinforced polymer may be self-reinforced polypropylene.

It will be understood that the straps shown in any of the embodiments described above could themselves be formed of self-reinforced polymer. In some circumstances, the straps may comprise ‘U’ or ‘V’ shaped cut outs, which interact with a buckle to tension the strap in a ratcheting motion.

The embodiments of the cargo cover above may be formed of a flexible selfreinforced polymer, which can be bent or folded in the manner of a tarpaulin. However, there is also a desire for a rigid cargo cover, which, when covering a load, allows loads to be stacked. Moreover, such rigid cargo covers may provide even greater impact resistance for a load. Each of the configurations for the cargo cover described above with respect to FIGURES 1 (a) to FIGURE 10 could be formed having rigid main 12 and side panels 14a, 14b, 14c, 14d. However, we below focus on some specific examples of the cargo cover which may be specifically beneficial if a rigid main panel 12 and side panels 14a, 14b, 14c, 14d are used.

A rigid panel can be formed comprising self-reinforced polymer. In one example, a rigid main panel 12 and side panels 14a, 14b, 14c, 14d may be formed from a thicker layer of the self-reinforced polymer than described above. For instance, the main panel 12 or side panels 14a, 14b, 14c, 14d could be formed using a self-reinforce polymer having a thickness of 1 .5 mm to 5 mm, which may be formed using 10 to 35 consolidated layers of self-reinforced polymer.

As an alternative, the main panel 12 and side panels 14a, 14b, 14c, 14d may comprise a layered structure. A first example for a layered configuration of the main and/or side panels is shown in FIGURE 11 (a). The panel of FIGURE 11 (a) comprises a layer of foam 110 arranged between a first 112 and a second 114 layer of self-reinforced polymer. For example, a layer of expanded polypropylene may be arranged between a first and second layer of self-reinforced polypropylene. The first 112 and second 114 layer of selfreinforced polymer and the layer of foam 110 may be bonded together by heating and compression, causing some flow of polymer at the interfaces between the self-reinforced polymer 112, 114 and the foam layer 110 which create bonds between the layers once the polymer cools.

Preferably, the first 112 and second 114 layer of self-reinforced polymer will have a thickness of 0.15 to 0.9 mm, and may be formed from 1 to 6 consolidated layers. More preferably, the first 112 and a second 114 layer of self-reinforced polymer will have a thickness of 0.2 to 0.6 mm, and may be formed from 2 to 4 consolidated layers. The first and second layer of self-reinforced polymer may have different thicknesses and comprise different numbers of consolidated layers. The foam layer 110 may be 6 to 12 mm thick. Examples of the self-reinforced polymer layer 112, 114 include self-reinforced polypropylene, or self-reinforced polyethylene. Examples of the foam layer 110 may include expanded polypropylene, or ethylene-vinyl acetate foam.

The layered structure of FIGURE 11 (a) can be formed by stacking each of the first 112 and second 114 layer of self-reinforced polymer and the foam layer 110, and then bonding the layers by application of heat and pressure to the stack. Alternatively, the first 112 and a second 114 layer of self-reinforced polymer could be arranged within the body of a mould, with the foam layer 110 inserted in between the first and second layer of selfreinforced polymer by injection of the foam material.

In another example, the layered structure in FIGURE 11 (a) may be arranged between further third 116 and fourth 118 layers of self-reinforced polymer. For instance, a further third 116 and fourth 118 layer of self-reinforced polymer may be loosely arranged over and under the layered panel 120 of FIGURE 11 (a) (so that the layered panel 120 of 11 (a) is between the further third 116 and fourth 118 layer of self-reinforced polymer). The further third 116 and fourth 118 layers of self-reinforced polymer and the layered panel 120 may be joined by stitching 122 through the layers, for instance at the perimeter of each panel and/or as a seam across only a portion of the face of the panel. Air cooled needles may be used for stitching said seam. Seams could instead be formed by heat welding, ultrasonic welding or localised heat and compression (localised to only the region of the seam).

Preferably, the third 116 and fourth 118 layers of self-reinforced polymer may have a thickness of between 0.5 and 2 mm. The third 116 and fourth 118 layers of self- reinforced polymer may comprise 4 to 12 consolidated layers of self-reinforced polymer, and more preferably 6 to 10 consolidated layers.

The embodiment of FIGURE 1 1 (b) provides a layered panel that is robust and strong. Superior protection for a load within a cargo cover is provided by having main 12 and side 14a, 14b, 14c, 14d panels formed from the layered structure. The inner layered panel 120 of FIGURE 1 1 (a) provides significant rigidity to the ultimate layered structure in FIGURE 1 1 (b), whilst the further layers of self-reinforced polymer, being loosely arranged compared to the inner layer structure of FIGURE 11 (a) and joined only at specific seams, offers a greater level of resilience and flexibility than simply using thicker self-reinforced polymer material in the layered structure of FIGURE 11 (a).

FIGURE 12(a) and 12(b) show cross-sectional views of a cargo cover similar to that of the example of FIGURE 1 (a) and 1 (b). However, in the cargo cover of FIGURE 12(a) and 12(b) the side panels 14b, 14d extend so as to reach the base portion of the pallet 10 on which the load 120 is mounted. In other words, the cargo cover extends almost to the surface on which the pallet 10 rests.

