GB2582967A

GB2582967A - Architectural valance panel

Info

Publication number: GB2582967A
Application number: GB1905176.2A
Authority: GB
Inventors: James Bowman Thomas
Original assignee: Dura Composites Ltd
Current assignee: Dura Composites Ltd
Priority date: 2019-04-11
Filing date: 2019-04-11
Publication date: 2020-10-14
Anticipated expiration: 2039-04-11
Also published as: GB201905176D0; GB2582967B

Abstract

An architectural valance panel for use around an edge of a canopy e.g. a railway station building or railway platform to help reduce sunlight or precipitation reaching the ground under the canopy and to provide a decorative finish. The valance panel 10 has a substantially planar first surface 12 and a substantially planar second surface 14, with the plane of the first surface 12 being substantially parallel to the plane of the second surface 14. At least one of the first and second surfaces 12, 14 has a plurality of grooves 16 formed therein, with the grooves 16 being substantially parallel to one another and extending from a first edge of the panel 18 to a second edge of the panel 20 to give the appearance of individual boards 22. The panel 10 comprises polyvinylchloride (PVC) foam. The panel 10 can be manufactured and installed on a canopy of a railway station building or railway platform quickly and easily.

Description

ARCHITECTURAL VALANCE PANEL

The present invention relates to an architectural valance panel and to arrangements incorporating an architectural valance panel.

An architectural valance is often provided around the edge of a canopy, e.g. of a railway station building or railway platform, to help to reduce the amount of sunlight or precipitation reaching the ground under the canopy and to provide a decorative finish to the canopy. Traditionally, architectural valances were constructed from a series of timber boards placed vertically side by side around the edge of the canopy. The timber boards are usually cut to form a decorative profile along their lower edges and are painted, typically white or green. However, over time, the paint can begin to flake and the timber boards can begin to deteriorate. Traditional architectural valances can, therefore, require a great deal of maintenance to prevent them from becoming unsightly and unsafe. It is known to replace the timber boards of traditional architectural valances with glass-fibre reinforced plastic (GRP) boards. Architectural valances formed of GRP boards can be highly durable and extremely low maintenance. However, as will be discussed in more detail below, GRP boards can have some significant drawbacks.

It is desired to provide an improved architectural valance panel and improved arrangements incorporating an architectural valance panel.

According to an aspect of the present invention there is provided an architectural valance panel, the panel having a substantially planar first surface and a substantially planar second surface, the plane of the first surface being substantially parallel to the plane of the second surface, wherein at least one of -2 -the first and second surfaces has a plurality of grooves formed therein, the grooves being substantially parallel to one another and extending from a first edge of the panel to a second edge of the panel, and wherein the panel comprises polyvinylchloride (PVC) foam.

In embodiments, by providing a plurality of substantially parallel grooves extending from a first (upper) edge of the panel to a second (lower) edge of the panel, the panel can have the appearance of individual boards, but without the need to provide individual boards separately. This can allow an architectural valance, which has a plurality of apparent boards, i.e. defined by the grooves, to be manufactured and installed on a canopy very quickly and easily. Furthermore, by providing a panel formed of PVC foam, the panel can be lightweight, durable, non-conductive, and/or highly fire-resistant. The panel can also be formed rapidly together with the grooves in a single extrusion process. The panel can also readily be drilled for fixing to a canopy or cut along the lower edge to provide a decorative profile. In contrast to this, it has been identified that an equivalent GRP panel would be relatively heavy and would, rather laboriously, need to have grooves machined into it following a moulding and curing process.

In embodiments, the panel may be of unitary construction. The panel may comprise an inner core formed of the PVC foam. The PVC foam may comprise closed cell PVC foam. Closed cell PVC foam can help to provide a neat edge when the panel is cut along the lower edge to provide a decorative profile and can help to reduce water retention. The panel may further comprise an outer skin. The outer skin may comprise polyvinylchloride (PVC). The outer skin may not comprise a foam material. The outer skin may be harder than the PVC foam -3 -and/or may be denser than the PVC foam. The panel may be substantially the same colour throughout, e.g. white or green. Thus, the inner core may be substantially the same colour as the outer skin. This can allow the panel to be cut along its lower edge without the need to then recolour the cut edge. At least one of the first and second surfaces may have a woodgrain effect provided thereon. In this regard, it has been identified that, when compared with moulded GRP boards, it is relatively easier to provide a sufficiently visible and realistic woodgrain effect in a PVC skin (e.g. with a heated roller during the extrusion process).

