Abstract:
A mounting receptacle is provided for securement to a flexible message panel. The mounting receptacle defines a housing for receiving a support rib. A threshold portion is hingedly coupled to the housing portion allowing a rib to contact the threshold portion while the housing portion is bent out of the way of the rib. The rib is telescopically received in the housing portion and, when released, tensions the message panel in a planar message-displaying condition.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation-in-part application of application Ser. No. 08/915,881, filed Aug. 21, 1997. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to flexible sign panels and in particular to such sign panels which are rolled up for compact storage. 
     2. Description of Related Art 
     Temporary highway signs warning motorists of roadside work activities have been employed for some time. It is common today, for warning sign systems to be considered in the early stages of planning a roadside improvement. With higher rates of speed and increased volume of traffic, a need for more advanced warning of temporary worksite conditions has been recognized. The implemetation of large numbers of signs of increased visibility and which are easy to deploy would aid in this regard. 
     Improvements to temporary warning signs have been realized by providing flexible message panels, typically make of a flexible fabric, such as plastic mesh material made of polyethylene or vinyl plastics. Over the years, these types of panels were improved with the addition of fluorescent materials to increase their ability to reflect light from oncoming vehicles. Commonly, reinforcing ribs or struts are used to maintain the flexible panels in a flat message-displaying condition. Ribs of glass fiber composition have been a popular choice for suspending flexible message panels. However, light weight metal tubing has also been a popular choice for displaying flexible message panels, and collapsible supporting systems have been proposed in commonly assigned U.S. Pat. No. 4,694,601. 
     Flexible sign panels must be stretched taut to maintain a flat position. Wind gusts and traffic induced wind bursts put substantial strain on a flexible sign panel, particularly at its points of support. Accordingly, various arrangements for joining supporting ribs to a flexible message panel have been proposed. For example, fabric pockets have been employed in U.S. Pat. Nos. 3,899,843 and 3,526,200, while resilient straps have been proposed in U.S. Pat. No. 4,592,158. As an alternative solution, rigid panel pockets have been proposed in U.S. Pat. Nos. 4,426,800 and 4,490,934. However, improvements are still being sought to provide a more compact storage of flexible message panel systems. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a means for attaching a support member to a flexible message panel, particularly at the corners of the flexible message panel. 
     Another object of the present invention is to provide a mounting arrangement of the above-described type which allows a flexible message panel and its supporting members to be collapsed and rolled into a compact package for storage. 
     A further object of the present invention is to provide mounting apparatus in the form of a rigid pocket which safely transmits forces from the supporting ribs to the message panel fabric while remaining flexible to permit advantages of compact storage. 
     Yet another object of the present invention is to provide mounting apparatus of the above-described type which is constructed from a minimum number of inexpensive parts. 
     These and other objects according to the principles of the present invention are provided in a mounting receptacle for attaching a support rib to a flexible panel, comprising: 
     a housing portion defining an interior cavity and an opening leading to the interior cavity, dimensioned to received the support rib, the housing portion having an upper wall, a floor with a bottom surface for engaging the flexible panel, and a rear wall and a pair of side walls extending between the upper wall and the floor; 
     the side walls and the floor extending beyond the rear wall to form a mounting location with first means for attachment to the panel; 
     a threshold portion having an upper surface for guiding the support rib toward the opening, a lower surface and second means for attachment to the panel; and 
     hinge means coupling the threshold portion and the housing portion so as to dispose the threshold portion in front of the opening. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a mounting receptacle for use with flexible message panels; 
     FIG. 2 is a top plan view thereof, shown attached to a corner of a flexible message panel; 
     FIG. 3 is a fragmentary cross-sectional view taken along the line  3 — 3  of FIG. 2; 
     FIG. 4 is a fragmentary view of FIG. 3 shown on an enlarged scale; 
     FIG. 5 is an exploded and view similar to that of FIG. 4; 
     FIG. 6 is a side elevational view of the mounting receptacle; 
     FIG. 7 is an elevational view of a message panel with mounting receptacle attached, rolled up for compact storage; 
     FIG. 8 is a fragmentary cross-sectional view taken along the line  8 — 8  of FIG. 7; 
     FIG. 9 is a perspective view of an alternative mounting receptacle according to the principles of the present invention; 