FIGURE 12(a) and 12(b) further illustrate the function of the tab 20 at the side panels. Here, the tab 20 is arranged to extend perpendicular to the face of the side panels 14b, 14d. The tab 20 may be formed as a cut-out from the side panel (as illustrated at FIGURE 13, for instance), or as a separate panel that is connected to an inner surface of the side panel. In any case, the tab 20 is hingedly attached to the side panel 14b, 14d. In an example, the tab 20 extends around 5 cm from the surface of the side panel.

When the cargo cover is in use, the side panels 14a, 14b, 14c, 14d are arranged to cover a side face of the load 120. The tabs 20 may be inserted between the load 120 and the pallet 10, as shown in FIGURE 12(b), in order to lock the cargo cover into place. The weight of the load 120 secures the cargo cover on the pallet 10 over the load 120. In an alternative configuration not shown in FIGURE 12(a) or 12(b), the tabs 20 may extend into the framework of the pallet 10 on which the load 120 is mounted.

FIGURE 13 shows a further configuration for the cargo cover. The arrangement of the main panel 12 and four side panels 14a, 14b, 14c, 14d are similar to the example of FIGURE 1 (a) and 1 (b). However, in the example of FIGURE 13, each side panel 14a, 14b, 14c, 14d is designed to extend to the base of the pallet 10. This helps to firmly hold the cargo cover and the load in place on the pallet 10 and against the side of the load. Moreover, the embodiment of FIGURE 13 may comprise rigid panels, for instance formed having the layered structure of FIGURE 11 (a) or 1 1 (b), or flexible panels. The panels may be joined at hinges 16, or formed from a single piece of self-reinforced polymer. In the example of FIGURE 13, tabs 20 are formed as cut outs from each side panel 14a, 14b, 14c, 14d. Each tab 20 is hingedly connected to the side panel 14a, 14b, 14c, 14d. Preferably the position and size of the cut-outs forming the tabs 20 are selected to allow entry for the fork of a fork-lift truck, for lifting the pallet when the pallet cover is in use.

In a further example, the side panels (being substantially rigid panels) may be connected by a fastener (rotatable fastener). The fastener will be described now by reference to FIGURES 13A and 13B.

In particular, there is a fastener, for coupling a first panel perpendicularly to a second panel, the fastener may comprise: a rotatable planar element, formed of self-reinforced polymer, the rotatable element rotatable around a pivot pin trough the rotatable element, the pivot pin connecting the rotatable element to a planar surface of the first panel; wherein the pivot pin is positioned at the planar surface of the first panel and at a point through the rotatable element so that: when the rotatable element is in a first position, a portion of the rotatable element protrudes beyond an edge of the planar surface of the first panel, so that the portion of the rotatable element protruding beyond the edge of the planar surface of the first panel is received in a groove or opening at a planar surface of the second panel, the planar surface of the second panel being perpendicular to the surface of the first panel; and when the rotatable element is in a second position, the second position being a rotation of the rotatable element around the pivot pin form the first position, no portion of the rotatable element protrudes beyond the edge of the planar surface of the first panel to the extent that it is received in the groove or opening at the planar surface of the second panel.

The rotatable element may be formed of self-reinforced polymer having a thickness of 0.5 to 2 mm. The rotatable element may be formed of 3 to 10 consolidated layers of self-reinforced polymer. The self-reinforced polymer may be self-reinforced polymer woven composite.

FIGURE 13A is a schematic diagram of such a fastener connecting a first panel 2005 and as second panel 2010. It will be understood that the first panel 2005 is planar, having a plane extending substantially parallel to the page, whereas the second panel 2010 is planar but shown in cross-section, having a plane extending substantially perpendicular to the page. The fastener has a rotatable element 2000 being a planar piece or disc of selfreinforced polymer. In the example of FIGURE 13A, the rotatable element 2000 is shaped as a chord of a circle (in other words, an incomplete circle, having a line segment removed). However, other shapes for the rotatable element 2000 can be envisaged, providing they have the functional characteristics described. The rotatable element 2000 is connected to a first panel 2005 via a pin 2015, which acts as a pivot for rotation.

As noted above, the second panel 2010 is arranged so that the plane of the second panel is substantially perpendicular to the plane of the first panel 2005. A groove 2020 is arranged in the planar face of the second panel 2020, directly below the position of the rotatable element 2000 connected to the first panel 2005.

In use, the rotatable element 2000 can be configured in a first position, as shown in FIGURE 13A(a). In this case, the curved edge of the rotatable element 2000 protrudes beyond the bottom edge of the first panel 2005, and into the groove 2020 in the second panel 2010. This secures the relative position of the first panel 2005 with respect to the second panel 2010, so that the first panel 2005 is held perpendicular relative to the second panel 2010.

Furthermore, the rotatable element 2000 can be configured in a second position, as shown in FIGURE 13A(b). In this case, the flat edge of the line segment of the rotatable element 2015 is positioned above the groove 2020 in the second panel 2010. As such, no portion of the rotatable element 2000 protrudes into or engages the groove 2020 in the second panel 2010. Accordingly the first panel 2005 can be easily moved relative to the second panel 2010, as there is no fastening therebetween.