In embodiments, the panel (e.g. the first surface and/or second surface) may be substantially regularly shaped. The panel (e.g. the first surface and/or second surface) may be substantially rectangular (including square). The first and second edges may be substantially parallel to one another. The panel (e.g. the first surface and/or second surface) may have a width (e.g. in a direction substantially parallel to the first edge and/or second edge) in the range 700- 1700mm, for example in the range 1000-1400mm. The panel (e.g. the first surface and/or second surface) may have a height (e.g. in a direction substantially perpendicular to the first edge and/or second edge) in the range 500-1500mm, for example in the range 800-1200mm. When compared with GRP boards, these relatively larger dimensions can mean that fewer panels are needed, and this in turn can reduce the amount of time it takes, to construct or refurbish a canopy. Furthermore, the use of PVC foam can allow these relatively larger dimensions to be used without the panel becoming excessively heavy. The panel may have a thickness (e.g. between the first surface and the second surface) in the range -4 - 8-25mm, for example in the range 17-23mm. The thickness of the panel may be substantially uniform across the panel. Relatively larger thicknesses can better replicate some timber boards. Again, the use of PVC foam can allow these relatively larger thicknesses to be used without the panel becoming excessively heavy.

It has been found that the above dimensions are generally suitable for most canopies. The panel may, however, then be provided with other dimensions or shapes, or cut to other dimensions or shapes, depending on the particular canopy, as desired. For example, the second (lower) edge of the panel may have, and may be cut so as to have, a particular profile, such as a pointed or "dagger board" profile. Indeed, the use of PVC foam can facilitate this by allowing the panel to be cut along its edge without the need to then treat the cut edge.

In embodiments, the plurality of grooves may comprise exactly an odd number of grooves, e.g. at least or exactly 7 grooves. Thus, there may be exactly an even number of apparent boards, e.g. at least or exactly 8 apparent boards. This can allow a complete cycle of certain traditional profiles, such as a pointed or "dagger board" profile, to be provided at the second (lower) edge of the panel. Adjacent grooves may be spaced apart by a separation in the range 100-200mm, for example in the range 125-175mm. Thus, the apparent boards may have a width in the range 100-200mm, for example in the range 125-175mm. The grooves may be substantially v-shaped in cross-section. The grooves may each have a depth in the range 1-4mm, for example in the range 2-3mm. The grooves may each have a span in the range 3-7mm, for example in the range 4-6mm. It -5 -has been found that these dimensions are able to provide the appearance of separate boards without significantly adversely affecting the strength of the panel. In embodiments, the panel may comprise a third (vertical) edge and a fourth (vertical) edge. The third and fourth edges may each extend from the first 5 edge to the second edge. The third and fourth edges may be substantially parallel to one another. The third edge may have one or more locating projections and/or recesses, and the fourth edge may have one or more corresponding locating projections and/or recesses, the correspondence being such that two of said panels can be placed adjacent one another with the one or more locating 10 projections and/or recesses of the third edge of one of the panels engaging and/or interlocking with the one or more locating projections and/or recesses of the fourth edge of the other of the panels. The one or more projections and/or recesses of the panel can help to hold together adjacent panels in correct alignment. Furthermore, it has been identified that, when compared with moulded GRP boards, it is relatively easier to provide one or more projections and/or recesses for a PVC panel (e.g. as the panel is being extruded).

In embodiments, the one or more locating projections and/or recesses may each comprise one or more elongate locating projections and/or recesses. The one or more locating projections and/or recesses may each extend along substantially the entire length of the edge in question. The one or more locating projections and/or recesses may each extend only partially across the thickness of the edge in question. The one or more locating projections and/or recesses may each be located centrally with respect to the thickness of the edge in question. These embodiments can, for example, allow adjacent panels to be -6 -engaged and/or interlocked with one another without a visible gap or join being present between the adjacent panels. These embodiments can also allow adjacent panels to be vertically offset from one another. This in turn can allow the panel to be used on non-straight and/or curved canopies.

