Patent Publication Number: US-2007094906-A1

Title: Lightweight sign suitable for outdoor advertising

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to lightweight signs for attachment to a pair of adjacent vertical supports.  
      2. Background of the Related Art  
      Signs of all types are pervasive in our modem culture. Examples of signs encountered routinely include road signs providing instructions and directions to drivers, construction signs notifying visitors of necessary precautions, permanent signs for business identification, and advertising signs informing customers about product features or pricing. Each of these types of signs, as well as other types of signs not mentioned, are designed in consideration of various parameters, such as environmental conditions, expected life, installation space, project budget, size required, and time to install.  
      Signs that are suitable for use outdoors must be particularly well built in order to withstand any number of prevailing weather conditions that may exist. Accordingly, many outdoor signs are made of metal, brick, or molded plastic that are generally weatherproof and sufficiently sturdy to provide a reliable display and avoid the need for frequent replacement. Still, it is generally desirable for the sign to draw attention and be attractive. However, simultaneously accomplishing these objectives can be an expensive proposition.  
      For permanent signs identifying a business, the investment in a substantial sign is warranted. However, on the other end of the spectrum, advertising a sale item for a limited time period can boost sales, but the potential return does not justify building a dedicated sign. One approach is the construction of a permanent sign structure with removable lettering allowing the content of the sign to be changed as needed. Unfortunately, these signs are frequently limited to changes of text and are prone to user mistake or the eventual loss of certain text characters. Other approaches for providing limited-time advertising may take the form of a wall poster, window decal or shelf display. Unfortunately, most of these inexpensive signs are designed for controlled indoor conditions and do not perform well for outdoor use.  
      Accordingly, there is still a need for improved designs of signs that are suitable for outdoor advertising without substantial investments of money, time and space. It would be desirable to have a sign that could display modem text and graphics without limitation. It would also be desirable to have a sign that could be efficiently shipped and stored, yet facilitate quick and easy installation. Furthermore, it would be quite desirable for the sign to be lightweight and securable to existing structures.  
     SUMMARY OF THE INVENTION  
      The present invention provides a sign securable to a pair of adjacent vertical structures, such as bollards. The sign comprises a corrugated plastic sheet or board having horizontal flutes and first and second opposing faces. The corrugated plastic sheet is foldable to form a display panel spanning between the pair of vertical structures. The sheet is positioned with the first face having a display directed away from the vertical structures. The sheet provides a set of at least two hinged panels on each end of the display panel, wherein each set of hinged panels is foldable away from the first face of the display panel to form a channel adjacent the second face. Each of the channels thus formed is adapted to receive one of the pair of vertical structures. Advantageously, each of the panels is delineated by a fold line running transverse to the flutes and extending across the entire sheet. While each fold line may include a score cut substantially across the face of the sheet, it is preferable that each fold line has a series of spaced apart collinear scores cut through the first face and extending at least half the distance through the thickness of the flutes to facilitate folding along the fold line. In order to couple the hinged panels in the channel formation, the foldable sign includes at least one fastener.  
      In one embodiment, the sign comprises a plurality of fasteners coupling a distal end of each set of hinged panels back to the display panel. Preferably, the display panel and the distal end of each set of hinged panels will include precut holes for looping a locking strap fastener therethrough. Further, the display panel and the distal end of each set of hinged panels are preferably coupled at two or more elevations. An optional feature includes providing precut holes at one or more of the elevations in sets of four or more horizontally spaced holes allowing selective use of holes aligning with one of the vertical structures. The adjacent vertical structures are most preferably bollards, but may include other pairs of adjacent vertical support structures.  
      In another embodiment, the at least one fastener secures a distal end of one set of hinged panels to a distal end of the other set of hinged panels. Preferably, the distal ends of each set of hinged panels will include precut holes for looping a locking strap fastener therethrough. Alternatively, the panels may be secured together using a fastener made solely from the material of the hinged panels themselves.  
      If the vertical structures that might be encountered have a range of different characteristics selected from the distance between vertical structures, width of the vertical structures, shapes of the vertical structures, and combinations thereof, then each set of hinged panels may optionally include three or more hinged panels that are selectively foldable around the structures.  
      In a further embodiment, the foldable sign is reversible by cutting the scores through the entire thickness of the sheet. The sign is reversed by removing the fasteners, positioning the sheet with the second face directed away from the vertical structures, folding each set of the hinged panels away from the second face of the display panel to form channels adjacent the first face, and securing the hinged panels in the reversed channel formation.  
