Multi-paneled signage substrate and method for making the same

An article (101) is provided which includes a plurality of panels (103), wherein each panel comprises a first edge having a first longitudinally extending protrusion (107) adjacent thereto and a second edge having a second longitudinally extending protrusion (109) adjacent thereto, wherein each of the first and second protrusions has a planar exterior surface (131) and an interior surface (133) having an indentation (135) therein, and wherein the plurality of panels are arranged in an abutting manner such that the planar exterior surface of at least one first protrusion and at least one second protrusion are disposed in an opposing relation to each other. A coupler (113) is also provided which extends over said first and second protrusions. The coupler is equipped with at least a first protuberance (145) which engages the indentation on the interior surface of the first protrusion.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to multi-paneled articles, and more particularly to multi-paneled signage substrates and methods for making the same.

BACKGROUND OF THE DISCLOSURE

The use of signage has become ubiquitous in modern society. This is especially true on roadways, where signage is used to direct and regulate traffic, provide navigational aids and information, warn motorists of potential hazards, and for various other purposes.

Due to their sheer numbers, roadway signs present significant resource consumption issues. For example, by the mid-1990s, about $250 million was being spent annually in the U.S. to maintain 58 million traffic signs spread over 3.8 million miles of roads, streets and highways. Aluminum (typically in the form of alloy grades 6061, 5052 and 3000) and wood have traditionally been the most commonly used substrates for signage applications.

SUMMARY OF THE DISCLOSURE

In one aspect, an article is provided which comprises (a) a plurality of panels, wherein each panel comprises a first edge having a first longitudinally extending protrusion adjacent thereto and a second edge having a second longitudinally extending protrusion adjacent thereto, wherein each of said first and second protrusions has a planar exterior surface and an interior surface having an indentation therein, and wherein said plurality of panels are arranged in an abutting manner such that the planar exterior surface of at least one first protrusion and at least one second protrusion are disposed in an opposing relation to each other; and (b) a coupler which extends over said first and second protrusions, wherein said coupler is equipped with a first protuberance which engages the indentation on the interior surface of said first protrusion.

In another aspect, a method is provided for making an article. The method comprises (a) providing a plurality of panels, wherein each panel comprises a first edge having a first longitudinally extending protrusion adjacent thereto and a second edge having a second longitudinally extending protrusion adjacent thereto, and wherein each of said first and second protrusions has a first planar surface and a second indented surface; (b) arranging the panels in an abutting manner such that the planar surface of at least one first protrusion and at least one second protrusion are disposed in an opposing relation to each other; and (c) applying a coupler to said first and second protrusions, wherein said coupler extends over said first and second protrusions and is equipped with a first protuberance which engages the indented surface of said first protrusion.

In a further aspect, an article is provided which comprises (a) a plurality of panels, wherein each panel comprises a first edge having a first longitudinally extending protrusion adjacent thereto and a second edge having a second longitudinally extending protrusion adjacent thereto, wherein each of said first and second protrusions are arranged in an abutting manner such that said first protrusion and said second protrusion are disposed in an opposing relation to each other, and wherein said first protrusion is equipped with an indented surface; and (b) a coupler which extends over said first and second protrusions, wherein said coupler is equipped with a first protuberance which engages the indented surface of said first protrusion.

DETAILED DESCRIPTION

At present, e-waste (waste from electronic products) is growing faster than any other type of waste, with an annual volume close to 40 million metric tons (88,200,000,000 pounds) globally. Such growth is expected to increase. Indeed, a 2010 UN study concluded that e-waste is likely to grow exponentially over existing levels, to as much as 500 times over the coming decade. This is equivalent to over 44,100,000,000,000 lbs of e-waste.

Plastics account for 23% of all e-waste. Unfortunately, the plastic in e-waste is not environmentally friendly, because it contains UV inhibitors and brominated flame retardants. These additives render such plastics virtually non-biodegradable in landfills.

Recently, some attempts have been made to create useful products out of e-waste. For example, commonly assigned U.S. Ser. No. 13/109,545 (Abadi et al.), entitled “PLASTIC RECYCLING METHOD AND MANUFACTURING PRODUCT”, (which is incorporated herein by reference in its entirety) discloses the use of recycled plastics, such as ABS, in the manufacture of various articles, including signage substrates. This application leverages the inherent UV stability and flame resistance of the waste stream material to make useful products. In doing so, it converts an environmental liability to a useful feedstock, while offering a variety of other advantages associated with recycling.

Despite the many advantages of the foregoing process, further improvements are required. For example, practical limitations exist with respect to the size of articles that can be generated by this process due, for example, to commonly available die sizes and processing equipment limitations. These limitations make it difficult to cast articles having a major dimension larger than about 3-4 feet from recycled plastics. However, it is frequently desirable to create larger articles than this, especially in signage applications. By way of example, highway signs having heights of 42″, 56″ or larger are common, and many highway signs have widths which are considerably larger than their heights (the actual widths are variable and dictated by the amount of lettering required and other such considerations).

