Patent Publication Number: US-2006010738-A1

Title: Sign structure and related tool and method

Description:
RELATED APPLICATION/CLAIM OF PRIORITY  
      This Application is related to and claims priority from Provisional Application Ser. No. 60/582,589, filed Jun. 24, 2004, entitled Sign Structure, which provisional application is incorporated by reference herein. 
    
    
     BACKGROUND  
      The present invention relates to sign structure, and particularly to wind actuated rotatable sign structure that is designed to be (i) efficient and cost effective to produce, (ii) easy to assemble and disassemble, in order to change the message conveyed by the sign structure, and (iii) effectively rotated by air movement in the vicinity of the sign structure, to attract the attention of those in viewing range of the sign structure. The present invention also relates to tool structure and methods for use in forming the sign structure.  
      In the applicants&#39; experience, rotating sign structures have often signs formed of aluminum, with fins at the ends of the signs, and special bearing/connecting structure that enables the signs to be connected with support frames in a manner that allows the signs to be wind actuated and effectively rotated.  
      Also in the applicants&#39; experience, there are areas in which such sign structures can be further improved. For example, applicants believe such sign structures can be designed in a manner that reduces the weight of the sign structure, and can be designed to be (i) efficient and cost effective to produce, (ii) easily and efficiently assembled, in order to change the message conveyed by the sign structure, and (iii) effectively rotated by air movement in the vicinity of the sign structure, to attract the attention of those in viewing range of the sign structure.  
     SUMMARY OF THE PRESENT INVENTION  
      The present invention relates to new and useful sign structure designed to be (i) efficient and cost effective to produce, (ii) easily and efficiently assembled, in order to change the message conveyed by the sign structure, and (iii) effectively rotated by air movement in the vicinity of the sign structure, to attract the attention of those in viewing range of the sign structure.  
      Sign structure according to the present invention comprises a support rod, and a sign comprising a specially formed panel that is rotatable on the support rod. A bearing surface is integrally connected with the panel (is preferably formed in one piece with the panel) and extends along a predetermined portion of the panel. The bearing surface is configured to slide over the support rod and to rotate on the support rod, so that the panel is rotatable about the support rod. In a preferred form, the panel comprises a synthetic material having a corrugated configuration with at least one corrugation forming the bearing surface for the panel. Additionally, in a preferred form, a pair of fins are formed in one piece with the corrugated panel, and are bent at an angle relative to the plane of the panel.  
      Additionally, a preferred sign structure according to the present invention is designed in a manner that enables a planar piece of corrugated synthetic material to be efficiently formed into the sign. Specifically, a planar piece of corrugated synthetic material is formed in a way that allows the fins to be efficiently bent out of the plane of the panel, and maintained in the bent configuration, to form the sign.  
      Still further, the present invention provides a new and useful tool that can be used in forming the sign structure, and to a method that uses the tool in forming the sign structure.  
      Further features of the present invention will become apparent from the following detailed description and the accompanying drawings and Exhibits.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS AND EXHIBITS  
       FIG. 1  is a schematic illustration of one embodiment of a Sign structure according to the principles of the present invention;  
       FIG. 2  is a schematic top view of a sign in the sign structure of  FIG. 1 , and specifically showing the center panel and fins forming the sign;  
       FIG. 2   a  is an enlarged, fragmentary view of the center of the sign of  FIG. 2 ;  
       FIG. 3   a  is a schematic top view, and  FIGS. 3   b  and  3   c  are schematic partial top views, of the sign of  FIG. 1 , as the sign is being formed and  FIG. 3   d  is an enlarged fragmentary view of the slits shown in  FIG. 3   b;    
       FIGS. 4   a  and  4   b  are additional schematic partial top views of the sign of  FIG. 1 , showing stiffener wire as the sign is being formed;  
       FIG. 5   a  is a schematic three dimensional view of another embodiment of a sign structure according to the principles of the present invention;  
       FIGS. 5   b,    5   c  and  5   d  schematically illustrate the manner in which the sign structure of  FIG. 5   a  is assembled, according to the principles of the present invention;  
       FIGS. 6   a,    6   b  and  6   c  are schematic illustrations of another sign structure, according to the principles of the present invention;  
       FIGS. 6   d  and  6   e  schematically illustrate the manner in which the sign structure of  FIGS. 6   a  and  6   b  is assembled;  
       FIG. 6   f  schematically illustrates another way of supporting the sign structure of  FIG. 6   c;    
       FIGS. 7   a - 7   e  schematically illustrate components for supporting a rotatable sign structure, according to the principles of the present invention;  
       FIGS. 8   a - 8   e  show a tool that can be used to cut the panel of the sign structure, to form the slits shown in  FIGS. 2, 3   c  and  4   b.    
