GB2595447A

GB2595447A - Hoarding panel & method of manufacture

Info

Publication number: GB2595447A
Application number: GB2007314.4A
Authority: GB
Inventors: White Matthew
Original assignee: OAKLANDS PLASTICS Ltd
Current assignee: OAKLANDS PLASTICS Ltd
Priority date: 2020-05-18
Filing date: 2020-05-18
Publication date: 2021-12-01
Also published as: GB202007314D0

Abstract

A hoarding panel 10 comprises a single skin plastics panel 16, manufactured by rotationally moulding a two sided hollow panel and cutting it in half, a plurality of ribs extending between opposing sides or ends of the panel, and a frame 18 extending around the periphery of the panel, the frame being fastened to at least one set of opposing edges of the panel. Also claimed is a method of manufacturing a hoarding panel comprising rotationally moulding a panel and splitting the panel into two panels by cutting the panel and then attaching at least one panel to a rectangular frame. The panel may include recesses for engaging with a metal or plastic tubular frame.

Description

HOARDING PANEL & METHOD OF MANUFACTURE The present invention relates to a hoarding panel and a method of manufacture of the hoarding panel.

BACKGROUND TO THE INVENTION

It is well known to use steel hoarding panels to provide privacy and temporary site security. Each panel is formed from a continuous steel sheet, which is pressed or rolled into a profile. The steel sheet is surrounded by a welded tubular framework, which is typically a square rolled hollow-section tubing along the top and bottom edges abutting the ends of the profile, and a circular tubing at the edges of the sheet, extending between the top and bottom edges. The tubing at the bottom end extends beyond the end of the sheet, enabling the tubing to be placed in a supporting block or the like, for supporting the hoarding panel in a vertical position from the ground.

The hoarding panel is generally provided in a galvanised finish. However, it can be powder coated or painted to a particular colour at significant extra cost.

The purpose of the circular tubing at the sides of the sheet is threefold, firstly it provides strength and rigidity, secondly it provides the means for supporting the panel in position, and thirdly it provides a means for connecting adjacent panels with couplers. The couplers generally comprise a pair of plates, which can be bolted together at their midpoint. The ends of the plates are curved to form cups for receiving the profile of the circular tubing.

One problem encountered in fastening hoarding panels together is that sometimes the couplers cannot be positioned around the tubing, because of the connected sheet impeding the positioning of the coupler, for example, when hoarding panels are connected together at an angle. There is then a need to cut clearance slots in the sheet on site, which is extremely difficult, because there is no straightforward access for a cutting device and the steel is difficult to cut.

It is an object of the present invention to reduce or substantially obviate the aforementioned problems.

STATEMENT OF INVENTION

According to the present invention there is provided a hoarding panel comprising a single skin plastics panel, manufactured by rotationally moulding a two sided hollow panel and cutting it into two, a plurality of ribs extending between opposing sides or ends of the panel, and a frame extending around the periphery of the panel, the frame being fastened to at least one set of opposing edges of the panel.

Advantageously, by manufacturing a panel by rotational moulding in plastics and cutting the moulding into two parts, preferably halves, the weight of the plastics panel produced is halved. Rotational moulding has been found suitable for producing plastics components of a large size, for example, like canoes, but the products are extremely heavy. Hence, plastics has not been adopted in producing hoarding panels until now.

The frame may be manufactured from metal or plastics, for example, from metal or plastics tubing.

Side edges of the panel may be shaped with a curve for receiving and engaging against the tubular frame. By profiling the side edges, the rigidity of the panel is improved.

An elongate recess may extend proximate to each side edge.

Each recess may extend partially along each edge and can be cut away in whole or in part, to enable attachment of a connecting coupler to the frame.

Advantageously, the plastics can be relatively easily be cut if needs be, compared to steel, facilitating quicker and easier installation of a hoarding on site.