The described catch may be especially useful to fasten rigid panels that are already connected or hinged together by some other means. For instance, the described catch may be especially useful to secure two side panels of the cargo cover of FIGURE 13. For instance, the described catch of FIGURE 13A could be applied between the edge of two adjoining panels 14a, 14b in place of the fastener 18 shown in FIGURE 13. However, the rotatable catch shown in FIGURE 13A can also be used together with various other of the described configurations for the cargo cover, especially those with rigid or semi-rigid side and/or main panels.

FIGURE 13B shows photographs of the described catch for connection of two panels, being a first 2005 and a second panel 2010. A rotatable element is connected to the first panel via a pin or pivot 2015. FIGURE 13B(a) shows the rotatable element 2000 in a first position, in which the rotatable element 2000 does not engage with a groove 2020 at the second panel 2010. FIGURE 13B(b) shows the rotatable element 2000 rotated to a second position, so that a portion of the rotatable element 2000 protrudes beyond the bottom edge of the first panel 2005, and engages with the groove 2020 at the second panel. FIGURE 13B(c) shows the first 2005 and second 2010 panel disconnected, providing a view of the rotatable element 2000 at the first panel 2005 and the groove 2020 in the face of the second panel 2010. In the example of FIGURE 13B, a finger aperture 2025 is provided at the rotatable element 2000 in order to assist with rotation by the user.

FIGURE 14 show a further configuration for the cargo cover. In this case the cargo cover is not formed from a single piece of self-reinforced polymer. Instead, the main panel 12 and each of the four side panels 14a, 14b, 14c, 14d are formed separately, although from the same type of self-reinforced polymer material. Preferably, in this configuration of the cargo cover, each of the main panel 12 and side panels 14a, 14b, 14c, 14d is formed from a relatively rigid panel of self-reinforced polymer, for instance having a thickness of greater than 0.5 mm and/or formed of four or more heat-compressed, consolidated layers of self-reinforced polymer, for instance. The embodiment of FIGURE 14 may comprise rigid panels, for instance formed having the layered structure of FIGURE 11 (a) or 1 1 (b).

Each of the side panels 14a, 14b, 14c, 14d has dimensions suitable to extend to the base of the pallet or roll cage on which a load is mounted. Each side panel has cut outs 42, arranged to align with the position at which a fork of a fork-lift truck would be inserted to the framework of the pallet, in order to lift and move the pallet and load. The edges of the cut-outs 42 have edge reinforcement 44, for instance using a self-reinforced polymer tape, or a plastic moulding. In some examples, the cut-outs 42 may create a flap, hingedly attached to the side panel 14a, 14b, 14c, 14d, so as to provide a tab that can fold perpendicularly inwards from the face of the side panel.

The side panels 14a, 14b, 14c, 14d of the cargo cover of FIGURE 14 further include a flap 26 at one edge of their perimeter. Said flaps 26 comprises hoop-and-loop fastener, arranged to cooperate with hook-and-loop fastener 28 at the outer surface of an adjacent side panel, when the cargo cover is in use. The flaps 26 may be formed of a self-reinforced polymer material.

In the example of FIGURE 14, the main panel 12 comprises a flap 40 extending from each edge of its perimeter. On the flaps 40 is mounted hoop-and-loop fastening, to be connected to hoop-and-loop fastening 154 at an adjacent portion of a face of a side panel 14a, 14b, 14c, 14d, when the cargo cover is in use. The flap 40 includes pull loops 46, to assist a user to pull the flap 40 tightly around a corner of the cargo cover, when enclosing a load with the cargo cover. It will be understood that the flap 40 may be one continuous flap extending around the perimeter of the main panel 12, or may be separate flaps at each edge of the perimeter of the main panel 12.

Each side panel has a handle 48 mounted at its outer surface.

FIGURE 15 shows a cross-sectional view of the main panel 12 of the embodiment of the cargo cover of FIGURE 14. The main panel can be formed of the layered structure of FIGURE 11 (a) or 11 (b), although the layers are not shown in FIGURE 15. It can be seen that the flap 40 is connected to the main panel 12, such that it extends over a portion of the main panel 12. The flap 40 may be formed of self-reinforced polymer. Here the flaps 40 are shown as being bonded to the main panel 12 by stitching 150, although it will be understood that other methods (heat or ultrasonic bonding) could be used. A waterproofing glue or sealant could be applied over the stitching to water proof the main panel. A hoop and loop fastener 152 is arranged on the underside of the flap 40, for connection with a cooperating hoop-and-loop fastener 154 at the top of the outer surface of each side panel 14a, 14b, 14c, 14d.

Also shown in FIGURE 15 are stiff tabs 156, protruding from the undersides of the main panel 12. When the cargo cover is in use such that the main panel 12 is arranged to overlie the load, the tabs 156 are arranged inside the side panels. The tabs 156 act to align the main panel 12 with respect to the side panels 14a, 14b, 14c, 14d when the cargo cover is in use. The tabs 156 are hingedly attached to the main panel 12, so that they can be folded flat to the surface of the main panel 12 if not required. The tabs 156 may be formed of a thick portion of self-reinforced polymer, which is relatively stiff. The thick portion of self-reinforced polymer may have a thickness of 1 mm to 4mm, for instance. It will be understood that similar tabs can be arranged protruding from the inner face of the side panels, for instance to provide an abutment for an adjoining side panel (as shown as tab 190 in FIGURE 19(d)), or to slot into a portion of the pallet or roll cage.