    
    
      Exhibits A1-A4 further show features of the tool and the method that uses the tool in forming the sign structure.  
     DETAILED DESCRIPTION  
      As described above, the present invention relates to new and useful sign structure, and particularly to rotatable sign structure. The principles of the invention are described below in connection with several versions of a sign structure. From that description, the manner in which various types of sign structures can be constructed, according to the principles of the present invention.  
      One embodiment of a sign structure, according to the principles of the present invention, is shown in  FIGS. 14 . The sign structure  100  comprises a support rod  102 , and a sign  104  that is rotatable on the support rod  102 . The sign  104  comprises a center panel  106  that is generally planar, and a pair of fins  108  formed in one piece with and extending angularly out of the plane of the panel  106 . By “formed in one piece” applicants mean that the fins are formed from the same piece of material that forms the panel. The center panel  106  and fins  108  are preferably formed in one piece of a synthetic material that is corrugated.  
      A bearing surface is integrally connected with the panel, so that the panel and bearing surface move together as a unit. According to a preferred version of the invention, at least one corrugation forms a bearing surface that extends through the center panel (from the top  110  of the center panel to the bottom  112  of the center panel). Preferably, the bearing surface comprises the inner surface  113  of a central corrugation  114  of the center panel  106  (see  FIGS. 2, 2   a ). The bearing surface  113  is configured to slide over the support rod  102  and allows the center panel  106  to rotate on the support rod  102 , so that the sign  104  rotates about the support rod. In  FIG. 2 , the arrow  107  depicts the direction of rotation of the sign  104  about the support rod  102 , when the fins  108  are in the bent orientations shown in that figure. While it is preferred that the bearing surface is formed in one piece with the panel, the bearing surface could comprise, e.g., a bushing located in the central corrugation and fixed to the panel, so that the panel and bearing surface move together as a unit.  
      The sign  104  has display material that is displayed to those in viewing range of the sign  104 , as the sign rotates on the support rod  102 . The material may be applied to the center panel  106  and/or to the fins  108 , either in a permanent form or in a removable form. If the display material is in a permanent form, changing the sign on the support rod can change the display. If the material is in a removable form, the material can be selectively removed and new material applied to the sign. In addition, the sign can also be changed, e.g. if it is desired to change the display content of the sign, if the original sign becomes worn or damaged, etc.  
      As can be seen from  FIGS. 2, 2   a,  the center panel  106  extends laterally from a central corrugation  114  in which the support rod  102  is located. The central corrugation  114  has the bearing surface  113 . The fins  108  are provided at the lateral ends of the center panel  106 . The fins  108  extend angularly in opposite directions out of the plane of the center panel, and are configured to allow air movement in the vicinity of the panel to rotate the sign  104  about the support rod  102 .  
      According to one preferred version of the invention, the fins  108  are bent relative to the planar center panel  106 . Specifically, each fin is bent at one or more slits  116  cut at predetermined locations in an exterior wall of the corrugated material (see e.g.  FIGS. 3   b,    3   c,    3   d,    4   a,    4   b ). The locations of the slits  116  depend on where the fins  108  are to be bent relative to the center panel  106 . The slits  116  are formed in an exterior wall of the corrugation, preferably at an angle  118  ( FIGS. 3   b  and  3   d ) relative to normal to the planar center panel. Preferably, each slit  116  is formed in a wall of the planar portion at an angle  118 , that is 10 to 80 degrees, and preferably between 40 and 50 degrees, relative to normal to the planar center panel. Cutting the slits at an angle, and in the orientation illustrated, enables the fins  108  to be bent relative to the planar center panel  106  without interference from the remainder of the corrugated material, because the slits can slide passed each other when the fins are bent. Alternatively the slits could be cut mirror image, i.e. at 100 to 170 degrees.  
