GB2399379A

GB2399379A - Plastics panel

Info

Publication number: GB2399379A
Application number: GB0305432A
Authority: GB
Inventors: John Frederick Saunders
Original assignee: NORFOLK GREENHOUSES Ltd
Current assignee: NORFOLK GREENHOUSES Ltd
Priority date: 2003-03-10
Filing date: 2003-03-10
Publication date: 2004-09-15
Anticipated expiration: 2023-03-10
Also published as: GB0305432D0; GB2399379B

Abstract

A plastics panel 1, for securing in the framework of a building structure, comprises a sheet of plastics material having a planar border 2 at least partially bounding a plurality of reinforcement strips 4 arranged in a latticework 3 to define a plurality of planar sub-panels 5. The latticework 3 may resemble the glazing bars of a window and may be arranged in the form of a Georgian grille or a leaded light latticework. The plastics material may be PVC, UPVC, SAN, PET or a polycarbonate. The border 2 may extend around all four sides of the panel or may extend only along two opposite sides. The plastics material may be transparent and may have portions which are frosted or opaque. The frosted or opaque portions may be the reinforcement strips 4. Alternatively the plastics material may be opaque. The plastics panel may be of one-piece manufacture comprising the sheet of plastics material formed with integral planar border 2 and reinforcement strips 4.

Description

PATENTS ACT 1977 Agent's Ref: P17418GB-LH/mf CA PLASTICS PANEL,' This

invention relates to a plastics panel and more particularly to a plastics panel to be secured in the framework of a building or outbuilding such as a greenhouse, lean-to, conservatory, summer-house or the like.

10Greenhouses have been conventionally manufactured from a metal or wooden framework to which is secured glass panes. There are a number of disadvantages associated with the use of glass in greenhouses and other outbuildings such as conservatories and summer-houses, in that the glass is expensive, heavy and difficult to transport because of its fragility. The glass 15panes for a 6ftx6ft (1.8mxl.8m) greenhouse would weigh in the region of lOOkg. There are further disadvantages with the use of glass such as the extra care which is needed when handling the glass either during manufacture of the building, when carrying out maintenance and repair work or at a demolition stage.

Despite the above disadvantages, glass continues to be used in greenhouses and the like, although there are greenhouses available which use planar plastics sheeting instead of glass panes. Such structures are lightweight, easy to construct and cheap to manufacture. However, the planar plastics sheeting cannot be regarded as a substitute or used as a substitute for glass panes because of the inherent instability and lack of rigidity of the planar plastics sheeting available. Examples of structures clad in plastics sheet not embodying the present invention are shown in Figures 1 to 3 of the accompanying drawings. l

The present invention provides a plastics panel to be secured in the framework of a building structure, the panel comprising a sheet of plastics material having a planar border at least partially bounding a plurality of reinforcement strips arranged in a latticework which defines a plurality of planar sub-panels.

In order that the present invention may be more readily understood, embodiments thereof will now be described by way of example, with reference to the accompanying drawings, in which: Figures 1, 2 and 3 are perspective views of structures with an aluminium frame clad in plastics sheets not embodying the present invention; Figure 4 is a perspective view of a plastics panel embodying the present invention; Figure 5 is a front view of a plastics panel embodying the present invention; Figure 6 is a cross-section taken along line A-A of Figure 5; Figure 7 is a detail of a reinforcement strip in the plastics panel of Figures 5 and 6; Figure 8 is a front view of another plastics panel embodying the present invention; l () Figure 9 is a front view of a further plastics panel embodying the present invention; Figures 10, 11 and 12 are details of reinforcement strips for use in embodiments of the invention; and Figure 13 is a front view of another plastics panel embodying the present invention.

Referring to Figure 4, a plastics panel 1 embodying the present invention comprises a sheet of PVC, U-PVC, SAN or PET plastics material which is preferably W-stabilised and which has a thickness in the region of 1 to 1. 5mm, preferably 1.2mm, although other thicknesses are possible. In the present example, the panel 1 is a square panel and has a 1 inch (25.4mm) surround around all four sides of the panel creating a planar border 2. The border 2 bounds a latticework 3 of reinforcement strips 4 which are integrally formed in the sheet. In the example shown in Figures 4, 5 and 6, the reinforcement strips 4 are laid out in a rectangular pattern to give the appearance of a Georgian grille as would appear in a Georgian window. In other examples, the latticework 3 of reinforcement strips 4 gives the appearance of a leaded-light window as shown in Figure 8 or the latticework 3 divides the area within the border 2 into square planar sub-panels as shown in Figure 9. The dimensions of the panel 1 are those of a conventional glass pane which the panel 1 would replace, i.e. a 2ftx2ft square (61cmx61cm).

