THIS INVENTION relates to protective packaging of rolls of sheet material. In particular, the invention is directed to end caps for use in packaging rolls of laminates and other such materials.

BACKGROUND ART

Many materials, particularly laminates, are manufactured as flat sheets. The conventional method of packaging sheets of laminate involves placing the laminate sheet on a table, rolling the sheet up, folding a length of cardboard over the trailing (outer) edge of the laminate, taping the roll three times around its circumference (once at either end and once in the middle) , and wrapping and taping more cardboard around the ends of the roll. Such method of packaging rolls for storage and transportation has a number of disadvantages.

For example, a roll of laminate will usually expand significantly after being rolled. This expansion puts strain on the tape or rope which is used to secure the roll, and may lead to deformation of the laminate. When the roll of laminate expands, the ends of the rolls spread, and may be damaged. Rolls of laminate stored upright may become unstable, and collapse.

In addition, the conventional method of packaging rolls of laminates is time consuming, and uses large amounts of essentially non-reusable materials such as cardboard and packaging tape.

The most common cause of damage to rolls of laminate occurs at the ends of the roll . The ends of rolls which are stored upright are easily damaged. Further, when corrugated cardboard is wrapped around the ends of rolls, as in the currently used methods, the cardboard does not provide a flat stable surface on which to stand the roll . Various forms of end caps are known. Some end caps, such as those described in U.S. patents 4,208,790; 5,100,076; 5,205,411; 5,310,058; 5,337,895 and 5,421,537, are fitted to the ends of a core tube on which the sheet

material is rolled. Such end caps are unsuitable for rolls of sheet material not having a tubular core. Similarly, the end plugs described in U.S. patents 4,015,711 and 5,351,825 are unsuitable for rolls of sheet material not having a tubular core.

Other end caps such as that described in U.S. patent 4,227,958, are folded or assembled on to the end of a roll. Each end cap must be folded or assembled individually on the rolls in a time consuming process, and is not reusable.

U.S. patent 3,946,066 describes a nose cone for a roll of yarn. However, the nose cone is fitted to the tubular core of. the roll, and does not assist in protecting or securing the yarn. It is an object of the present invention to provide an end cap and a packaging method for rolls of material, which overcome or substantially ameliorate the abovementioned disadvantages, or which at least provide the user with a useful choice. SUMMARY OF THE INVENTION

In one broad form, the present invention provides an end cap for fitting to an end of a roll of sheet material, the end cap being generally of cup-like configuration and comprising an end portion, and a generally tubular side portion extending substantially normally from the end portion and adapted to receive therein, in use, an end of the roll.

Preferably, the end portion has an outer contact face, consisting of a planar surface or several coplanar surfaces, normal to the axis of the tubular side portion. This contact face provides a stable rest surface for the end portion. Diametric channels may suitably be formed in the outer contact face for receiving a strapping tape in recessed form, as described more fully below.

Throughout the specification the term "strapping tape" is intended to cover not only a tape,

but also any rope, wire, cord, string or similar filament suitable for binding the end caps and roll together.

The side portion is preferably of fluted configuration having a plurality of circumferentially spaced ribs extending axially therealong. The thickness of the ribs in the circumferential dimension may taper.

A radial flange is suitably provided at the end of the side portion distal to the end portion. The radial flange preferably has a polygonal outline, such as square or hexagonal.

Typically, the side portion is of tapering diameter to allow the end cap to be stackable with similar end caps. -

In another form, the present invention provides packaged sheet material, comprising a roll of the sheet material, at least one end cap placed on an end of the roll, the end cap being generally of cup-like configuration and comprising an end portion, and a generally tubular side portion extending substantially normal to the end portion, the end of the roll being received within the side portion.

In yet another form, the present invention provides a method of packaging of sheet material, comprising the steps of rolling the sheet material into a roll, placing at least one end cap on a respective end of the roll, the end cap being generally of cup-like configuration and comprising an end portion, and a generally tubular side portion extending substantially normal to the end portion, such that the end of the roll is received within the end cap.

Typically, one end cap is placed at each end of the roll, and the end caps are bound longitudinally to the roll with strapping tape which passes around the outer ends of the end caps (in the channels provided for this purpose) and axially alongside the roll.

