Plate edge protector

Abstract

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

1 . An edge protector mountable to a cathode plate, the edge protector comprising a set of elongate channels, each elongate channel defining a slot, the set of elongate channels including a first and second channel adapted to receive and cover respective side edges of the cathode plate, and a third channel adapted to receive and cover a lower edge of the cathode plate, the first, second and third channels beings channels of a first, second and third body, respectively, wherein the edge protector further includes:
 a first and second insert, the first insert being adapted to be placed into or over a feature of a first end of the first body and a feature of a first end of the second body to form a first corner, the second insert being adapted to be placed into or over a feature of a second end of the second body and a feature of a first end of the third body to form a second corner; and   first and second corner over moldings adapted to seal the first and second corners, the first corner over molding being separate to the second corner over molding.   
     
     
         2 . The edge protector as claimed in  claim 1 , wherein, the first, second and third channels (channels) have a transverse cross section which is substantially cruciform in shape. 
     
     
         3 . The edge protector as claimed in claim, wherein, the cruciform shape includes four ends, the four ends including an open end which is adapted to receive the cathode plate and three closed ends, the three closed ends including a first closed end opposite the open end and two side ends, the two side ends each adapted to receive a seal. 
     
     
         4 . The edge protector as claimed in  claim 1 , wherein the first and second inserts each include a slot adapted to receive the cathode plate. 
     
     
         5 . The edge protector as claimed in  claim 1 , wherein the first corner over moldings is formed in an over molding process in which injected plastic melts an outer surface of the first body, therefore fixing the first body to the first insert rotationally and axially. 
     
     
         6 . The edge protector as claimed in  claim 1 , wherein the first and second bodies are formed in an over moulding of the first and second corners whereby the respective outer surfaces of the first and second bodies are melted. 
     
     
         7 . The edge protector as claimed in  claim 1 , wherein the first and second corners include the first body aligned or oriented at an angle of between 80 and 100 degrees relative to the alignment or orientation of the second body, and the second body is aligned or oriented at an angle of between 80 and 100 degrees relative to the alignment or orientation of the third body. 
     
     
         8 . The edge protector as claimed in  claim 1 , wherein all of the components of the edge protector are made of plastic. 
     
     
         9 . The edge protector as claimed in  claim 1 , wherein the feature of the first end of the first body is substantially in the form of a cylinder. 
     
     
         10 . The edge protector as claimed in  claim 1 , wherein the first insert includes an interference or press fit into the feature of the first body. 
     
     
         11 . The edge protector as claimed in  claim 1 , wherein the first channel is substantially uniform along its length. 
     
     
         12 . The edge protector as claimed in  claim 1 , wherein a transverse cross section of the first channel is substantially identical to a transverse cross section of each of the second and third channels. 
     
     
         13 . The edge protector as claimed in  claim 1 , wherein the open end of each of the first, second and third channels includes a taper from a larger thickness of the channel to a smaller thickness of the channel at an open edge of each of the channel, the open end of each of the channel being adapted to receive the cathode plate. 
     
     
         14 . The edge protector as claimed in  claim 1 , wherein the first and third bodies include holes adapted to line up with holes in the cathode plate such that bolts can be inserted through the holes in the first and third bodies and the cathode plate. 
     
     
         15 . (canceled) 
     
     
         16 . A method of manufacturing an edge protector for a cathode plate as claimed in  claim 1 , comprising the steps of:
 (a) receiving and covering the respective side edges of the cathode plate with the first and second elongate channels;   (b) receiving and covering a lower edge of the cathode plate with the third elongate channel;   (c) placing the respective first and second inserts into or over the respective feature of the first and second ends of the respective first and second bodies to form the corresponding first and second corners;   (d) placing the second insert into or over the feature of the second end of the second body and the feature of a first end of the third body to complete the second corner; and   (e) over molding the first and second corners to seal the first and second corners.   
     
     
         17 . A method as claimed in  claim 16 , further comprising the step of:
 (f) inserting a brace into the first second and third channels and slots to hold a longitudinal axis of the first body at 90 degrees to a longitudinal axis of the second body and the longitudinal axis of the second body at 90 degrees to a longitudinal axis of the third body whilst the first and second corners are over-molded.   
     
     
         18 . A method as claimed in  claim 17 , further comprising the step of:
 (g) injecting a suitable plastic into spaces between the two halves of the mould and the first corner in an over-molding process forming the first molded body.   
     
     
         19 . A method as claimed in  claim 18 , further comprising the step of:
 (h) melting the plastic outer surfaces of the bodies, therefore fixing the bodies to the first insert rotationally and axially.   
     
     
         20 . A method as claimed in  claim 19 , further comprising the step of:
 (i) placing the second corner between two halves of a mold and injecting plastic into spaces between the two halves of the mold and the second corner in an over molding process forming a second molded body.   
     
     
         21 . A method as claimed in  claim 20 , further comprising the steps of:
 (j) injecting the plastic to melt the outer surfaces of the first, second and third bodies and fixing same to the second insert rotationally and axially; and   (k) removing the brace from the first, second and third channels and slots.