Straps 158 can be seen in FIGURE 15. Straps 158 may have hoop-and-loop fastener to attach the straps to the hook-and-loop fastener 154 on the side panels, prior to the hook-and-loop fastener 152 on the flaps 40 being connected with the hook-and-loop fastener 154 on the side panels. As such, the straps 158 provide an initial connection, which acts as a secondary stabilising connection compared to the fastener at the flaps 40.

FIGURE 16 shows a photograph of the cargo cover in use, and mounted around a load on a pallet. The cargo cover has a main panel 12 and side panels 14b, 14c according to the configuration described in relation to FIGURE 15(a) and 15(b). It can be seen that flaps 26, on which a hoop-and-loop fastener is mounted, are used to connect adjacent side panels 14b, 14c. A flap 40, on which a further hoop-and-loop fastener is mounted, is used to connect the main panel 12 to the side panels 14b, 14c.

FIGURE 17 shows a photograph of a side panel 14a according to the configuration described in relation to FIGURE 15(a) and 15(b).

FIGURE 18(a) shows a photograph of the main panel 12 according to the configuration described in relation to FIGURE 15(a) and 15(b). FIGURE 18(b) shows a photograph of a corner of the main panel 12 of a cargo cover according to the configuration described above in relation to FIGURE 15(a) and 15(b). This main panel 12 is formed using the layered configuration of FIGURE 11 (b), and it can be seen that a stitched seam is formed as a cross on the surface of the panel, connecting the third and the fourth selfreinforced polymer layers to sandwich the layered structure 120 shown in Figure 1 1 (a).

FIGURES 19(a), 19(b), 19(c) and 19(d) shows a series of photographs of the cargo cover according to the embodiments discussed with reference to FIGURE 15(a) and 15(b). FIGURE 19(a) and 19(b) show the main panel 12 and two side panels 14c and 14b arranged to cover a load on a pallet. FIGURE 19(c) shows the main panel 12 before it is arranged on top of the side panels 14b, 14c.

In FIGURE 19(a) and 19(b) the two side panels 14b, 14c are shown in an upright position to align with the sides of the load, and the main panel 12 overlies the load and top edges of the side panels 14b, 14c. The two side panels 14b, 14c are connected at an upright corner by a flap 26, which extends from one of the side panels 14b around the corner to overlap the adjacent side panel 14c. The main panel 12 overlies the upper edge of the side panels 14b, 14c. T abs 156 are slotted inside the side panels 14b, 14c for alignment. A strap 158, connected to the main panel 12, is attached to hook-and-loop fastener 154 at the side panel 14b. The straps 158 act as an initial, stabilising connection between the main panel 12 and the side panels 14b, 14c, before flap 40 can be pulled down from the main panel 12, around the side panels14b, 14c. The flap 40 connected to the main panel 12 is shown in FIGURE 19(a) and 19(b) as being open, and not yet connected to the side panels 14b, 14c.

FIGURE 19(d) shows a portion of the inner surface of the side panel 14b, arranged with respect to a pallet 10 to which the cargo cover is to be connected. It can be seen that a stiff tab 190 protrudes from the inner surface of the side panel 14b. This tab 190 acts as an abutment for an adjacent side panel (which is not yet connected in FIGURE 19(d)), and also provides alignment to the pallet 10.

FIGURE 20(a) shows a photograph of the bottom corner of a side panel 14b, and FIGURE 20(b) shows a photograph of the same corner of a side panel 14b adjacent another side panel 14c, when the cargo cover is in use. The described cut out 42 can be seen clearly, arranged at a location at the base of the side panel 14b, 14c to allow a fork of a fork lift to carry the pallet 10 (and any mounted load) even when the cargo cover is applied. The reinforcement 44 of the edging of the cut out 42 can be seen in more detail.

FIGURE 20(b) shows a strap 160 for use in securing the cargo cover to a pallet 10. The strap 160 is attached to a corner of one side panel 14c using rivets. The strap 160 is threaded through a loop 22 at the outer surface of the adjoining side panel 14b. The strap 160 feeds though the body of the pallet 10, and can be tightened (via a buckle, not shown) to secure the cargo cover to the pallet 10.

FIGURE 21 shows a cargo cover 200 according to a further example. The cargo cover 200 includes a panel 210 (also called a main panel), comprising self-reinforced polymer. The panel 210 includes a plurality of side panels 212a, 212b, 212c, 212d, defined by a fold 214a, 214b, 214c, 214d between each side panel. The folds 214a, 214b, 214c, 214d extend the vertical height of the panel 210. Two straps 216a, 216b are arranged at one end of the panel 210, with cooperating buckles 218a, 218b arranged at the opposite end of the panel 210.