      The embodiments of the present invention can provide a number of advantages over other signs. For example, the unitary seamless sheet design makes the signs strong, while allowing shipment and storage in a near zero-waste space configuration. Furthermore, the design is simple. The embodiments disclosed may generally include further elements or components, but will typically consist essentially of the corrugated plastic sheet described and the fasteners. No complex assembly or collection of parts in necessary. Furthermore, the sheets facilitate the use of modern printing methods for creating the display. These features keep the cost of the sign low and meet a strong and long-felt need for a lightweight sign suitable for outdoor use.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      So that the above recited features and advantages of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.  
       FIG. 1  is a plan view of a sign before it is folded or made up.  
       FIG. 2  is a perspective view of the sign after being folded once on each end of the sign.  
       FIG. 3  is a perspective view of the sign after being folded twice on each end of the sign and secured in the desired configuration with fasteners.  
       FIG. 4  is a perspective view of the sign installed and secured to a pair of bollards typical of those used to protect gasoline pumps.  
      FIGS.  5 (A) and  5 (B) are top views of the installed sign, illustrating how the sign can be secured to vertical support structures, such as bollards, even if the spacing of the structures is different between installations.  
       FIG. 6  is a cross-sectional side view of the sign of  FIG. 5 .  
       FIG. 7  is a perspective view of a fold line that includes a series of spaced apart collinear scores cut through the first face and extending at least half the distance through the thickness of the flutes to facilitate folding along the fold line.  
       FIG. 8 (A)- 8 (C) are schematic top, assembled back and unassembled back views of a further embodiment of the foldable sign in which the sets of hinged panels attach to each other without using separate fasteners.  
       FIG. 9  is a schematic top view of yet another embodiment of the sign, wherein the sets of hinged panels are adhesively secured back to the second face of the sign. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       FIG. 1  is a plan view of a first face of a sign  10  before it is folded or made up. The sign is made from a unitary sheet  12  of corrugated plastic. The sheet  12  may be formed or cut into any desirable shape, but a rectangle is preferred. The sheets are easily stacked in a manner that almost zero space is wasted. The sheet  12  includes cut or scored fold lines  14  that delineate the sheet into panels. Specifically, the sheet  12  provides a display panel  16  receives a desired text or graphic display  18  (marked “MAIN DISPLAY”). The sheet  12  also includes a set of hinged panels  20 , on both sides of the display panel  16  (as shown, to the right and left). Each set  20  includes two or more hinged panels ( 22 A,  22 B, and more) including a hinged panel that is the distal panel having a distal end  24 . According to certain preferred embodiments, the sheet  12  may have a number of precut holes, including a set of pre-cut holes  26  at an upper elevation and a set of precut holes  28  at a lower elevation. These pre-cut holes are used for securing the sign to a pair of adjacent vertical support structures as will be described below.  
       FIG. 2  is a perspective view of the sign  10  after being folded once on each end of the sign. The order in which the fold lines  14  are folded is not particularly important. Here, the sign is illustrated with the most distal hinged panel  22 A being folded back away from the front face of the sheet  12  that contains the display  18 . As shown, the fold is made neatly and precisely along the fold line  14  that was created by a series of collinear scores  30  in the face of the sheet  12 . Between each of the scores or cuts  30 , the sheet  12  is locally stressed as shown by the lines  32 . However, the sheet  12  is made of plastic and plastic compositions typically resist tension. It is preferred that the corrugations of the sheet  12  form parallel flutes and that the sign  10  is made with the flutes or other corrugations running horizontally. In this configuration, the uncut or unscored flutes that extend between the scores  30  remain intact and add strength to the folded corner.  
       FIG. 3  is a perspective view of the sign  10  after being folded twice on each end of the sign and secured in the desired configuration with fasteners  34 . Each of the fold lines  14  have been folded back away from the front face of the display panel  16  containing the display  18  such that each set of hinged panels  20  forms a channel  36  adjacent the back face of the display panel  16  (opposite the front face shown). The panels  16 ,  22 A,  22 B, etc. are secured in this configuration by fasteners of any suitable type, but are shown using wires, straps or bands. A most preferred fastener is a locking strap fastener. The fasteners  34  are passed through the pre-cut holes in both the display panel  16  and the distal panels  22 A and closed into a loop in the typical manner. It should be recognized that the sign  10  may be configured as shown in  FIG. 3  before placing the sign on vertical support structures, or the sign may be configured in place around the structures. Accordingly, it is not necessary for the channel to fit tightly around the support structures as long as the structures extend into the channels  36  and prevent the sign from falling over or drifting out of place. Still, it may be preferably to draw up any slack in the fasteners once the configured sign  10  has been position around the support structures so that the portions of the flexible panels  16 ,  22 A,  22 B that form the channel  36  are slightly flexed. With a slight flex in these panels, the channel will hug the support structure and prevent movement of the sign during normal conditions.  