A layer of cushioning material is suitably

provided in each end cap, between the end portion of the end cap and the proximal end of the roll received within the end cap.

A protective sheet may be wound around the roll of sheet material before the end caps are applied, the opposite ends of the protective sheet being received within respective end caps. The protective sheet is preferably of fluted configuration having rib-like formations extending axially therealong. The side portion of the end cap is also fluted configuration, having circumferentially spaced ribs extending axially along the side portion. The end sections of the rib-like formations on the protective sheet are received internally within the ribs of the respective end caps, thereby radially locking the sheet and the end caps.

Further, or in the alternative, the roll of material may be housed in a tube of cardboard or similar material. The tube has a polygonal section and the inside of each end cap has a similarly shaped and dimensioned socket section such that each tube end is received in a respective end cap in a snug fit. The end caps are not rotatable relative to the tube.

In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of an end cap according to one embodiment of the invention; Fig. 2 is a plan view of the end cap of Fig. 1;

Fig. 3 is an elevational view of the end cap of Fig. 1;

Fig. 4 is a sectional elevational view along A- A of Fig. 2; Fig. 5 is an exploded view of packaging for a roll of laminate;

Figs. 6 to 8 are pictorial views illustrating the use of the packaging of Fig. 5;

Fig. 9 is an elevational view of a packaged roll of laminate; and

Fig. 10 is a sectional plan view along B-B of Fig. 9. DESCRIPTION OF THE INVENTION

As shown in Figs. 1 to 4, an end cap 10 is of cup-like configuration and comprises a generally planar base or end portion 11, and a generally tubular side portion 12 extending from the periphery of the end portion 11 to form a cylindrical skirt. The side portion 12 is of fluted configuration, having a plurality of circumferentially spaced, axially extending ribs 13.

A polygonal flange 14 is provided at the end of the skirt-like side portion 12 distal to the end portion 11. The flange 14 is preferably hexagonal in outline as shown, or may be square.

The thickness of the ribs 13 (in the circumferential direction) increases gradually from the end portion 11 to the flange 14, i.e. the ribs 13 are of tapered thickness.

Orthogonally orientated diametric channels 15 are formed in the end portion 11. These channels are located between adjacent ribs 13. The space between certain pairs of adjacent ribs 13 on side portion 12 forms a shallow channel 15A which serves as a continuation of the channel 15 on the end portion 11. Recesses 15B are formed in the flange 14 at positions aligned with the channels 15A, so as to form a continuation of such channels. Recesses 16 are provided around the periphery of the end portion 11 between the ribs 13, other than the location of the channels 15. The interior counterpart surfaces of the recesses 16 form shoulders inside the end cap on which the end of the roll rests. The recessed portions provide mechanical strength and rigidity, and impact resistance to the material inside the end cap. The energy of a shock force on the end cap is dispersed over a larger area before it reaches the material .

The end cap is suitably formed integrally of tough shock-resistant plastics material by injection moulding. However, the end cap 10 may be formed of other suitable materials, such as moulded or pressed cardboard. The skirt-like side portion 12 is slightly tapered as shown in Fig. 3 (i.e. it is generally frusto- conical in shape) so that the end caps are stackable. The flange end of the side portion 12 has a larger diameter taper to counteract the slight conical shape of the end cap, retaining the same strength from top to bottom.

The end caps 10 are used in packaging rolls of sheet material, such as laminates. The end caps 10 are typically used in conjunction with foam discs 20 and a ribbed outer sheet 21 in the configuration shown in exploded form in Fig. 5. The packaging components are bound together around the roll with strapping tapes 22, 24. The strapping tapes may be tied with fasteners 25.

In use, the laminate or other sheet material is rolled up into a generally cylindrical roll 30. A bench of the type shown in Fig. 6 may be provided for this purpose. For reference, the cap size may be marked on side panel 33. A strip of cardboard 31 may be folded over the trailing edge of the laminate to protect it from damage, if desired.