     FIG. 10 is a top plan view thereof, showing the mounting receptacle attached to a corner of a flexible message panel; 
     FIG. 11 is a cross-sectional view taken along the line  11 — 11  of FIG. 10; 
     FIG. 12 shows the mounting receptacle of FIG. 9 attached to a flexible message panel which has been rolled up for compact storage; 
     FIG. 13 is an elevational view of a message panel assembly; 
     FIG. 14 is a side elevational view thereof; 
     FIG. 15 is a fragmentary cross-sectional view taken along the line  15 — 15  of FIG. 13; 
     FIG. 16 is a view similar to that of view FIG. 15, but showing a subsequent operation; 
     FIG. 17 is a bottom plan view of a mounting receptacle; 
     FIG. 18 is a rear elevational view thereof; 
     FIG. 19 is a top plan view thereof; 
     FIG. 20 is a fragmentary cross-sectional view taken along the line  20 — 20  of FIG. 19; 
     FIGS. 21 and 22 are elevational views showing storage of a message panel assembly; 
     FIG. 23 is a rear elevational view thereof; 
     FIG. 24 is a front elevational view thereof showing a subsequent stage of the rolling operation; 
     FIG. 25 is an elevational view showing rolling of a package completed, and with the flexible tether secured; 
     FIG.  26 . is a cross-sectional view taken along line  26 — 26  of FIG. 25; 
     FIG. 27 is an elevational view of a message panel assembly being rolled in a direction opposite to that shown in FIGS. 21-26; 
     FIG. 28 is an elevational view showing further rolling of the sign assembly; 
     FIG. 29 shows the message sign panel in a fully rolled condition; 
     FIG. 30 is a fragmentary cross-sectional view taken along the line  30 — 30  of FIG. 29; 
     FIG. 31 is a top plan view similar to that of FIG. 19; 
     FIG. 32 is an elevational view similar to that of FIG. 18; and 
     FIG. 33 is a side view thereof. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning now to FIGS. 1-8, a mounting receptacle is generally indicated at  10 . As will be seen herein, mounting receptacle  10  is preferably made as a monolithic one-piece body made of a molded plastic material. The mounting receptacle  10  includes a plate-like hinged threshold  12  of modified triangular configuration. The threshold  12  has a front edge  14  and side edges  16 ,  18 . Mounting holes  20 ,  22  are located at the corner of front edge  14  and side edges  16 ,  18 . 
     Mounting receptacle  10  further includes a housing portion generally indicated at  30 , including side walls  32 ,  34  and a recessed top wall  36 . The housing portion  30  includes a floor  38  (see FIG. 3) which preferably has a top surface lying in the plane of the top surface of threshold  12 . Housing portion  30  defines an internal cavity  40  dimensioned to telescopically receive a panel support member such as the panel rib  42  illustrated in FIG.  2 . In a preferred embodiment, the panel rib  42  is of conventional fiberglass construction and has a conventional flat rib shape with an elongated generally rectangular cross section. 
     As can be seen in FIG. 1, the side walls  32 ,  34  extend above top wall  36  of housing portion  30 . The cooperating structure resembles a channel which, as will be seen, receives and supports a conventional strap  46 , as shown in FIGS. 7 and 8, to maintain the rolled configuration of a message panel assembly which has been prepared for storage. 
     As can be seen in FIGS. 1-3, an extension  48  of floor  38  projects beyond an end wall  50  of housing portion  30 , between the rear portions of side walls  32 ,  34 . A mounting aperture  52  is located in floor extension  48 . The bottom surfaces of threshold  12 , floor  38  and floor extension  48  form a continuous generally flat bottom surface  56 . As indicated in FIGS. 3-5, the apertures  20 ,  22  and  52  extend to the generally flat bottom surface  56  of the mounting receptacle. As indicated in FIGS. 3-5, the apertures  20 ,  22  and  52  have enlarged recessed portions  20   a ,  22   a  and  52   a , respectively, extending from bottom surface  56 . The enlarged recessed portion  22   a  can be seen in FIG. 5, and apertures  20 ,  52  have recessed portions of similar size and shape. 
     FIG. 2 shows mounting receptacle  10  attached to a corner portion of a flexible message panel  60 . In the preferred embodiment, the cavity of housing portion  30  faces toward the middle of the message panel. As indicated in FIG. 6, the flat bottom surface  56  of the mounting receptacle is positioned on one surface of the message panel  60  and conventional fasteners  64 , preferably rivets, secure the message panel  60  to the mounting receptacle. As can be seen by comparing FIGS. 4 and 5, a portion of the message panel  60  is drawn into the enlarged recess to securely trap or clinch the message panel. As can be seen in FIGS. 1 and 2, for example, it is generally preferred that the mounting receptacle be secured at three points to the message panel  60 . 