Referring to Figure 4, the reinforcement strips 4 are formed horizontally I and vertically in the plastics panel across the area surrounded by the border 2 to create an external square frame 4A divided up by two equispaced internal vertical reinforcement strips 4B and one internal horizontal reinforcement strip 4C. The latticework 3 thereby creates a 2x3 array of rectangular planar sub- panels S. which arrangement looks very similar to that of a similarly divided Georgian window. The reinforcement strips 4 are integral to the panel 1, being molded from the planar plastics sheet so that the walls of the reinforcement strips 4 are of substantially the same thickness as the rest of the panel 1.

Preferably, the planar border 2 lies in substantially the same plane as the planar sub-panels 5. In cross-section, the reinforcement strips 4 in Figure 4 have a square profile but this profile is not essential as will be described below.

On one surface of the panel 1, an exterior surface of the panel in use, the i reinforcement strips 4 comprise ribs standing up from the exterior panel surface and, on the opposite surface, an interior surface of the panel in use, the reinforcement strips 4 comprise channels in the interior panel surface.

The latticework 3 of reinforcement strips 4 significantly increases the rigidity of the panel over an identically manufactured panel without reinforcement strips. The increase in rigidity is such that plastic panels 1 embodying the present invention can be readily used as substitutes or replacements for glass panes of an identical size from a greenhouse, lean-to, conservatory, summer-house or the like. This substitution or replacement was previously impracticable with conventional plastics sheeting used in greenhouse assembly.

The provision of the planar border 2 around the periphery of the plastics panel 1 allows the plastics panel 1 to be secured in place of, for example, a broken glass pane in a greenhouse using the same frame and clip fittings which I would have been used to affix the broken glass pane being replaced. The planar border 2 provides a perfect fixing or securing site and can further be readily drilled or punched to provide a registering or fixing means to secure the panel 1 to the framework of the structure which the panel is to clad if the original frame and clip fittings are not to be used. In the plastics panel 1 of Figure 4, a pair of fixing holes 6 is provided on opposite sides of the latticework 3 in the border 2. The fixing holes 6 can be pre-drilled for ease of assembly or can be drilled during assembly. Thus, an entire greenhouse can have its glass panes replaced by plastics panels 1 embodying the present invention. On a less extensive basis, broken glass panes can be replaced on an individual basis by panels 1 embodying the present invention.

The provision of the latticework 3 of reinforcement strips 4 not only provides reinforcement to the plastics panel 1 enabling them to be used as direct replacements of glass panes but also significantly increases the aesthetic - appeal of the plastics panel 1 and the structure within which the panel is (or panels are) incorporated, the reinforcing strips 4 looking like the glazing bars of a window. Aesthetic appeal may be considered to be lacking from earlier plastics panel greenhouses and other outbuildings and also from glass greenhouses and other outbuildings, whereas the panels 1 embodying the present invention have improved aesthetic appeal.

In Figure 5, in which the same reference numerals are used to denote the same elements as in Figure 4, the profile of the reinforcement strips 4 is a trapezoidal rib as shown in the cross-section of Figure 6 and the detail of Figure 7. It should be noted, however, that the particular profile chosen for the reinforcement strip 4 can be varied, see Figures 10, 11 and 12, so as to be curvilinear, square, trapezoidal or as otherwise required, the important consideration being that the latticework 3 of reinforcement strips 4 increases the rigidity of the panel compared to a planar plastics sheet of similar manufacture. ()

Other possibilities for the material from which to make plastics panels 1 embodying the present invention include polycarbonates which although expensive can be considered as alternatives to PVC, U-PVC, SAN or PET plastics materials.

The plastics panel can be provided in any desired shape and size to fit a structure framework. Figure 13 shows a 4ft x 2ft rectangular panel.

In some embodiments of the invention, the plastics panel 1 is transparent although it is possible for some portions of the panel to be frosted by selection of an appropriate surface finish on the mold used to produce the plastics panel.