      A tool  200  (also referred to as a Slicer) for use in slicing a corrugated panel is illustrated in  FIGS. 8   a - 8   e  and in Exhibits A1-A4. A corrugated panel  106  that is sliced by the tool  200  is formed of a synthetic material such as Coroplast (described further below) and includes a pair of generally parallel walls  204  and connecting webs  206  between the walls (see  FIGS. 2   a,    8   e  and Exhibit A3). One of the walls  204  is sliced, in a direction parallel to the webs  206 , to enable a portion of the corrugated panel to be bent out of the plane of the main panel to form a fin on each of the outboard edges.  
      The tool  200  comprises a support  210 , a handle  212 , a guide rod  216 , and a slicing blade  218  connected with the support. In addition, a surface roller  214  is connected with the handle  212 . The guide rod  216  is configured and oriented to be inserted into a corrugation in a panel. The surface roller  214  is configured and oriented to roll along the surface  205  of one of the walls  204  of a panel  202  when the guide rod  216  is in a corrugation in the panel. The slicing blade  218  is configured and oriented to slice through the wall  204  of the panel on which the surface roller  214  rolls, at a predetermined angle to the surface  205  of the panel wall  204 . The handle  212  is configured and oriented to enable a user to hold the tool, insert the guide rod  216  into a corrugation in the panel with the surface roller  214  disposed on the surface  205  of the panel, and push the tool  200  along the surface  205  of the panel, so as to slice the surface of the panel at the predetermined angle with the blade. Once the guide rod  216  of the Slicer has gone into a corrugation, it brings the edge of the blade of the Slicer in contact with the outer edge of the wall  204  of the panel. The blade is at an angle of from 10 to 80 degrees (relative to surface  205 ) and will then make a slice cut in the wall  204  at that angle. The surface roller  214  is configured to roll on surface  205  of the corrugated panel wall  204  to insure a smooth cut of the panel wall.  
      As the slicing tool is moved along the surface  205  of the corrugated panel in a direction parallel to the connecting webs, the wall  204  of the panel is sliced at a predetermined angle. This forms the slits  116  in the panel. Cutting the slits at an angle of from 10 to 80 degrees allows the edge portion of the corrugated panel to be bent in the direction of the slits ( FIGS. 8   d,    8   e,  Exhibit A3), without the sliced portions binding while being bent. Instead the angled slits allows the two cut pieces to slide over/under each other, making the folding the outside angle very easy without any binding of the cut areas ( FIG. 8   e  and Exhibit A3). If the cuts are made at 90 degrees it is difficult if not impossible to bend the edge portion relative to the main panel.  
      When it is desired to provide two fins in the panel, that are bent out of the plane of the panel, each fin is produced by moving the slicing tool along the surface  205  of the wall  204  of the panel, at least once and preferable twice, along adjacent corrugations of the panel, to form a pair of slices in the wall  204  of the panel, along adjacent corrugations of the panel. If only one slice is used the angle at which the panel can be bent is limited. Then the panel is bent at those slices, in a direction such that that the slices in the one surface can slide under each other, thereby to facilitate bending the panel in the one direction, to form the fin ( FIGS. 8   d,    8   e,  Exhibit A3). The support wires  120 , described below, are provided in the bent fins, in the manner described below, to maintain the fins in the bent condition.  
      It is preferred that one or more structural supports extend at least partially in the planar center panel  106  and at least partially into a fin  108  to maintain the fin bent relative to the center panel  106 . Referring to  FIGS. 4   a,    4   b,  each structural support is preferably a support wire  120  (e.g. formed of copper or another metal that is easily bent) that extends at least partially in the planar center panel and at least partially in a fin  108  that is bent relative to the center panel  106 , to maintain the fin bent relative to the center panel  106 . The wire  120  can be inserted in openings in the center panel and the fin, before the fin is bent out of the plane of the center panel. Since the wire is malleable, it can be conveniently bent when the fin is bent relative to the center panel. However, the malleable metal wire  120  is rigid enough that when the fin  108  has been bent relative to the center panel  108 , the wire  120  will hold the fin in the bent configuration during normal operation of the sign. The cross section of the wire  120  can be any shape (e.g. round, square, rectangular, oval, etc.)  