     With reference to FIG. 2, as support rib  42  is mated with the message panel assembly, the support rib passes over the front edge of threshold  12 . Threshold  12  provides a guide surface for the support rib to help align the support rib  42  for entry into a housing pocket or cavity  40 . Typically, mounting receptacle  10  is much smaller than the message panel to which it is attached. For example, with reference to FIG. 2, the distance between front and rear edges  14 ,  68  of the mounting receptacle is approximately 2½ inches, whereas the message panels typically have square configurations, measuring 30 to 48 inches on a side. The support rib  42  is initially held close to the surface of the message panel as the message panel receives a stretching force imparted to it by the support rib, and is thereby approximately aligned with threshold  12 . 
     Typically, the reinforcing ribs of conventional flexible sign panels are joined together at the center so as to collapse with a scissors action, once one of the cross ribs is loosened from its attachment to the message panel. With the support ribs pivoted so as to overlie one another, the message panel is then rolled about the support ribs in the manner indicated in FIG.  7 . As mentioned, the tether or strap  46  is attached in a conventional manner to the message panel so as to provide an outer wrap for the rolled package in the manner indicated in FIGS. 7 and 8. Accordingly, the mounting receptacle is pressed against the rolled package. 
     Referring to FIGS. 1,  2  and  8 , the housing portion  30  is joined to the forward portion of plate  12  by a flexible portion or living hinge  72 . In the preferred embodiment, hinge  72  is conveniently provided by forming a groove in the upper surface of the threshold thereby reducing the thickness and increasing the flexibility of the threshold in the region immediately in front of the housing portion  30 . As can be seen in FIG. 2, the hinge  72  lies in the mid-portion of the mounting receptacle. With reference to FIG. 8, the hinge portion allows the mounting receptacle to bend about its mid-portion to more closely conform to the rolled sign panel. 
     When the sign panel is tightly rolled, considerable stresses are required to secure the strap  46 . Accordingly, it is desirable that the rolled sign panel be protected or cushioned from forces imparted by the strap  46 , and that the strap be constrained in a desired position. For example, with reference to FIG. 7, it can be seen that the direction of rolling of the message panel results in a cross section resembling a triangle. Accordingly, if strap  46  were allowed to shift toward the top or bottom of the rolled package, the desired tension in the strap would be lost and the integrity of the rolled package would be compromised. Accordingly, the mounting receptacle of the present invention is provided with a recessed top wall  36  with the strapping received in the recess formed between side walls  32 ,  34  as indicated in FIG.  8 . 
     The hinged threshold  12  also allows the housing portion to momentarily bend back, away from the desired flat plane of the message panel while the panel rib is initially aligned for eventual entry into the housing cavity. With the hinged connection, the upstanding housing portion can be readily grasped for application of a pulling force on the flexible message panel to properly tension the panel in preparation for insertion of the panel rib into the housing cavity. At times, considerable tension must be applied to the message panel to pull it flat and taut, to assume a planar configuration. The hinged connection allows a user to bend the housing portion (located at the outermost corner of the message panel assembly) at an angle to the message panel for a better grip on the panel. The hinge portion  72 , made of a tough plastic material, transmits the pulling force to the message panel in a safe manner. During this time, thumb pressure can also be applied to the upstanding housing portion while the free end of the support rib is placed against threshold  12 . Thereafter, the hinge connection allows the housing portion to be rolled onto the free end of the support rib. Bending of the housing portion also brings the housing portion into ready alignment if the support rib must be bowed, a practice which has become widespread. 
     Turning now to FIGS. 9-12, an alternative mounting receptacle is generally indicated at  90 . Receptacle  90  includes the housing portion  30  as described above. Wing portions  92 ,  94  contain apertures  96 ,  98 , respectively, for mounting the forward end of receptacle  90 . If desired, the mouth  102  of cavity  40  can be flared in the shape of a funnel to help direct a support rib into the cavity, if desired. As a further alternative, the wing portions  92 ,  94  can be omitted if a swiveling action of the mounting receptacle about the rivet connection in hole  52  is desired. 
     As can be seen in FIGS. 9-12, the overall depth of the mounting receptacle is made considerably shorter by omitting the threshold and hinge portions discussed above. It has been found that if the depth is made short within certain limits, that adequate support of the panel rib can still be provided, while avoiding interference with the rolled panel package (see FIG. 12, for example). If the overall depth of the mounting receptacle is too long without benefit of a hinge for any included threshold, then it will not be able to conform to the outer surface of the rolled package, but instead will rock along tangent lines to the rolled package&#39;s circular cross-section. The following information is given for commonly available fiberglass panel ribs. 
     
