GB2565032A - Moulding procedure to incorporate flag material within a tubular spine for full visibility flag - Google Patents

Abstract

A method of producing a flag is disclosed where a round mould (A, figure 1) longer than the intended width of the flag to be produced is brushed with release agent which after drying is coated with a layer of Gelcoat, onto which is laid the edge of the flag to be treated (figure 2). The mould may then be rotated up to two times so as to wrap the flag material around it (figure 2a). A thin layer of gel coat is then applied to the material touching the mould (figure 2b) and when set the mould is removed leaving a flag with a rigid tubular spine comprising the flag material and gel coat combined. The rigid spine may be slid onto a flag staff and secured by means of stopper F and movable fitting G. When moulding the flag around the mould, discs (C) may be attached to the mould so as to provide flat surfaces to the ends of the flag. The edge of the flag opposite the staff may have pockets K into which a rod J may be inserted so as to spread the flag. The flag may be specifically used as a warning flag at motor sports events.

Description

Moulding procedure to incorporate flag material within a tubular spine for full visibility flag.

This invention relates to a method of using a round mould being at least the length of the width of the flag to be treated and a diameter slightly bigger than the staff or pole of the flag wherein a coating of moulding compound or Gelcoat is applied all over the mould and by the nature of the adhesive properties of the coating the straight edge of the required end of the flag material is set in place down the length of the mould and when in place the mould is rotated until the flag is wrapped around the tube once or twice as required, the flag can then be pulled with a little pressure to squeeze the Gelcoat through, after which another layer of Gelcoat is applied around the flag material in contact with the mould to offer more support and give a more pleasing finish when set. When the moulding compound has set, the mould can be withdrawn leaving a smooth finish inside the now self - supporting flag spine, then by preparation in the moulding process or hand finishing to the ends of the newly created tube a flat clean surface can be achieved allowing minimal resistance against the faces of the components which, with a little end clearance, hold the flag in place on the flag staff and allow it to rotate around said staff when the flag is waved. Also, the flag has ability of not to tangle or wrap itself around the staff when wet due to the nylon or water repellent treated cloth used. The stiffening rod in the leading edge of the flag also contributes to this advantage.

Different types of round moulds could be employed, round solid smooth poles with release agent which would allow easy removal of the finished item, nylon poles which when given a tap would detach from the Gelcoat or even silicone tubing with a tube or pole inserted in it to offer support, when the Gelcoat has set the tube or pole can be removed and the ends of the silicone tube can be pulled thus “narrowing” it, allowing it to detach from the Gelcoat and be removed from the now self-supporting spine of the flag.

This invention relates to a previous application, no. 1500801.4, for a full visibility warning flag for motor sports, wherein a flag of a light weight nylon material or a material treated for water resistance and being slightly perforated to lower wind resistance was designed to have a tube inserted into a sleeve sewn down the spine of the flag allowing it to perform the same functions, by forming the tube using Gelcoat and the flags own material it helps to reduce the weight slightly as a marshal can sometimes be required to wave or hold a flag stationary for one or two minutes, it also removes the need for another sewing task. The opposite or “leading” edge of the flag contains a small diameter supporting rod to assist in the flag being held in such a way as to present the full area of the flag, especially in windy conditions. The ends of this rod were first designed with plastic caps fitted to hold the rod in place externally over the flag, but now have been changed to have smaller caps or even curved and rounded end pieces which will fit into pockets sewn into the comers of the flag, thus removing any potential hazard to anybody’s eyes should they inadvertently stand too close to the person waving the flag.

The invention will now be described solely by way of example and with reference to the accompanying drawing in which:

Figure 1 shows a round mould “A” being about 2mm bigger in diameter than the diameter than the flag staff and the width “B” being the width of the flag to be treated. Flat discs “C” can be attached so as to give a flat surface to the ends or this can be achieved by filing and polishing afterwards. A brush is used to apply a release agent. The mould can either be hung by cord “D” at each end or put in a cradle to assist in rotating. A thin coat of Gelcoat can now also be applied when the release coat has dried.

Figure 2 shows the straight edge of the flag being offered up along the length of the mould and being held in place by the Gelcoat, the mould can now be slowly rotated, figure “2a”, for one or two revolutions as required allowing the flag to wrap around the mould, making sure that the flag lays nice and flat, a gentle pull of the flag should wrap it tighter around the pole and squeeze some of the Gelcoat through the flag material. In figure “2b” a further thin layer of Gelcoat can then be brushed on the flag material in contact with the mould for more support and to give a more pleasing finish.

Figure 3 shows the flag after removal of the pole when the Gelcoat has set. The ends, “E” have a flat clean face due to the discs applied at the moulding stage or by filing and finishing as required.

Figure 4 shows the finished flag fitted to the flag staff with the stopper “F” fitted and the movable gland type fitting “G” being secured with a small amount of end clearance so as to allow free movement of the flag on the staff. The opposite or “leading” edge of the flag has a narrow sleeve sewn into it “H”, to accept the narrow diameter rod “J”, which is used to help display the whole area of the flag. Pockets “K” are sewn into the corners into which the ends of the narrow rod “J” locate to secure the rod in place after it has been inserted into the narrow-sewn sleeve and the plastic end caps in options “L” or “M” fit on the end of the rod before it is located in the pockets “K” so that the rod cannot protrude and cause injury.

Claims (5)

1. Claims

   1: A moulding procedure to incorporate flag material by which a round mould the length of one side of a flag and being of wooden, metal, fibreglass, nylon or silicon construction having a smooth finish and having a diameter of at least 2mm bigger than the flag staff is coated with release agent and a layer of Gelcoat is applied. Flat discs can be attached to the mould at the width of the flag to provide flat surfaces if required.
2. 2: A moulding procedure according to claim one where the edge of the flag to be treated is laid along the length of the mould and due to the adhesive properties of the Gelcoat stays in place allowing the mould to be rotated maybe two times so that the flag is wound around the mould, by applying a slight pull on the flag the Gelcoat could be squeezed through the flag material which to assist in lowering resistance to wind is slightly perforated and will help in its absorption of Gelcoat.
3. 3: A moulding procedure according to claim 1 and 2 where a further thin layer of Gelcoat is applied to the flag material in contact with the mould so as to give a bit more rigidity and a better finish. The material of the flag acting in the same way as the fibres used in fibre glassing or carbon fibre applications where the fibres add to the strength of the moulding.
4. 4: A moulding procedure according to claims 1, 2, and 3 wherein the mould is removed when the Gelcoat sets leaving a smooth finish internally and externally, and if flat discs were added at the beginning a flat surface is achieved at the ends, or if not this can be formed by filing.
5. 5: A moulding procedure as stated in previous claims where the finished item is slid onto the flag staff and the stopper inserted, the adjustable gland type at the other end is moved to a position with a slight clearance to allow the flag to rotate on the staff. The moulded flag removing the need for a separate tube to be inserted in the spine of the flag as in other designs and the removal of one sewing procedure.