In use, the panel 210 can be wrapped around a load or cargo on a pallet or in roll cage. The panel 210 can then be secured in the wrapped configuration by connection of one of the straps 216a with a buckle 218a at the opposing end of the panel. When applied to a load, each fold 214a, 214b, 214c, 214d in the panel 210 aligns with a corner of the load. The cargo cover 200 provides a strong yet lightweight cover to protect the sides of a load, and also to hold or contain the load into place on the pallet or roll cage.

FIGURE 22 shows a further example of the cargo cover 300. As before, the cargo cover 300 includes a panel 310, comprising self-reinforced polymer. The panel 310 has a number of folds 314a, 314b, 314c, 314d dividing the panel 310 into side panels 312a, 312b, 312c, 312d or portions. As before, a fastener (being straps 316a, 316b and buckles 318a, 318b) are arranged at the panel 310 in order to allow the panel to be secured around the load when in use.

The cargo cover of FIGURE 22 also includes reinforcement panels 320a, 320b, 320c, 320d covering a portion of the surface of the panel 310, the portion of the surface of the panel 310 being around or in the vicinity of the folds 314a, 314b, 314c, 314d. The reinforcement panels 320a, 320b, 320c, 320d comprise self-reinforced polymer. The reinforcement panels 320a, 320b, 320c, 320d are arranged so that the folds 314a, 314b, 314c, 314d are replicated in the reinforcement panel 320a, 320b, 320c, 320d. The folds 314a, 314b, 314c, 314d (and reinforcement panels 320a, 320b, 320c, 320d) are arranged so that, in use, the reinforcement panels 320a, 320b, 320c, 320d and folds 314a, 314b, 314c, 314d are configured to be at the corner of a load mounted on a pallet or roll cage. The spacing of the folds 314a, 314b, 314c, 314d, d, is substantially the same as the dimensions of a pallet or roll cage on which the cargo cover will be applied (so that folds 314a, 314b, 314c, 314d align with the corners of the load).

FIGURE 27 to 28 shows photographs of a cargo cover 300 similar to that shown in FIGURE 22 when in use. As can be seen, the cargo cover panel 310 is wrapped around a load so as to have the folds 314a, 314b, 314c, 314d aligned at the corners of the load and the side panels 312a, 312b, 312c, 312d arranged at the sides of the load. Further aspects of the cargo cover shown in FIGURES 27 to 28 are discussed below.

FIGURE 23 shows a still further example of the cargo cover 400. This cargo cover 400 is similar to the cargo cover 300 of FIGURE 22, having a main panel 410 and a plurality of reinforcement panels 420a, 420b, 420c, 420d, each comprising self-reinforced polymer as described above. This example of the cargo cover 400 also comprises a strap 416a, 416b and buckle 418a, 418b fastener as described above.

Different to the example of FIGURE 22, the example of FIGURE 23 includes multiple folds 414a, 414b, 414c, 414d between one or more pairs of the side panels 416a, 416b, 416c, 416d. This is so that the spacing between the folds 414a, 414b, 414c, 414d may differ, according to the size of a load around which the cargo cover is to be wrapped. This may allow the cargo cover to be adapted to be used for the different standard pallet sizes used in different countries. In particular, a fold in a first set of folds may be spaced apart by a distance di from a first fold in a second set of folds. Here, distance di may be the standard dimension for the length and width of a pallet in a first country. The fold in the first set of folds may be spaced apart by a distance cfefrom a second fold in the second set of folds, wherein distance cfe is the standard dimension for the length and width of a pallet in a second country. Finally, the fold in the first set of folds may be spaced apart by a distance ds from a third fold in the second set of folds, wherein distance ds is the standard dimension for the length and width of a pallet in a third country. In this way, the cargo cover can be adaptable to fit pallet having the standard sizes typical in the US, in Europe or in the UK, which are all slightly different. The reinforcement panels 420a, 420b, 420c, 420d covers the portion of the surface of the main panel that encompasses each set of folds.

In addition, the cargo cover 400 of FIGURE 23 includes a base panel 426 and a lid panel 428. The base panel 426 and lid panel 428 could both be used, or only one or other could be used. The base panel 426 can be applied to underlie or be underneath the load once the main panel 410 is wrapped around the sides of a load. The lid panel 428 can be applied to overlie or be on top of the load once the main panel 410 is wrapped around the sides of a load. The base 426 and/or lid 428 panels can be attached using a fastener 422a and 424b, 424b and 422b, such as hook-and-loop fastener. The base 426 and lid 428 portions can provide additional protection for the load on a pallet or roll cage, and can also help to prevent ingress of moisture into the load from outside of the cargo cover.

The base 426 and/or lid 428 panel may be formed comprising self-reinforced polymer. The base 426 and/or lid 428 polymer may be formed of a different thickness of self-reinforced polymer than the main panel 410, for instance to increase the stiffness of the base 426 and/or lid 428 portion in comparison to the main panel 410.

It will be understood that in any of the examples for the cargo cover discussed above with reference to FIGURE 21 to 23, a further fastener or strap may be provided at the panel to attach the panel to a pallet or roll cage when the cargo cover is in use.