       
         
               
             
               
               
               
               
               
               
             
           
               
                 TABLE I 
               
             
             
               
                   
               
               
                 Cavity and Receptacle Relative Sizes 
               
               
                 For Fiberglass Panel Ribs 
               
             
          
           
               
                 Panel Size 
                 Avg. Max. Rolled 
                 Minimum Rib 
                   
                 Cavity Relative 
                 Receptacle Relative 
               
               
                 (Unrolled) 
                 Circumference (C) 
                 Size (T, w) 
                 Cavity Depth (D) 
                 Size (D/W) 
                 Size (D/C) 
               
               
                   
               
               
                 30″ × 30″ 
                  8″ 
                 .125 × 1.00 
                  0.5-1.2″ 
                 .50-1.2 
                 6.25%-15%   
               
               
                 36″ × 36″ 
                 10″ 
                 .1875 × 1.25  
                 0.625-1.5″ 
                 .50-1.2 
                 6.25%-15%   
               
               
                 48″ × 48″ 
                 12″ 
                  .25 × 1.25 
                 0.625-1.5″ 
                 .50-1.2 
                  5.2%-12.5% 
               
               
                 24″ × 48″ 
                 12″ 
                 .1875 × 1.25  
                 0.625-1.5″ 
                 .50-1.2 
                  5.2%-12.5% 
               
               
                   
               
             
          
         
       
     