      In the embodiment of  FIG. 1  the sign includes a base  122  that is configured to rest on a surface. The base  122  comprises parallel bottom pieces  122   a  and a cross piece  122   b  that is notched to fit the bottom pieces and is coupled to the bottom pieces, e.g. by bolt, washer and wing nut assemblies  122   c.  The bottom pieces and cross piece are preferably formed of material known in the trade as “plastic lumber”. A post  123  is connected to and extends upward from the base  122 . The post has an upper portion  123   a  that is bent to a generally horizontal orientation when the post is supported on the base. The support rod  102  extends upward from the cross piece  122   b  of the base and is coupled with the cross piece  122   b  and the horizontal portion  123   a  of the post. As illustrated in  FIGS. 7   a - 7   d,  the support rod  102  can have threaded upper and lower ends. In the embodiment of  FIG. 1 , the lower threaded end of the support rod can be screwed into an opening in the cross piece  122   b  of the base. The upper threaded end of the support rod  102  extends through an opening in the horizontal portion  123   a  of the post, and is coupled with the portion  123   a  by a washer, lock nut and acorn nut assembly  125  ( FIGS. 7   a,    7   b,    7   e ). The corrugated sign  104  is inserted onto the support rod  102 , by inserting the support rod through the central corrugation  114  that includes the bearing  113 . Bearing and support structure, described further below, provides bearing support for the sign, and allows the sign  104  to easily rotate on the support rod  102 .  
       FIGS. 7   a - 7   d  schematically illustrate examples of bearing and support structure  700  for the sign. The bearing a support structure comprises a pair of larger washers  702 , smaller washers with a thrust bearing  706  between those smaller washers, a spacer  708  (e.g. a nylon sleeve) and a lock nut  710 . Those components enable the sign to rest on one of the large washers  702 , and to rotate easily on that large washer. The lock nut  710  enables the position of the bearing and support structure to be adjusted (to some extent) along the support rod  102 , to allow a degree of vertical adjustment of the position of the sign. In addition, a lock nut and washer assembly  712  can be provided at the bottom of the support rod, so that rather than screwing the lower end of support rod into an opening in cross piece  122   b,  the threaded lower end of the support rod can extend through a hole in the cross piece  122   b,  and the lower lock nut and washer assembly  712  can be tightened to couple the lower end of the support rod to the cross piece  122   b.    
       FIG. 5   a  shows another embodiment of a sign structure, according to the present invention, and  FIGS. 5   b - 5   d  show how the sign structure is assembled. The sign structure of  FIG. 5   a  includes a base  522  with parallel lower pieces  522   a  and a cross piece  522   b  that are similar to the base of  FIG. 1 . A central post  523  extends upward from the cross piece  522   b,  and has horizontal top sections  523   a.  A pair of support rods  502  are provided, each of which is coupled with the cross piece  522   b  and a horizontal top section  523   a,  in a manner similar to the embodiment of  FIG. 1 . The base  522  and post  523  are initially assembled in the manner schematically illustrated in  FIG. 5   b.  The support rod  520  is then inserted through the central corrugation in the sign  504 , the lower end of the sign is coupled with the cross piece  522   b,  in the manner schematically illustrated in  FIG. 5   c,  and the upper end of the support rod  502  is coupled with the horizontal top section  523   a  of the post, as schematically illustrated in  FIG. 5   d  (essentially in the same way as described above in connection with  FIG. 1 ).  
       FIGS. 6   a,    6   b  and  6   c  schematically illustrate some other sign structures according to the present invention. In  FIGS. 6   a  and  6   b,  a base  622  is provided, and includes parallel pieces  622   a  and a cross piece  622   b  similar to the base of the previous embodiments. The support rod  602  and sign  604  are shown in  FIG. 6   c.  The support rod has a knob shaped member  640  that can be formed, e.g. by synthetic ball shaped material that is formed about a threaded insert (not shown). The threaded insert can be screwed onto the threaded top end of the support rod  102 , to couple the knob shaped member  640  to the support rod. The support rod  602  has a pointed lower end  650  that effectively forms a stake. The sign  604  is a corrugated panel with bent fins  608 , as illustrated and described above. The support rod  602  is inserted through a central corrugation in the panel, and that central corrugation forms a bearing surface for the sign, as described above. At the bottom of the sign, a large washer and spacer assembly  660  are provided, and they are held on place by a self locking retainer ring  670  ( FIG. 6   c ) below the spacer.  