In all of the examples for the cargo cover referred to with respect to FIGURE 21 to 23, the panel (and in some cases, the reinforcement panel, the lid panel and the base panel) comprise self-reinforced polymer. The self-reinforced polymer may be any selfreinforced polymer (such as self-reinforced polypropylene, or self-reinforced polyethylene), including a self-reinforced polymer woven composite (such as Dewforge ^RTM ). The thickness of the self-reinforced polymer can be chosen according to the rigidity or stiffness required for the given panel, compared to its weight. In an example according to FIGURE 22, the main panel comprises a single layer of self-reinforced polymer, and each reinforcement panel comprises four thermo-compressed or consolidated layers of self-reinforced polymer. This means that the reinforcement panels are stiffer than the main panel, which can be helpful to provide additional protection to the corners of the load, and also to provide some structure to the cargo cover, when in use.

FIGURE 24 shows a cargo cover similar to that in FIGURE 22 when not in use to cover a load. Beneficially, the flexibility of the main panel 310 allows the cover to be easily rolled or folded up into a small volume for storage or transportation.

FIGURES 25(a), 25(b) and 26 show photographs giving more detail of the straps 316a and buckles 318a used to fasten the cargo cover around the load. In particular, the cargo cover is wrapped around the load, and the strap 316a is fastened through a buckle 318a and then tightened. Both the straps 316a and buckles 318a may be formed from or comprising the self-reinforced polymer. Ideally all aspects of the cargo cover are formed from the same type of self-reinforced polymer, as this allows for easier end of life recycling, without complex separation of materials. In some examples, the strap may be elastic or elasticated to allow the cargo cover to more tightly wrapped around a load. FIGURES 27, 28 and 29 show the cargo cover similar to that in FIGURE 22 in use when wrapped around a load on a pallet. It can be seen that the main panel 310 is wrapped around the side of the load. Reinforcement panels 320a are visible at the corners of the load, the reinforcement panels 320a comprising an additional panel applied to the outer surface of the main panel 310 in the vicinity of the folds. Folds 314d in the main panel 310 and reinforcement panel 320a align with corners of the load. The folds 314a may be made via perforation at the pivot of the fold (as shown in the example of FIGURE 22), or by other means such as by application of heat and pressure applied at the pivot of the fold.

A number of the cargo covers described above use straps and/or buckles to secure or fasten together different panels of the cargo covers. For instance, straps and buckles can be used to fasten the side panels of the cargo cover around the load (for example, but not limited to, straps 84, 216a, 216b, 316a, 316b, 416a, 416b and or buckles 86, 218a, 218b, 318a, 318b, 418a, 418b in FIGURES 8(a) and 8(b), 21 , 22 and 23). In other examples, straps and/or buckles can be used at the corner of different side panels, to be threaded through a pallet on which a load stands and over which the cargo cover is arranged. For instance, this use of a strap and/or buckle is shown in the example of FIGURE 1 with strap 24, and in the example of FIGURE 20(b) with strap 160.

Ideally, these straps and buckles will be formed from the same type of polymer as used in the panels of the cargo cover. This allows for more straightforward recycling of the cargo cover at end of life, because less separation of the various components (and types of polymer) is required. Thus, provision of the strap and buckles formed in the same type of polymer as the rest of the cargo cover reduces the environmental impact of the product.

Moreover, where straps and buckles are formed from the same type of polymer as used in the panels of the cargo cover, this allows for better bonding of different components. For instance, if the strap is formed from the same type of self-reinforced polymer as the panel of the cargo cover to which it was attached, connection can be made by heating and applying pressure to the strap and panel, which causes melting and mixing of the polymer at the interconnecting surfaces, and generation of chemical bonds upon cooling. The adhesion of said strap will be better when the same type of polymer is used than compared to use of different types of polymer. Moreover, adhesion in this way avoids use of different types of fastener (including stitching and adhesive), which can make end- of-life recycling more complex by introduction of additional types of materials. Some innovative configurations for a strap and buckle formed from self-reinforced polymer are shown in FIGURE 30 to 37. The buckles shown in these examples are particularly useful for joining an end of a strap to another entity.

FIGURE 30 shows a first example of a buckle 3000. The buckle is planar, and formed from self-reinforced polymer (for instance, cut from a panel of self-reinforced polymer). The buckle 3000 is formed from a rigid or stiff self-reinforced polymer.

Referring to FIGURE 30(a), the buckle has a body portion, comprising a hook portion 3010 and two spaced-apart and parallel elongate openings 3015a, b. The hook portion 3010 is arranged at an edge of the body portion that is at an opposite edge to that which the openings are adjacent. The two spaced-apart openings 3015a, b are dimensioned to allow a strap 3020 to pass therethrough. The hook portion 3010 is dimensioned to allow a strap (for instance, being part of an anchor loop 3025) to pass through the opening of the hook.

FIGURE 30(b) shows a plan view of the buckle 3000 when in use. In particular, a strap 3020 is connected to or retained in the body portion by being passed through the two spaced-apart and parallel elongate openings 3015a, b. FIGURE 30(c) shows a cross- sectional view of the buckle 3000 when in use, which illustrates an arrangement of the strap 3020 through the openings. In particular, the strap 3020 is passed through a first of the elongate openings 3015a in a first direction. In the example of FIGURE 30(c), the first elongate opening 3015a is the opening closer to the centre of the body of the buckle 3000. Next, the strap 3020 is passed through a second of the elongate openings 3015b in a second direction, where that second direction is opposite to the first direction. In this way, the strap 3020 is passed back upon itself and through the buckle 3000. Pulling on an end of the strap 3020 pulls the strap though the openings 3015a, b in the buckle 3000, to allow the length of the strap 3020 to be altered. In use, this allows the strap 3020 to be tightened or loosened around a load under the cargo cover, for instance.