A flange may be provided along the upper edge of the plastics panel. Conveniently, an upper part of the frame may rest against the upper flange.

A flange may also be provided along the lower edge of the plastics panel and a lower part of the frame may rest against the lower flange.

The upper and lower flanges increase rigidity and strength and serve to locate the frame.

Mechanical fasteners may fasten the plastics panel to the frame. The fasteners may be rivets or screw fasteners. Alternatively, the plastics panel can be attached to the frame using cable ties.

The frame may be rectangular, and a pair of legs may extend from the frame beyond the lower edge of the plastics panel for engaging with support blocks to support the hoarding panel in a substantially vertical position.

According to a second aspect of the invention there is provided a method of manufacturing a hoarding panel comprising rotationally moulding a unitary plastics panel in a mould, separating the unitary plastics panel into first and second panels after moulding by cutting them apart around their periphery, and attaching the or each separated panel to a rectangular framework.

The framework may be of metal or plastics, for example, of metal or plastics tubing.

The method enables unitary plastics panels to be used for each hoarding panel, without having double skinned heavy panels. Utilising plastics means that the panels can be formed in any desired colour, for example, to blend in with surroundings, to be highly visible, or to match a brand colour.

The rotational mould is preferably constructed in two halves, each half comprising three parts, including a bottom section, a mid-section and a top section. Optionally the mid-section of each half may be removable, enabling the manufacture of panels of two different heights.

By constructing the rotary mould in a modular way, with an optional insert, positioned within the length of the panel, significant expense can be spared in manufacturing hoarding panels of different heights, for example, 2m and 2.4 m tall.

Each separated plastics panel may be attached to the framework using mechanical fasteners, for example, rivets or screw fasteners. Alternatively, the plastics panel can be attached to the frame using cable ties.

An edge of the separated plastics panel may include at least one flange. The flange is designed to rest against the frame, thereby positioning the fasteners at a predetermined position away from the flange to connect to a central axis of the tubing forming that part of the frame.

In this way, the area of the plastics panel where it is weakened by the fastening is strengthened by the flange. By the plastics flange nearing against the frame, the panel is effectively reinforced around its periphery. In other words, the frame nestles into the panel.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which: Figure 1 shows a front view of a barrier formed by three hoardings of the invention; Figure 2A shows a front view of the hoarding of Figure 1 in more detail; Figure 2B shows an enlarged cross-sectional view of the attachment of the plastics panel to a metal frame at an upper end of the hoarding; Figure 2C shows an enlarged view of part of the front of the hoarding; Figure 2D shows a perspective view of an upper corner of the hoarding from the rear; Figure 2E shows a perspective view of the rear of the plastics panel; Figure 3 shows a perspective view of a typical hoarding coupler of the type intended to be used with the invention; Figure 4A shows a perspective view of a closed rotational mould for manufacturing a plastics panel for use in the hoarding of Figure 1; Figure 4B shows a perspective view of the rotational mould in Figure 4A in an open position; Figure 4C shows a perspective view of the parts of the rotational mould of Figures 4A and 4B; Figure 5A shows a front view of a plastics panel formed from the full rotational mould of Figures 4A to 4C; Figure 5B shows a front view of a plastics panel formed from a reduced form of the rotational mould of Figures 4A to 4C; and Figure 6 shows a front view of an alternative embodiment of plastics panel formed with reinforcement profiles running laterally.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring firstly to Figure 1, three embodiments of hoarding panel are indicated at 10, 12 and 14. Hoarding panel 10 is a standard panel of the invention, hoarding panel 14 is of the same height, but includes a central reinforcing member, described further below, and hoarding panel 12 is a reduced height panel. The standard hoarding panel 10 is 2m wide by 2.4m high and the reduced height panel is 2m wide by 2m high. The hoarding panels 10, 12, 14 are shown from the rear and each comprise a single skin plastics panel 16, 16a and a frame 18, 18a, 18b. The frame is preferably metal, but may be of plastics.