In embodiments, the one or more locating projections and/or recesses may each extend out of or into the plane of the edge in question by a distance in the range 5-15mm, for example in the range 8-12mm. This can, for example, allow adjacent panels to remain engaged and/or interlocked when those panels are rotated relative to one another within the planes of the panels. Again, this can allow the panel to be used on non-straight and/or curved canopies.

In embodiments, the one or more locating projections and/or recesses may each comprise substantially rounded corners. This can, for example, facilitate insertion of a projection into a corresponding recess and allow adjacent panels to remain engaged and/or interlocked when the planes of the surfaces of those panels are angled relative to one another. Again, this can allow the panel to be used on non-straight and/or curved canopies.

In embodiments, the one or more locating projections may each have a thickness in the range 5-9mm, for example in the range 6-8mm. Similarly, the one or more locating recesses may each have a span in the range 5-9mm, for example in the range 6-8mm. Notwithstanding this, the one or more locating projections may not have a friction fit with the one or more corresponding locating recesses. For example, the one or more locating projections may each have a thickness which is 0.5-1.5mm less than the span of the one or more corresponding locating recesses. This can provide some play between adjacent -7 -panels, allowing the planes of the surfaces of those panels to be angled relative to one another, and thus allow the panel to be used on non-straight and/or curved canopies.

In embodiments, the panel may be formed of, and from, extruded material.

The panel may have a substantially uniform cross-section in planes orthogonal to the direction in which the grooves extend (the direction of extrusion). The panel may be substantially solid and/or not hollow. This can provide a panel which may be cut without the risk of exposing a hollow section in the panel, which might then need to be resealed.

According to another aspect of the present invention, there is provided a method of manufacturing an architectural valance panel, the method comprising forming a panel as described herein in any aspect or embodiment.

In embodiments, the method may comprise extruding the panel. The method may comprise forming the grooves as the panel is being extruded. The method may comprise forming the outer skin as the panel is being extruded. The outer skin may be formed by coating the PVC foam with a relatively denser, e.g. PVC, material. The method may comprise providing at least one of the first and second surfaces with a woodgrain effect. The woodgrain effect may be provided as the panel is being extruded or after the panel is extruded. Providing the woodgrain effect as the panel is being extruded can help to reduce manufacturing time. The woodgrain effect may be applied with a roller. The roller may be heated. These embodiments can provide a highly visible and realistic woodgrain effect. The method may further comprise cutting the lower edge of the panel so as to provide a particular profile, such as a pointed or "dagger board" profile. -8 -

According to another aspect of the present invention, there is provided an architectural valance kit comprising plural architectural valance panels as described herein in any aspect or embodiment.

According to another aspect of the present invention, there is provided a 5 canopy having fixed thereto one or more architectural valance panels as described herein in any aspect or embodiment.

The canopy may comprise plural architectural valance panels fixed thereto. The plural architectural valance panels may be positioned side by side. The plural architectural valance panels may be positioned in an engaging and/or interlocking manner.

According to another aspect of the present invention, there is provided a method of constructing or refurbishing a canopy, the method comprising fixing to the canopy one or more architectural valance panels as described herein in any aspect or embodiment.

The method may comprise fixing plural architectural valance panels to the canopy. The plural architectural valance panels may be positioned side by side. The plural architectural valance panels may be positioned in an engaging and/or interlocked manner. The method may further comprise cutting the lower edge of one or more panels so as to provide a particular profile, such as a pointed or "dagger board" profile. The particular profile may be provided prior to fixing the one or more architectural valance panels to the canopy.