      The sign structure of  FIG. 6   c  can be directly inserted into the ground. Specifically, the stake  650  formed at the lower end of the support rod enables the sign structure to pierce the ground, and the support rod can be forced into the ground, e.g. with a hammer, as illustrated in  FIG. 6   f.  In addition, the base can have an upwardly extending hollow post  680  ( FIGS. 6   b,    6   d,    6   e ), so that the pointed lower end of the support rod can be simply inserted into the post, as illustrated in  FIG. 6   b.    
      A sign  104  ( 504 ,  604 ) can be easily changed, by uncoupling the acorn nut, lock nut and washer assembly ( FIGS. 1, 5   a ) or unscrewing the knob shaped member  640  ( FIGS. 6   a - 6   f ), sliding one sign (and if necessary the associated bearing structure of  FIGS. 7   a - 7   d ) off the support rod, sliding a new sign (and bearing structure) onto the support rod, and recoupling the support rod with the base and post ( FIGS. 1, 5   a ) or reattaching the knob shaped member  640  onto the top of the support rod ( FIGS. 6   a - 6   f ).  
      As should be clear to those in the art, the sign structure described above enables the sign structure to be easily and efficiently assembled, and easily and efficiently disassembled and then reassembled, to enable the particular sign panel to be changed. In assembling the sign structure, a corrugated sign is selected, the support rod is inserted into the central corrugation, the desired bearing structure inserted onto the support rod, and the support rod coupled with a base, or pressed into the ground, in the manner described above. In order to disassemble the sign structure, any coupling structure associated with the support rod is uncoupled, the sign panel (and any bearing structure necessary) is slid off the support rod. Then, if a new sign panel is selected, that new sign panel is slid onto the support rod, the bearing structure slid back onto the support rod (if the bearing structure had been removed), and the support rod either pressed into the ground, or coupled with the base, to reassemble the sign structure with the new selected sign.  
      In all of the foregoing embodiments, the sign is preferably formed of extruded plastic, e.g. of a material known as Coroplast (Coroplast Inc, Quebec, Canada; Dallas, Tex.) As explained in the manufacturer&#39;s literature, the material is preferably extruded corrugated plastic, produced from a high impact polypropylene copolymer, which is chemically inert and has a NIL pH factor. Moreover, as further explained by the manufacturer&#39;s literature, the material can optionally have features like ultra violet protection, flame retardant, custom colors, corrosion inhibitors, static-dissipation, etc, that are melt blended into the plastic material. The support rod  102  is preferably formed of metal. The bearing and support structure  128  at the lower end of the sign can be selectively located in a predetermined position along the support rod.  
      Thus, the present invention provides a sign structure that is conveniently formed and assembled. While the sign is preferably formed of corrugated material, it will be appreciated that the sign structure may also comprise a panel formed in one piece with the bearing surface, where the panel extends laterally from the bearing surface, and the lateral ends of the panel include fins formed in one piece with the panel, the fins configured to allow air movement in the vicinity of the panel to rotate the panel about the central axis.  
      Accordingly, the foregoing disclosure provides sign structure that is (i) efficient and cost effective to produce, (ii) easily and efficiently assembled, in order to change the message conveyed by the sign structure, and (iii) effectively rotated by the air in the vicinity of the sign structure, to attract the attention of those in viewing range of the sign structure. Specifically, as seen from the foregoing description, a sign can be easily and efficiently produced, with a center panel and a pair of fins, from the corrugated synthetic material. The preferred embodiment describes a way of configuring the corrugated material so that the fins can be easily bent from the corrugated material and maintained in a bent state. The synthetic corrugated material is relatively lightweight (in comparison to an aluminum sign), and is relatively inexpensive relative to produce and efficient to assemble, primarily because the bearing and support structure is simpler and easier to produce and assemble than the special types of bearing structures that have been used in the past.  
      In addition, the foregoing disclosure provides a tool for use in forming the sign structure, and to a method that uses the tool in forming the sign structure.  
      With the foregoing disclosure in mind, it is believed that various ways of constructing sign structures, in accordance with the principles of the present invention, will become apparent to those skilled in the art.