It has now been found that the foregoing limitations may be overcome through the provision of a plurality of interlocking panels that may be connected together to provide a signage substrate or other article. The panels are preferably fabricated from recycled plastics, and may be made in small enough sizes to accommodate conventional processing equipment. In a preferred embodiment, the design of the panels allows them to be readily assembled together to form various rigid multi-paneled articles which have a planar surface suitable for imaging.

The devices and methodologies disclosed herein may be further appreciated with respect toFIGS. 1-8, which depict a first particular, non-limiting embodiment of a multi-paneled article, and a method for making the same, in accordance with the teachings herein. As seen inFIGS. 1-2, the multi-paneled article101in the particular embodiment depicted consists of a plurality of panels103that are assembled into a desired construct by adjoining them laterally.

The profile of the individual panels103may be appreciated with respect toFIG. 4. As seen therein, each panel103is equipped with a plurality of longitudinal protrusions (denoted collectively by105) or ridges. In the particular embodiment depicted, these protrusions105include a first terminal protrusion107which is disposed along a first edge of the panel103, a second terminal protrusion109which is disposed along a second end of the panel103, and one or more interior protrusions111which are disposed between the first107and second109protrusions. The first107and second109terminal protrusions in the depicted embodiment are essentially R-shaped in cross-sectional profile and are mirror images of each other, and the interior protrusions111are essentially A-shaped in cross-sectional profile. Of course, one skilled in the art will appreciate that various embodiments may be made in accordance with the teachings herein that contain varying numbers of protrusions, and these protrusions may have various profiles or various dimensions, and may be arranged in various ways. Notably, the panel103has a first major surface112which is preferably planar or essentially planar, and an opposing second major surface114which has the protrusions105disposed thereon.

The manner in which panels103may be adjoined to form a multi-paneled article may be appreciated with respect toFIGS. 7-8. As seen therein, the panels103are arranged in an abutting manner such that a first terminal protrusion107and a second terminal protrusion109are disposed in an opposing and abutting relation to each other. A coupler113is then applied to the abutting first107and second109terminal protrusions to bind them together, thus securing the panels103in an abutting relation to each other. As seen inFIG. 8, in some applications, an optional fastener115(which may be, for example, a screw, nail, clip, pin, or other threaded or non-threaded fastener or element) may be utilized to maintain the coupler in place. As seen inFIGS. 3 and 7, in the resulting article101, the panels103are adjoined across a tight seam119on a first (preferably planar or essentially planar) surface121of the article101, with the protrusions105on a second surface123of the article101.

In the particular embodiment depicted inFIG. 3, the first surface121is planar, thus rendering the article101useful as a signage blank or for other applications where such a surface is required. Of course, it will be appreciated that, in alternative embodiments, an article having a non-planar first surface121may be achieved by using panels103that have a non-planar surfaces, or which couple to each other at an angle other than 180°. By way of example, the panels103may be equipped with a first surface112(seeFIG. 4) which has a curved, polygonal, irregular, or other desired profile.

The manner in which the coupler113attaches to the protrusions105may be understood with greater specificity by reference toFIGS. 5-6, which show, respectively, the detailed profile of the protrusion109(protrusion107is a mirror image) and the coupler113. With reference thereto, each of protrusions107and109in this particular embodiment has a first surface131which is planar, and a second opposing surface133which is equipped with an indentation135. The protrusions105in this particular embodiment are hollow to reduce the weight of the article and reduce manufacturing costs, though one skilled in the art will appreciate that solid protrusions could be used as well in some applications.

The coupler113is essentially U-shaped, and consists of first141and second143opposing (and preferably resilient) walls, each of which terminates in a prong145. The prongs145are preferably complimentary in shape to the indentations135on the coupler113(seeFIG. 5). Moreover, the area147encompassed within the coupler113is preferably complimentary in shape to the profile formed by two protrusions105when their first planar surfaces131are in abutment (seeFIG. 5). Consequently, when the coupler113is placed over the abutting protrusions105, the prongs145snap into place into the indentations135, thus securing the coupler113in place. In so doing, the first flat regions151on each prong145(seeFIG. 6) of the coupler113pressingly engage second flat regions153on the indented surfaces of each protrusion109(seeFIG. 5).

Various materials may be utilized in the devices and methodologies described herein. However, the use of plastics or polymeric materials is preferred, and the use of recycled plastics (especially thermoplastics) or polymeric materials is especially preferred. Such materials may include acrylonitrile-butadiene-styrene (ABS), polycarbonate, polystyrene, styrene-acrylonitrile (SAN), polyvinylchloride (PVC), acetal, nylon, polyethylene, polypropylene, polyesters polyvinylchloride (PVC), acrylics, fluoropolymers and polymides. Mixtures and copolymers of the foregoing materials may also be used in the devices and methodologies described herein. Any portion or component (including the couplers) may be made partially or wholly out of the foregoing materials, though in some embodiments, the couplers may also comprise various metals.