     As can be seen from the above preferred arrangements for fiberglass ribs, the cavity depth (D) ranges between 50% and 120% of the rib width (W). Preferably, with any type of rib, the cavity depth ranges between 50% and 120% of the rib width and most preferably the cavity depth ranges between 80% and 100% of the rib width. This allows the cavity depth (D) to range between 5% and 15% of the Max. Rolled Circumference (C). Most preferably the cavity depth (D) ranges between 7% and 14% of the Max. Rolled Circumference (C). 
     It is generally preferred that the mounting receptacle be made of plastic material so as to provide a degree of conformance to the flexible message panel during deployment of the message panel. Further, the preferred plastic material can be readily adapted to form a living hinge coupling the housing portion to any threshold portion that may be provided with the mounting receptacle. As mentioned, the hinge provides an increased conformance to a message panel rolled into a compact form, and to relieve stresses which might be imparted to the mounting receptacle, preventing the stresses from being transferred to the message panel in a manner which would damage or otherwise deteriorate coupling of the mounting receptacle to the message panel. If desired, however, the mounting receptacle can be made of rigid materials joined together by a separate hinge. 
     In the arrangement shown in FIG. 9, for example, the threshold and consequently the hinge portion have been omitted. However, it may be desirable in certain applications to break the sidewalls  32 ,  34  at points adjacent the housing portion rear wall  52  so as to provide an increased compliance, and so as to also provide a mounting receptacle which is temporarily bent adjacent its mid-portion to allow a user a better purchase or grip on the message panel as the message panel is being pulled taut in preparation for mating of the support rib with the mounting receptacle. The preferred line of bending is indicated by dotted line  104  in FIG.  10 . Preferably, the parting line would extend through sidewalls  32 ,  34  from the upper surface, to a point adjacent the upper surface of floor extension  48 . 
     Turning now to FIGS. 13-16, an alternative message panel assembly is generally indicated at  150 . A flexible message panel  60  has mounting receptacles  90  attached at the corners thereof, with panel ribs extending between the mounting receptacles. The arrangement illustrated in FIG. 13, the vertical panel rib is preferably made of two rib parts  152 ,  154 , colinearly aligned, with their adjacent ends received in a central housing  156 . Similarly, the horizontal rib preferably comprises rib parts  158 ,  160  colinearly aligned with their adjacent ends received in central housing  162 . As can be seen in FIG. 15, the rib part  158  is received in an opening  164  formed in one end of central housing  162 . The rib part  158  is biased in an outward direction by spring member  168 . The other rib parts  152 ,  154  and  160  are similarly spring loaded within their respective central housings, and the central housings  156 ,  162  are pinned together at  172  for relative rotation. 
     As explained above with reference to FIG. 11, panel ribs  42  are received within the pocket formed in mounting receptacle  90 . In use, it is customary to bend the panel rib  42  (in the manner of bending an archer&#39;s bow) and to introduce the free end of the panel rib into the mouth of the receptacle pocket. By releasing the panel rib from its bent position the free end of the panel rib travels within the receptacle pocket. It has been found difficult, on occasion, to perform the above-described maneuver. For example, when flexible message panels are required to be installed along a roadside, dusty wind conditions and wind bursts from passing vehicles can generate very substantial sail forces, making it difficult to thread the free end of the panel rib in the receptacle pocket. With the arrangement shown in FIGS. 13-16, the need for bending the panel ribs is avoided. Rather, the panel ribs are translated in the direction of the arrows shown in FIG. 13, along their central axes so as to compress the bias springs  168 . As the free end of the panel ribs are lined up with the mouth of the respective receptacle pocket, the ribs are released so as to allow the springs  168  to extend, bringing the free ends of the ribs into more complete insertion within the mounting receptacle pockets. If desired, the panel ribs and biasing springs can be dimensioned so as to maintain a predetermined force on the rear wall of the panel receptacle pocket and to maintain the force on the mounting receptacle after the panel assembly is erected. This allows a flexible message panel to be maintained in a taut condition despite dimensional changes to the message panel caused by temperature. For example, when the flexible message panels are placed in intense sunlight and allowed to become heated, the material properties of the panels changes substantially, allowing the message panels to “grow”. With the arrangement of the present invention, in effect, the panel ribs will grow along with the message panel to maintain the desired predetermined taut condition. 
     Turning now to FIGS. 17-20 and  31 - 33 , an alternative mounting receptacle is generally indicated at  200 . Receptacle  200  includes a floor  202  and an upper wall  204  having a recessed portion  206 . A hollow pocket  208  is formed between floor  202  and top wall  204 . The hollow pocket  208 , as can be seen for example in FIGS. 31 and 33, extends from rear wall  230  to an internal stop wall  232  (visible in FIG. 32) formed on either side of an opening  234 . As can be seen in the top plan view of FIG. 19, top wall  204  is cut out at  212  to expose a portion of floor  202  which serves as a landing or threshold to help align the panel rib with the hollow pocket. Bevelled walls  214  also help to orient the panel ribs at the mouth of pocket  208 . 