Furthermore, in use, the buckle 3000 can be removabley connected to an anchor loop 3025 (which itself can be connected to an element 3035 such as a side panel of the cargo cover). The connection takes place by passing the hook portion 3010 of the buckle 3000 through an anchor loop 3025. If the strap 3020 is subsequently tightened then the hook portion 3010 is held firmly in place and in connection with the anchor loop 3025.

The buckle 3000, the strap 3020 and the anchor loop 3025 can together form the components of a fastener 3100. Each of the components may themselves be formed of or comprise self-reinforced polymer. This is beneficial for the reasons described above. Although the buckle 3000 is formed of a rigid or stiff form of self-reinforced polymer, the straps 3020 (including an anchor loop 3025 formed as a loop of strap) are formed of bendable, flexible self-reinforced polymer. The resilience of the self-reinforced polymer can be modified by changing the thickness of the self-reinforced polymer material. For instance, the strap 3020 and anchor loop 3025 can be formed from a strip of a thin panel of self-reinforced polymer (for example, having a thickness of 0.1 to 0.25 mm), whereas the buckle 3000 can be formed or cut-out from a thicker panel of self-reinforced polymer (for example, having a thickness of 1 to 1 .5 mm). The thickness of the self-reinforced polymer used in the buckle 3000 will be thicker than the thickness of the self-reinforced polymer used in the strap 3020 or anchor loop 3025.

In the example of FIGURE 30 the anchor loop 3025 is formed from a loop of selfreinforced polymer strap. Nevertheless, it will be understood that that the anchor loop 3025 could be formed from a more rigid self-polymer portion, ring or hoop instead.

FIGURE 31 shows a further example of a fastener 3200. The fastener 3200 of FIGURE 31 has a number of parts that are common with the fastener 3100 shown in FIGURE 30. In particular, the buckle 3000, strap 3020 and anchor strap 3025 are the same as those described above with respect to the example of FIGURE 30. However, in the example of FIGURE 31 the anchor loop 3025 is mounted to a rotating anchor plate 3040. The rotating anchor plate 3040 is arranged to rotate compared to the element 3035 or panel to which it is attached (see FIGURE 31 (a)). As shown in FIGURE 31 (b), the rotating anchor plate 3040 may be connected by a pin or axis 3045 through the element or panel 3035. The pin or axis 3045 may pass through the element or panel 3035 so that is can rotate freely. The pin or axis 3045 may be secured to a back plate 3050, for instance, to be held in place.

FIGURES 32(a), 32(b), 33(a), 33(b) and 33(c) show photographs of the fastener 3200 of FIGURE 31 when in use. The rotation or change of orientation of the rotating anchor plate 3040 can be seen by comparison of the images of the fastener 3200 of FIGURE 32(a) and 32(b). FIGURE 33(a) shows the hook portion 3010 in the process of being connected to the anchor loop 3025, and FIGURE 33(b) shows in more detail a rotating anchor plate 3055, although in this case the strap 3020 is anchored at the element (here a side panel of the cargo cover 3500) using the rotating anchor plate 3055, rather than the anchor loop. Finally, FIGURE 33(c) shows the strap 3020 of the fastener 3200 connected to a cargo cover 3500 and being passed through the body of a pallet 3550 at a corner of the cargo cover 3500. In this way, the fastener 3200 acts to secure the cargo cover 3500 to the pallet 3550 and around the load. FIGURE 34 shows an alternative example for a buckle 4000 comprising selfreinforced polymer. FIGURE 34(a) shows the buckle 4000 in an open configuration, in which two portions 4005, 4010 of the buckle are separated. FIGURE 34(b) shows the same buckle 4000 in a closed configuration, in which the two portions 4005, 4010 of the buckle are connected.

The buckle 4000 comprises a first portion 4005 and a second portion 4010 that are discrete and separable. Each portion 4005, 4010 may be connected to a different strap, or at a different end of the same strap. Similar to the buckle 3000 described above with respect to the examples of FIGURES 30 to 33, the first portion 4005 and second portion 4010 of the buckle in FIGURE 34 are each planar, and formed from self-reinforced polymer (for instance, cut from a panel of self-reinforced polymer). In particular, the first 4005 and second portions 4010 are formed from a rigid or stiff self-reinforced polymer.

The first portion 4005 comprises an opening or hole 4020 therethrough. Typically, as shown in FIGURE 34(a) and 34(b), the first portion 4005 is elongate, and the opening 4020 is arranged closer to a first end of the first portion 4005. The opening 4020 is also elongate and extending in the same direction as the extension of the first portion 4005.