By way of example only, embodiments of the invention will now be described in detail with reference being made to the accompanying drawings in which: -9 -Figure 1 shows a perspective view of an architectural valance panel according to an embodiment of the present invention; Figure 2 shows a front view of the architectural valance panel of Figure 1; Figure 3 shows vertical edge views of the architectural valance panel of Figure 1; Figure 4 shows a lower edge view of the architectural valance panel of Figure 1; Figure 5 shows a more detailed view of the region A of the architectural valance panel as shown in Figure 4; Figure 6 shows a front view of the architectural valance panel of Figure 1 with a profiled lower edge; Figure 7 shows a lower edge view of two of the architectural valance panels of Figure 1 when engaged with one another; Figure 8 shows a more detailed view of the engaged region B of the architectural valance panels of Figure 7; Figure 9 shows a lower edge view of two of the panels of Figure 1 when engaged and angled with respect to one another; and Figure 10 shows a front view of two of the panels of Figure 1 when engaged and rotated with respect to one another.

Figures 1-5 illustrate an architectural valance panel 10 for fixing to a canopy, e.g. of a railway station building or railway platform. The panel 10 is of unitary construction and comprises extruded polyvinylchloride (PVC) closed cell foam having a relatively harder PVC outer skin. The outer skin is formed by coating the PVC closed cell foam core with a relatively denser PVC material -to -during the extrusion process. The panel 10 has a substantially planar first surface 12 and a substantially planar second surface 14. The plane of the first surface 12 is substantially parallel to the plane of the second surface 14. The first and second surfaces 12,14 have seven grooves formed therein during the extrusion process (for clarity, only one groove 16 is indicated). The grooves 16 are substantially parallel to one another and extend from a first upper edge 18 of the panel 10 to a second lower edge 20 of the panel 10 so as to form eight apparent boards (for clarity, only one apparent board 22 is indicated). In this embodiment, the grooves 16 are substantially v-shaped in cross-section, have a span of approximately 5mm, and have a depth of approximately 2.5mm. The first surface 12 has a woodgrain effect (not shown) provided thereon with a heated roller that is positioned around 30cm downstream of the extrusion mould. In this embodiment, the panel 10 is rectangular and has a width of approximately 1220mm, a height of approximately 1000mm, and a thickness of approximately 19mm. The apparent boards 22 accordingly each have a width of approximately 150mm. The panel further comprises a vertical third edge 24 and a vertical fourth edge 26. The third edge 24 has an elongate locating projection 28 that extends along the entire length of the third edge 24, and the fourth edge 26 has a corresponding elongate locating recess 30 that extends along the entire length of the fourth edge 26. The locating projection 28 and locating recess 30 are also formed during the extrusion process. The panel 10 accordingly has a substantially uniform cross-section in planes orthogonal to the direction in which the grooves 16 extend, i.e. the direction of extrusion. However, as is shown in Figure 6, the panel 10 can later -11 -be readily cut along its lower edge 20 so as to provide a particular profile, such as a pointed or "dagger board" profile.

As is shown in Figures 7 and 8, two such panels 10 can be placed adjacent one another on a canopy with the locating projection 28 of the third edge 24 of 5 one of the panels 10 engaging and interlocking with the locating recess 30 of the fourth edge 26 of the other of the panels 10. In this embodiment, the locating projection 28 extends out of the plane of the third edge 24 by a distance of approximately 10mm and has a thickness of approximately 7mm. The locating recess 30 extends into the plane of the fourth edge 26 by a distance of 10 approximately 10mm and has a span of approximately 8mm. The difference between the thickness of the locating projection 28 and the span of the locating recess 30 can provide some play between adjacent panels 10. Also, as can best be seen in Figure 8, the locating projection 28 and locating recess 30 have rounded corners to facilitate engagement and play between those parts. The locating projection 28 and locating recess 30 can allow adjacent panels 10 to be engaged and interlocked with one another without a visible gap or join being present between the adjacent panels 10, even when not fully engaged with one another. The elongate nature of the locating projection 28 and locating recess 30 can also allow adjacent panels to be vertically offset from one another.

Furthermore, as is shown in Figure 9, adjacent panels 10 can remain engaged and interlocked when the planes of the surfaces of those panels 10 are angled relative to one another by approximately 10°. Furthermore, as is shown in Figure 10, the adjacent panels 10 can remain engaged and interlocked when rotated relative to one another within the planes of the panels 10 by approximately 0.7°.