The metal frame 18, 18a, 18b is rectangular and is sized to sit just inside the external edges of the plastics panels 16, 16a. It will be appreciated that the plastics panels are moulded slightly large, to allow for manufacturing tolerances and plastics shrinkage.

Each frame, for example, frame 18 has two vertical side posts 20, a horizontal top bar 22 and a horizontal bottom bar 24. The two vertical side posts 20 extend beyond the horizontal bottom bar 24 and the lower edge of the plastics panel 16, to provide short legs 26. The legs can be positioned in apertures in concrete or rubber blocks to support the hoarding panel substantially vertically. Each frame 18 is made from tubular metal, which may be circular in cross-section, and welded at the joints. It can be galvanised, painted or plastics coated.

The frame 18b has an additional vertical member 28, which is positioned midway between the two vertical side posts 20b. This extra vertical member 28 provides extra rigidity and reinforces the central area of the plastics panel 16, for use, for example in very windy locations or where greater security is required.

Referring now to Figures 2A to 2C, an upper edge of each plastics panel 16, 16a is provided with a flange 30. The flange 30 extends rearwardly of the panel 16,16a, at 90 degrees to the plane of the face of the panel. The flange 30 provides structural rigidity at the top edge of the panel 16, 16a, but also acts as a location for the horizontal top bar 22 of the frame. Mechanical fasteners, in this case self-tapping screws 32 are driven from the front of the plastics panel 16, 16a into the centre of the horizontal top bar 22 at spaced intervals along its length. The fasteners 32 have enlarged heads or washers to spread the load of the fastener onto the surface of the plastics. Rivets may also be utilised as fasteners, as may cable ties. If cable ties are used, then suitable positioned holes are drilled in the panels 16, 16a to enable them to pass through and wrap around the frame members.

Referring to Figure 2D, the flange 30 terminates at each side of the plastics panel 16 in an open top-hat feature 34. Each top hat feature 34 partially covers the upper distal end of one of the vertical side posts 20.

Referring also to Figure 2E, a lower edge of the plastics panel 16, 16a is also provided with a flange 36. As with the flange 30, the flange 36 extends rearwardly of the panel 16,16a, at 90 degrees to the plane of the face of the panel. The flange 36 provides structural rigidity at the lower edge of the panel 16, 16a, but also acts as a location for the horizontal bottom bar 22 of the frame. The flange 36 terminates in a part-circular cut-away, which allows the legs 26 to pass past the flange 36 below the plastics panel 16,16a.

Reinforcing ribs 37 extend vertically between flat lands running laterally along the top and bottom of the panel 16, 16a. These flat lands provide a sound surface for the fasteners 32. The ribs 37 are formed as individual depressions, and the surrounding flanges that are formed between the base of the depressions and front face of the panel 16, 16a provide rigidity and structural reinforcing. The ribs 37 are positioned so as not to align with the centre of the panel, which would impede the central additional vertical member 28 of the frame 18b.

Elongate recesses 35 extend vertically along the side edge of each panel adjacent the vertical parts of the metal frame. The recesses facilitate cutting away of the plastics next to the verticals to allow for unimpeded fitting of couplers, discussed further below.

Figure 3 shows 3 hoarding panels 10 positioned in a line to form a hoarding and an example of a known coupler or clamp 38. The coupler 38 is formed from two plates, with cups at either end for engaging around adjacent vertical side posts of adjacent panels 10. The coupler is tightened by a centrally disposed bolt with nut. It will be appreciated that to fit the couplers 38, particularly when the panels are at an angle to each other, the plastics of the recesses 35 may need to be cut away. This can be relatively easily achieved with a hand-held cutting device such as tin snips or other cutting device.