The second portion 4010 comprises an engagement member 4025 for insertion through the opening 4020 in the first portion 4005 so as to connect the first and the second portions. In the example of FIGURE 34(a) and 34(b), the engagement member 4025 protrudes from a body portion 4028 and comprises a trunk portion 4030 and a head portion 4035. The head portion 4035 is connected to the body portion 4028 via the trunk portion 4030, and the width of the trunk portion 4030 is less than the width of the head portion 4035 at the point where the truck portion 4030 and the head portion 4035 are connected. Moreover, in the example of FIGURE 34(a) and 34(b), the head portion 4035 has a width, W _h , that is greater than the width, W _o , of the opening 4020 in the first portion 4005 in an equivalent direction when the first and second portion are arranged in opposition. It will be understood that the widths 1/1 , 1/14 are in the direction orthogonal to the direction of extension of the elongate first and second portion. In some circumstances, the head portion 4035 may form a barbed connection compared to the opening 4020.

Both of the first portion 4005 and the second portion 4010 also include two spacedapart and parallel elongate openings 4015a,b,c,d. These openings 4015a,b,c,d can be used to receive or retain a strap 4022, 4024 when the buckle 4000 is in use, in the same way as described above with respect to FIGURE 30(b) and 30(c).

To join the first portion 4005 and second portion 4010 of the buckle, the head portion 4035 of the engagement member 4025 at the second portion 4010 can be passed through the opening 4020 of the first portion 4005. The head portion 4035 may need to be turned or rotated with respect to the first portion 4005, in order to allow the head portion 4035 to pass through the opening 4020. However, once the engagement portion 4025 is retained in the opening 4020 and the connected first portion 4005 and second portion 4010 are arranged in alignment, the engagement portion 4025 is held in the opening 4020.

When the straps 4022, 4024 at either or both of the first portion 4005 and second portion 4010 are tightened to ensure the straps 4022, 4024 are taut, then the first portion 4005 and second portion 4010 of the buckle will be held in a connected position.

It will be understood that the buckle 4000 and the straps 4022, 4024 together comprise a fastener. In one example, the strap retained at the first portion of the buckle 4000 may be a first end of a strap wherein the second end of the same strap is retained at the second portion (so that when the buckle is connected, said strap creates a closed loop). In this way, a belt or retaining strap can be provided using the described fastener. Alternatively, the first portion 4005 and second portion 4010 of the buckle 4000 may be connected to or configured to retain ends of different straps 4022, 4024. The straps 4022, 4024 may be themselves formed from self-reinforced polymer, being flexible as described with respect to the strap 3020 of the example in FIGURE 30 and 31 .

Although the example of FIGURE 34 shows specific shapes and configuration for the first portion 4005 and second portion 4010 of the buckle 4000, it will be understood that different shapes and configuration could be used. Importantly, the width of the head portion 4035 of the engagement portion 4025 of the second portion 4010 must extend beyond the edges of the opening 4020 of the first portion 4005 when the first and second portions of the buckle are held aligned and opposing each other (for instance, as required in use when the straps are tight, as shown in FIGURE 34(b)).

FIGURE 35 shows photographs of a buckle 4000 similar to that in FIGURE 34. The head portion 4035 of the buckle in FIGURE 35 has a slightly different shape compared to that in FIGURE 34, but the function is the same. FIGURE 35(a) shows the buckle 4000 in a configuration in which the first portion 4005 and second portion 4010 are connected. In FIGURE 35(b) the buckle 4000 is shown in a ‘twisted’ configuration during insertion of the head portion 4035 of the engagement portion 4025 at the second portion 4010 through the opening 4020 in the first portion 4005.

FIGURE 36 shows an exploded view of a variation of the buckle 4000 shown in FIGURE 34. In the example buckle 4500 of FIGURE 36, the two spaced-apart and parallel elongate openings 4015a,b,c,d in each of the first portion 4010 and the second portion 4005 are separated by a moveable retaining bar 4040a, 4040b. The moveable retaining bar 4040a, 4040b is formed form a strip of self-reinforced polymer, and anchored at each end in the body portion of the first portion 4005 or the second portion 4010. The anchoring of the moveable retaining bar is by the extension of retaining arms 4045a-h from the bar 4040a, 4040b beyond the extent of additional openings 4050a, b,c,d in the body of each portion. The mechanism for the anchoring of the movable retaining bar 4040a, 4040b can be seen in more detail in the photographs of FIGURE 37(a) and 37(b). The movable retaining bar 4040a, 4040b is shown as a dotted element in the position required in use in FIGURE 36 at the first and second portions 4005, 4010.

Use of the moveable retaining bar 4040a, 4040b in this way allows for easier tightening of the strap 4022, 4024 in each of the first and the second portion 4005, 4010. When at least one of the straps 4022, 4024 is in a relaxed or loose configuration, said strap will move freely through the two spaced-apart and parallel elongate openings 4015a,b,c,d separated by the moveable retaining bar 4040a, 4040b. However, when said strap is tightened and held in a non-relaxed configuration, the strap cannot move freely.

In all the examples shown, the buckles and/or fasteners are formed from selfreinforced polymer, allowing better end-of life recyclability. All the buckles and/or fasteners shown are straightforward to use, and allow for reversible fastening between two elements (such as panels of a cargo cover).

A number of combinations of the various described embodiments could be envisaged by the skilled person. All of the features disclosed herein may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. In particular, the preferred features of the invention are applicable to all aspects of the invention and may be used in any combination. Likewise, features described in non-essential combinations may be used separately (not in combination).