      In the embodiment shown in  FIG. 3 , fasteners  34  are secured through pre-cut holes  26  at an upper elevation and through pre-cut holes  28  at a lower elevation (in this view, some of the holes some in  FIGS. 1 and 2  are hidden behind the display panel  16 ). Fastening the panels at more than one place provides a more secure configuration of the sign  10  as well as providing more uniform flexing of the panels if the panels are to be installed firmly against the support structures. Still further, the pre-cut holes  28  at the lower elevation are preferably provided in greater number than will be utilized in a single installation of the sign. The holes  28  are disposed in a generally horizontal row so that the fastener  34  passing therethrough can loop around the support structure as it extends between the display panel  16  and the distal hinged panel  22 A. Accordingly, the fastener not only secures the two panels together (front to back), but also secures the sign to the support structures in a manner that prevents shifting (as shown, right to left) whether or not the support structure is disposed exactly at the deepest part of the channel  36 . Preferably, the pre-cut holes  28  are provided in sufficient number and spacing so that there are holes available to accommodate a range of possible spacings between support structures that will be encountered in the field. In addition, the number and spacing of the holes can engage support structures of various widths or diameters by selecting the appropriate holes. As shown, the fastener  34  loops through two holes  28  on the display panel  16 , but one hole was intentionally skipped between those two holes to approximate the width of the structure. Adjacent holes may be used for narrower support structures or additional holes may be skipped for even wider support structures.  
       FIG. 4  is a perspective view of the sign  10  installed and secured to a pair of bollards  40  typical of those used to protect gasoline pumps. A bollard is a pole used to block a path to vehicles. Conventional bollards are constructed in various shapes, sizes and spacings, but frequently comprises a pair of adjacent vertical support structures. Notably, some pairs of vertical bollards may be coupled, such as at the top to produce a single inverted “U” shaped bollard. Whether the pair of support structures  40  are provided by separate bollards or a single bollard, the support structures are still received within the channels  36  formed by the foldable sign  10 .  
      FIGS.  5 (A) and  5 (B) are top views of the installed sign  10  of  FIG. 4 , illustrating how the sign can be secured to vertical support structures  40 , such as bollards, even if the spacing of the structures is different between installations. In  FIG. 5 (A), the structures  40  are received deep into the channels  36  and the fasteners  34  are secured through a pair of the lower elevation holes  28  that are widely spaced (as shown in  FIG. 3 ). In  FIG. 5 (B), the structures  40  are significantly closer together, such that the structures are received shallow within the channels  36 . Accordingly, the fasteners  34  that secure the sign at the lower elevation are secured through a different pair of holes in the row of holes  28  (See  FIGS. 1 through 4 ) that are closer together (for example, the unused pair of holes  28  is  FIG. 3 ). Because the distal hinged panel  22 A was wide enough, and formed a channel  36  that was deep enough, the fasteners  34  in the upper elevation holes  26  do not require adjustment. While this is the preferred arrangement to simplify installation and possibly to loop around any horizontal structures (for example, in an inverted “U” shaped bollard), it is possible to arrange the upper elevation holes  26  in the same or similar number and configuration as the lower elevation holes  28 . In addition, it should be recognized that the hinged panel  22 B, or some number of other panels, approximate the thickness of the support structure. If wide variations exist in the width of the support structures, then the sheet  12  may be made with an excess number of scored fold lines in the region that will form the channel, so that appropriate fold lines are available and selectable in the field in order to fold around the support structure.  