Referring now to Figures 4A to 4C, a modular rotational mould tool for manufacturing the plastics panels 16, 16A is indicated generally at 40. The mould tool 40 includes 6 components, first and second bottom sections 42, 42a, first and second mid-sections 44, 44a, and first and second top sections 46, 46a. The sections 42, 44, and 46 form one side of the mould and the sections 42a, 44a, and 46a form the other side of the mould. The mould sides are symmetrical and the sections of each side are connected together, for example, by being bolted together. If a large panel is required, then all three sections of each side are connected, but if a smaller panel is required, then the mid-sections are omitted In this case, the respective lower sections and top sections are connected together.

Flanges shown byway of example at 48 in Figure 4A extend around the outer periphery of each section. Abutting flanges 48 can be connected together enabling the fastening of the sections of a side.

Figure 5A shows an example of a plastics panel 16 moulded using the tool incorporating the mid sections 44, 44a. Figure 5B shows an example of a plastics panel 16a moulded using the tool without the mid-sections 44, 44a.

Once the panels 16,16a have been rotationally moulded, they have two symmetrical sides, the outer faces of which form front faces of the panels 16, 16a. The panels are then mechanically cut in half, around their periphery as viewed in Figures 5A and 5B, to provide two separated panels, for use in constructing two separate hoarding panels 10.

An alternative design of plastics panel is indicated at 50 in Figure 6. In this design, elongate recesses 52 are provided on either side of the panel, as for the panel 16,16a. However, a plurality of reinforcing ribs 54 extend laterally, that is from side to side across the panel, rather than vertically. Other features of the panel 50 are similar to that of the panel 16.

The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.

Claims

CLAIMS1 A hoarding panel comprising a single skin plastics panel, manufactured by rotationally moulding a two sided hollow panel and cutting it into two, a plurality of ribs extending between opposing sides or ends of the panel, and a frame extending around the periphery of the panel, the frame being fastened to at least one set of opposing edges of the panel.
2. A hoarding panel as claimed in claim 1, in which the frame is manufactured from metal or plastics.
3. A hoarding panel as claimed in claim 2, in which side edges of the panel are shaped with a curve for receiving and engaging against the tubular frame.
4. A hoarding panel as claimed in claim 2 or 3, in which an elongate recess extends proximate to each side edge.
5. A hoarding panel as claimed in claim 4, in which each recess extends partially along each edge, and can be cut away in whole or in part, to enable attachment of a connecting coupler to the frame.
6. A hoarding panel as claimed in any preceding claim, in which a flange is provided along the upper edge of the plastics panel.
7. A hoarding panel as claimed in claim 6, in which an upper part of the frame rests against the upper flange.
8. A hoarding panel as claimed in any preceding claim, in which a flange is provided along the lower edge of the plastics panel.
9. A hoarding panel as claimed in claim 8, in which a lower part of the frame rests against the lower flange.
10. A hoarding panel as claimed in any preceding claim, in which mechanical fasteners fasten the plastics panel to the metal frame.
11. A hoarding panel as claimed in any preceding claim, in which a pair of legs of the frame extend beyond the lower edge of the plastics panel for engaging with support blocks to support the hoarding panel in a substantially vertical position.
12. A method of manufacturing a hoarding panel comprising rotationally moulding a unitary plastics panel in a mould, separating the unitary plastics panel into first and second panels after moulding by cutting them apart around their periphery, and attaching the or each separated panel to a rectangular framework.
13.A method of manufacturing a hoarding panel as claimed in claim 12, in which the rotational mould is constructed in two halves, each half comprising three parts, including a bottom section, a mid-section and a top section, optionally the mid-section of each half being removable enabling the manufacture of panels of two different heights.
14. A method of manufacturing a hoarding panel as claimed in claim 13, in which each separated plastics panel is attached the framework using mechanical fasteners.
15. A method of manufacturing a hoarding panel as claimed in claim 14, in which an edge of the separated plastics panel includes at least one flange, the frame engages against the flange and the position of the fasteners is set at a position away from the flange to connect to a central axis of the tubing forming that part of the frame.