The roll 30 is then bound with tape 22 having VELCRO fastenings (or other resealable fastenings) around the middle of the laminate roll. Once the roll 30 has been securely fastened around its middle, the end caps 10 are placed on either end of the roll, as shown in Fig. 7. Protective discs 20 are placed inside the end caps 10 before being applied to the ends of the laminate roll . The discs 20 are typically made of foam or other compressible material. The centre tape 22 is slowly released so that the end caps 10 take the strain of the expanding rolled material. The radial force applied by the expanding roll material assists in retaining the end caps on the roll.

The centre of the roll is then restrapped tautly.

If required or desired, a protective sheet 21 may be placed around the roll. This sheet is normally placed around the roll before the roll is strapped with tape 22. In other words, the strapping tape 22 is tied around the middle of the protective sheet 21 which envelopes the roll of laminate.

The protective sheet 21 is preferably of fluted configuration having rounded channels which form ribs 23 extending axially along the sheet 21. The protective sheet may be a reusable (plastics) sheet, or disposable (pressed cardboard or pulp) . When placed around the material, the ends of the sheet 21 overlap and the ribs 23 interlock. The ribs 23 are dimensioned to fit snugly within the ribs 13 formed on end caps 10. Thus, when the end caps 10 are placed over the ends of the protective sheet 21 rolled around the laminate roll 30, the ribs 23 on the protective sheet 21 interlock with the female side of corresponding ribs 13 on the end caps 10. In the alternative, the laminate roll 30 is placed in a cardboard tube (not shown) of polygonal section, typically hexagonal. Each end cap 10 has a correspondingly shaped socket formation on the inside of the tubular portion 12. In this manner, each end cap is fitted to an end of the tube in a snug fit, and is rotationally locked to the tube.

The end caps 10 are then tied together with strapping tape 24 which passes along the channels 15, 15A, 15B of the end caps 10 and axially alongside the protective sheet 21. Typically, two straps 24 are arranged in orthogonal axial planes.

The packaged roll of laminate can now be stored safely and securely on its end as shown in Fig. 8 without damage to the laminate material. If the packaged roll is stored horizontally, the laminate is raised off the ground by the flanges 14 on the end caps 10 at either end of the roll (as can be seen in Fig. 10) , thereby minimising soiling and moisture damage to the roll. The

end caps 10 may be colour coded for easy identification of the packaged contents.

The use of the end caps 10 in the abovedescribed method of packaging results in a number of advantages, including:

• The end caps protect the rolled material from axial stress, and longitudinal and radial impact damage.

The packaging provides structural support and torsional rigidity to the rolled material.

The end caps are reusable.

• The tapered fluted configuration of the end caps distributes impact energy over a greater area, thereby cushioning the impact and protecting the product inside. The energy of a shock force on the end cap is dispersed by the end cap and absorbed by the foam disc inside the end cap before reaching the rolled material.

• The end caps provide a stable base on which to stand the packaged roll of material .

• The strapping tape is protected by being recessed in channels on the end cap, and does not destabilise rolls standing on their ends.

• As the end cap is made from rigid durable material, it will maintain its shape (unlike cardboard folded over the ends of rolls) .

The disc of cushioning material inside the end cap provides added protection to the rolled material .

The hexagonal flange on the end cap allows packaged rolls to be stacked horizontally by flange contact only.

The hexagonal shape of the flange allows the packaged rolls to be stacked in interlocking honeycomb configuration. The hexagonal flange also minimises the likelihood of twisting of the rolls.

• The hexagonal flange provides 'clearance between the material and a supporting surface, thereby preventing soiling and damage.

• The longitudinal strapping of the end caps to the roll of material prevents axial movement of the material within the package, thereby minimising damage to the ends of the sheet material.

• The cylindrical skirt of each end cap helps the rolled material maintain a cylindrical shape.

• The ribbed protective sheet locks into the end caps, thereby preventing relative twisting in transit of the sheet (and rolled material) relative to the end caps. (Such twisting could lead to loosening of the strapping tape) . The interlocking protective sheet and end caps creates a rigid protective structure.

• The ribs on the protective sheet also serve to absorb and disperse the energy of impacts or shock forces on the middle portion of the packaged roll.

• The protective sheet may be reused.

• The end caps and protective sheet also provide moisture protection for the rolled material.

• As the packaged rolls can stand upright, there is greater economical use of space in their storage and transport.

• The use of the end caps renders the packaging less labour intensive and time consuming than conventional methods.