-12 -The locating projection 28 and locating recess 30 therefore allow the panels 10 to be used on non-straight or curved canopies.

Claims

-13 -CLAIMS1. An architectural valance panel, the panel having a substantially planar first surface and a substantially planar second surface, the plane of the first surface being substantially parallel to the plane of the second surface, wherein at least one of the first and second surfaces has a plurality of grooves formed therein, the grooves being substantially parallel to one another and extending from a first edge of the panel to a second edge of the panel, and wherein the panel comprises polyvinylchloride (PVC) foam.
2. An architectural valance panel as claimed in claim 1, wherein the panel comprises an inner core formed of the PVC foam.
3. An architectural valance panel as claimed in claim 1 or 2, wherein the PVC foam comprises closed cell PVC foam.
4. An architectural valance panel as claimed in claim 1, 2 or 3, wherein the panel comprises an outer skin.
5. An architectural valance panel as claimed in claim 4, wherein the outer skin comprises polyvinylchloride (PVC).
6. An architectural valance panel as claimed in claim 4 or 5, wherein the outer skin does not comprise a foam material.
7. An architectural valance panel as claimed in claim 4, 5 or 6, wherein the outer skin is relatively harder and/or denser than the PVC foam.
8. An architectural valance panel as claimed in any one of the preceding claims, wherein the panel is substantially the same colour throughout. 9.
An architectural valance panel as claimed in any one of the preceding claims, wherein the panel has a width in the range 700-1700mm and/or a height in the range 500-1500mm.
10. An architectural valance panel as claimed in any one of the preceding claims, wherein the panel has a thickness in the range 8-25mm, for example in the range 17-23mm.
11. An architectural valance panel as claimed in any one of the preceding claims, wherein adjacent grooves are spaced apart by a separation in the range 100-200mm, for example in the range 125-175mm.
12. An architectural valance panel as claimed in any one of the preceding claims, wherein the grooves each have a depth in the range 1-4mm, for example in the range 2-3mm.
13. An architectural valance panel as claimed in any one of the preceding claims, wherein the grooves each have a span in the range 3-7mm, for example 15 in the range 4-6mm.
14. An architectural valance panel as claimed in any one of the preceding claims, wherein the panel comprises a third edge and a fourth edge, the third edge having one or more locating projections and/or recesses, and the fourth edge having one or more corresponding locating projections and/or recesses, the correspondence being such that two of said panels can be placed adjacent one another with the one or more locating projections and/or recesses of the third edge of one of the panels engaging and/or interlocking with the one or more locating projections and/or recesses of the fourth edge of the other of the panels.
15. An architectural valance panel as claimed in claim 14, wherein the one or more locating projections and/or recesses each comprise one or more elongate locating projections and/or recesses.
16. An architectural valance panel as claimed in claim 14 or 15, wherein the 5 one or more locating projections and/or recesses each extend along substantially the entire length of the edge in question.
17. An architectural valance panel as claimed in claim 14, 15 or 16, wherein the one or more locating projections and/or recesses each extend only partially across the thickness of the edge in question.
18. An architectural valance panel as claimed in any one of claims 14-17, wherein the one or more locating projections and/or recesses is each located centrally with respect to the thickness of the edge in question.
19. An architectural valance panel as claimed in any one of claims 14-18, wherein the one or more locating projections and/or recesses each extend out of 15 or into the plane of the edge in question by a distance in the range 5-15mm, for example in the range 8-12mm.
20. An architectural valance panel as claimed in any one of claims 14-19, wherein the one or more locating projections and/or recesses each comprise substantially rounded corners.
21. An architectural valance panel as claimed in any one of claims 14-20, wherein the one or more locating projections do not have a friction fit with the one or more corresponding locating recesses.
22. A method of manufacturing an architectural valance panel, the method comprising forming a panel as claimed in any one of claims 1-21.
23. An architectural valance kit comprising plural architectural valance panels as claimed in any one of claims 1-21.
24. A canopy having fixed thereto one or more architectural valance panels as claimed in any one of claims 1-21.
25. A method of constructing or refurbishing a canopy, the method comprising fixing to the canopy one or more architectural valance panels as claimed in any one of claims 1-21.