The use of ABS, and especially recycled ABS, in the devices and methodologies described herein is especially preferred. Suitable ABS resins include, for example, general purpose high gloss grade ABS resins having a melt flow rate (MFR) of 6.0 g/10 min (3.8 kg, 230° C.) and an Izod impact strength of 5.5 ft-lb/in. ABS is commonly used to form rigid computer parts, such as computer and printer housings, and ink cartridges. Hence, ABS represents a significant waste stream that is available in large volumes. Moreover, ABS resists biodegradation due to the flame retardants and UV inhibitors it is typically compounded with, and hence presents disposal and landfill issues. The devices and methodologies disclosed herein advantageously utilize these properties in applications such as signage, and thus turn an environmental liability into useful products.

As noted above, the polymeric materials used in the devices and methodologies described herein may contain various flame retardants. Such flame retardants may include various halogenated materials such as, for example, tetrabromobisphenol-A (TBAA), 1,2-bis(2,4,6-tribromophenoxy)ethane (TBPE) or octabromodiphenyl oxide (OBDPO). These flame retardants may be used in various amounts, but are typically used in amounts in the range of about 5% to about 40%, preferably in the range of about 10% to about 30%, more preferably in the range of about 10% to about 25%, and most preferably in the range of about 15% to about 17%, based on the total weight of the formulation. The polymeric materials may also contain one or more UV stabilizers.

The polymeric materials used in the devices and methodologies described herein may also contain various metal oxides. Some of these metal oxides may provide a synergistic effect with the foregoing flame retardants and thus reduce the amount of flame retardant required, which in turn can give rise to polymeric compositions having improved physical properties. Examples of such materials may include antimony pentoxide (such as that available commercially under the designation BurnEx ADP494) and antimony trioxide. These materials may be utilized in various amounts. ABS polymers compounded with bromine-containing flame retardants, the antimony pentoxide or antimony trioxide is preferably formulated at mole ratios of 3:1 and 4:1 (bromine:antimony).

While virgin polymeric materials used in the devices and methodologies described herein may be compounded with the above noted materials, recycled materials may already contain these additives. In this case, it is preferred to process these materials in a way that will avoid loss of these materials. For example, U.S. Ser. No. 13/109,545 (Abadi et al.), which has been referenced above, discloses methods for processing recycled ABS and other materials which avoids volatilization of the flame retardants these materials contain, and which may be utilized to produce the articles described herein. These methods may involve processing the recycled materials at lower temperatures (e.g., over the glass transition temperature of the recycled polymers) and possibly under pressure).

While the foregoing description has described the inventive articles and methodologies primarily with respect to flat panels, one skilled in the art will appreciate that various articles of various shapes may also be produced through suitable application or modification of the principles disclosed herein. For example, connector pieces of various shapes and configurations may be utilized in combination with the panels described herein to achieve articles having various shapes. By way of example, connector pieces (which may essentially be a panel of the type described herein, but bent or curved at a given angle such as, for example, 45°, 60° or 90°) may be used in conjunction with the foregoing panels to achieve multi-panel articles having various configurations.

It will further be appreciate that the articles produced in accordance with the methods described herein are not limited to signage. By way of example (but not limitation), such articles may include plastic pavers, decking, wall coverings, playground structures, and the like.

It will also be appreciated that the articles produced in accordance with the teachings herein may be subjected to further processing to produce various products. For example, signage may be created from these articles by applying reflective sheeting, reflective layers or indicia (both shown generally as element122inFIG. 7), lettering, UV protective layers, and other suitable components. In some applications, the substrate may have to be primed, roughened, or otherwise prepared prior to the application of these materials.

It will also be appreciated that the articles produced in accordance with the teachings herein may be derived from polymers that have been mixed or compounded with various dyes, pigments, colorants, fillers, stabilizers, plasticizers, surfactants and other additives as are known to the art. These may include, without limitation, carbon black, titanium dioxide, and/or various metal powders or particles.

It will also be appreciated that the articles produced in accordance with the teachings herein may include various films, powders or inks which may be applied to one or more surfaces thereof for various purposes. For example, films with printing, artwork or indicia161(seeFIG. 1) may be applied to blank signage substrates produced in accordance with the methodologies described herein.

The above description of the present invention is illustrative, and is not intended to be limiting. It will thus be appreciated that various additions, substitutions and modifications may be made to the above described embodiments without departing from the scope of the present invention. Accordingly, the scope of the present invention should be construed in reference to the appended claims.