       FIG. 6  is a cross-sectional side view of the sign  10  of  FIG. 5 . The front display panel  16  is disposed on one side of the support structure  40  with the display  18  directed away from the structure for viewing. The hinged panel  22 B passes around (behind) the structure  40  and the distal hinged panel  22 B is disposed on the side of the support structure opposite the display panel  16 . As previously described, a fastener  34  is secured through the lower elevation holes  28  (a pair of holes in the display panel  16  and a pair of holes in the distal hinged panel  22 A) and a fastener  34  is secure through the upper elevation holes  26  (a pair of holes in the display panel  16  and a pair of holes in the distal hinged panel  22 A). The cross-sectional view is shown from the position indicated in  FIG. 5 . Whereas only the display panel  16  is truly shown in cross-section, the distal edge  24  of the distal hinged panel will typically have an exposed cross-section. Accordingly, both of the panels  16 ,  22 A shown in  FIG. 6  illustrate the construction of a corrugated plastic sheet or board. Each sheet or panel of the corrugated material has opposing faces with the internal structure defined by a plurality of “flutes.” The design and production of such a corrugated plastic sheet and the flutes within the sheet is well known in the art. However, the panels are shown here in the preferred orientation having the flutes run horizontally between the fold lines. This orientation is believed to provide the sign with increased strength of the display panel, since the flutes span between the support structures.  
       FIG. 7  is a perspective view of one part of a fold line  14  that includes a series of spaced apart collinear scores  50  cut through the first face and extending at least half the distance through the thickness of the flutes to facilitate folding along the fold line. The series of scores or cuts  50  delineates the two adjacent panels  22 B,  22 A and enables the otherwise rigid sheet to be folded easily and neatly along the intended fold line  14 . Upon folding, the scores  50  expose a number of the internal flutes. Experience has shown that the scores or cuts may extend entirely through the sheet without jeopardizing the integrity of the sign, so long as there is some material along the fold line  14  that remains intact.  
      Furthermore, making the scores or cuts extend through the entire thickness of the sheet may facilitate the sign being reversible. Since the original flat sheet  12  (See  FIG. 1 ) is preferably symmetrical about a vertical centerline (running from top to bottom in  FIG. 1 ), there is nothing to prevent the back face from having a display of its own. Then, the user can select which display to exhibit and can easily switch between the two displays by releasing the fasteners, inverting the panels by folding them in the opposite direction, and refastening the sign. The reversibility is preferably facilitated by incorporating a re-usable fastener or strap (such as grommets and arrows) to allow for quick and non-destructive changes in the face that is outwardly directed.  
      FIGS.  8 (A) and  8 (B) are schematic top and back views, respectively, of a further embodiment of a foldable sign  60  that is identical in most respects to sign  10 , but in which the distal hinged panels  62  attach to each other without using separate fasteners. The distal hinged panels may utilize any of a variety of fasteners, but preferably the fasteners are integral to the sheet, such as a pair of cooperating slots cut into the sheet itself. Specifically, the integral fasteners may be locking tabs and slots or interlocking tabs. For clarity,  FIG. 8 (C) shows the slots cut into these two distal hinged panels  62  prior to being fastened. Alternatively, this sign can be secured with separate fasteners as previously disclosed, or with other more permanent types of fasteners, such as staples. Accordingly, a sign may have hinged panels secured together and folded prior to shipment to the installation site and the sign still folded flat. Still further, such a pre-folded sign may still include strap-type fasteners, for example, for securing the sign to the adjacent vertical structures in the field. In the embodiments that completely surround both of the adjacent vertical structures, as does sign  60  in FIGS.  8 (A) and  8 (B), there may be three hinged panels on one side of the display and one hinged panel on the other side of the display, such that the panels overlap and are secured together to one side of the display panel rather than behind the display panel.  
       FIG. 9  is a schematic top view of yet another embodiment of a foldable sign  70 , that is identical in most respects to sign  10 , but wherein each set of hinged panels includes four fold lines  14  delineating four panels  72 A- 72 D and the distal panel  72 A is secured directly to the back of the display panel. Here, the fastener is preferably a grommet (and arrow), snap or screw, but could also be an adhesive or hook and loop fastener.  
      The foregoing description is intended for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be determined only by the language of the claims that follow. The terms “comprising,” “including,” and “having,” as used in the claims and specification herein, shall be considered as indicating an open group that may include other elements not specified. The term “consisting essentially of,” as used in the claims and specification herein, shall be considered as indicating a partially open group that may include other elements not specified, so long as those other elements do not materially alter the basic and novel characteristics of the claimed invention. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. For example, the phrase “a solution comprising a phosphorus-containing compound” should be read to describe a solution having one or more phosphorus-containing compound. The term “one” or “single” shall be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” are used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.