Preferably, the reinforcement strips 4 are frosted or rendered at least partially T obscured by using a roughened surface finish on those portions of the mold used to form the reinforcement strips 4 and a smooth or polished surface finish for those portions of the mold used to form the border 2 and the sub-panels 5 within the latticework 3. This arrangement gives the panel 1 the appearance of a window having a frame or latticework (the frosted or opaque reinforcement strips 4) and clear panes (the clear sub-panels 5). The plastics panel 1 can also be made entirely from opaque plastics materials in selected colours.

Preferably, the plastics panel embodying the present invention is manufactured from a thermo-forming or vacuum forming technique using a two-part mold which, when the mold is closed, is evacuated to assist in the molding process. Plastics panels 1 in PVC, PET or SAN plastics materials are particularly well-suited to manufacture in this manner in thicknesses of in the region of lmm to 1.5mm. Such molds are simple to produce and comparatively Inexpenslve. ()

Although the planar border 2 is preferably provided around the entire periphery of the panel 1, it is also possible to provide the planar border 2 only on two opposite sides of the plastics panel 1 to bound the latticework 3 and allow those sides to be secured to the framework of the structure being assembled, it not being essential to secure all sides of the panel in some circumstances.

A twin-shot molding process could also be used to add an additional layer of molding material in pre-selected areas such as along the reinforcement strips 4. The first mold is in the clear plastics material and the second mold is an over-molded using an opaque plastics material of only the reinforcement strips. The end effect is of a realistic looking window with an opaque latticework and clear panes.

Another way of creating some level of contrast between the latticework 3 and the sub-panels 5, for example to make the reinforcement strips 4 look more opaque than the sub-panels 5, is to insert white plastic inserts within the channels provided by the reinforcement strips in one surface of the panel and secure the inserts to the panel by gluing or the like.

Whilst the reinforcement strips 4 are most preferably formed integrally in the plastics panel 1 (in the above examples) for ease of manufacture and the least manufacturing steps, it is also envisaged that the latticework 3 of reinforcement strips 4 is formed as a distinct element from the plastics sheet and is adhered or fixed to the plastics sheet to produce a composite plastics panel. c)

In the present specification "comprises" means "includes or consists of'' and "comprising" means "including or consisting of".

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof. o

Claims

CLAIMS: 1. A plastics panel to be secured in the framework of a building

structure, the panel comprising a sheet of plastics material having a planar border at least partially bounding a plurality of reinforcement strips arranged in i a latticework which defines a plurality of planar sub-panels.
2. A plastics panel according to Claim 1, wherein the latticework of reinforcement strips has the appearance of the glazing bars of a window.
3. A plastics panel according to Claim 1 or 2, wherein the reinforcement strips are arranged in the form of a Georgian grille, a leaded-light latticework or a latticework defining square sub-panels.
4. A plastics panel according to any preceding claim, wherein the plastics material is PVC, UPVC, SAN, PET or a polycarbonate.
5. A plastics panel according to any preceding claim, wherein the planar border surrounds all four sides of the plastics panel.
6. A plastics panel according to any one of Claims 1 to 4, wherein the planar border is provided only on two opposite sides of the plastics panel.
7. A plastics panel according to any preceding claim, wherein the plastics material is transparent.
8. A plastics panel according to any preceding claim, wherein at least portions of the plastics panel are frosted, partially obscured or opaque. c)
9. A plastics panel according to any one of Claims 1 to 7, wherein the plastics material is an opaque material.
10. A plastics panel according to any preceding claim, wherein there is a contrast in the level of transparency between the reinforcement strips and the sub-panels, the sub-panels being more transparent than the reinforcement strips.
11. A plastics panel according to Claim lO, wherein the reinforcement strips are frosted, partially obscured or opaque and the sub panels are substantially transparent.
12. A plastics panel according to any preceding claim, wherein the sheet of plastics material has a thickness in the order of 1 to 1.5mm.
13. A plastics panel according to any preceding claim, wherein the plastics panel is of one-piece manufacture comprising the sheet of plastics material formed with the planar border and the latticework of reinforcement strips.
14. A building structure having a framework and one or more plastics panels according to any preceding claim secured to the framework.
15. A plastics panel substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
16. Any novel feature or combination of features disclosed herein.