     As can be seen, for example, in FIGS. 19 and 31, floor  202  extends forwardly of recessed portion  206  of the top wall. Relatively massive side portions  240  are bevelled at their forward ends to form converging front walls  242  to facilitate insertion of the mounting receptacle  200  in a sign-mounting socket such as that described in U.S. Pat. No. 4,888,894. As can be seen, for example, in FIG. 31, the bevelled front walls  242  are blended with the bevelled edges  244  of the wing-like outlying portions  202   a  of floor  202 . This aids in coordinating the simultaneous entry of the outlying floor portions  202   a  in a slot of the sign mounting socket as the remainder of the mounting receptacle  200  is also inserted in the sign-mounting socket. Preferably, the end of the top wall formed by cut-out  212  engages a releasable hook associated with the sign mounting socket of U.S. Pat. No. 4,888,894. 
     As can be seen in FIG. 20, mounting holes  218  have optional surrounding step depressions  220  to trap flexible message panel  60  by a step button-like fastener  224 . Fastener  224  is compressed against floor  202  by rivet fastener  226  which is headed over after passing through washer  228 . 
     Turning now to FIGS. 21-30, it will be seen that the flexible message panel assembly generally indicated at  250  can be rolled in one of two ways, the first illustrated in FIGS. 21-26 and the second illustrated in FIGS. 27-30. Advantages of the flexible message panel assembly  250  include its relatively light weight, and its ability to be readily collapsed and rolled in a small package (see FIGS. 25 and 29) for storage. Referring to FIG. 21, either the vertical or the rib is released from its mounting receptacles and rotated in the direction to bring the two ribs in overlying relationship as indicated in FIG.  21 . Preferably, the ribs of the flexible message panel assembly are pinned together at their central portions to allow the relative rotation. It is not necessary to release the second rib from its mounting receptacles and in practice, the second rib is preferably left connected to its respective mounting receptacles such that the flexible message panel remains stretched or taut in at least one linear direction. If desired, the second rib may be permanently joined to the flexible message panel. 
     As indicated in FIGS. 21 and 22, the lower corner of the flexible message panel  60  is folded underneath the major portion of the flexible message panel assembly. As illustrated in the figures, the reverse surface  60   a , i.e. the surface contacting the support ribs and which does not typically carry the message indicia, is made visible. Accordingly, as indicated in FIG. 22, the reverse surface  60   b , normally carrying the message indicia is folded against itself, as can be seen in FIG.  23 . 
     In FIGS. 23 and 24, the mounting receptacles are shown in phantom since they are hidden underneath the flexible message panel. FIG. 24 shows the direction of rolling of the message panel in preparation for strap  46  to be wound about the rolled package, as indicated in FIG.  25 . As mentioned above, fastening means are provided for securing strap  46  to the rolled package. Preferably, strap  46  is provided with hook and loop fastener material and is of a length so as to completely encircle the rolled flexible message panel assembly, in the manner indicated in FIG.  26 . Referring now to FIG. 26, a first mounting receptacle  90 a is located beneath a layer of flexible message panel  60 , and is secured by a rivet fastener  256  to a first free end of strap  35 . A strap  46  extends from the first mounting receptacle  90   a  to encircle the rolled package, passing over the top of a second mounting receptacle  90   b  and passing over the first mounting receptacle  90   a  before being joined at its free end  46   a  to an underlying layer of strap material. As can be seen in FIG. 26, the strap  46  is laid within the recessed upper surface  36  of the second mounting receptacle  90   b . As can be seen in FIG. 25, and as explained above, the strap  46  is secured in the recessed portion  36  against inadvertent lateral dislodgement as when the rolled package illustrated in FIG. 25 is slid end-first into a storage chamber so as to drag the strap  46  against the walls of the chamber or against materials previously deposited in the storage chamber. 
     Referring now to FIGS. 27-30, the flexible message panel  60  is rolled in an opposite sense, such that its front surface  60   b , the surface normally carrying the message indicia, is fully exposed after folding. The flexible message panel assembly is rolled in the manner of FIG.  28  and strap  46  is rolled about the package and secured to itself to develop the completely rolled package as illustrated in FIG.  29 . As can be seen in FIG. 30, the upper recess of the mounting receptacle  90   a  guides the strap  46  and retains the strap against inadvertent lateral dislodgement. As can be seen from the above, the mounting receptacles are disposed such that their upper recesses effectively guide the strap against inadvertent lateral misalignment no matter which direction the flexible message panel assembly is rolled. 
     The drawings and the foregoing descriptions are not intended to represent the only forms of the invention in regard to the details of its construction and manner of operation. Changes in form and in the proportion of parts, as well as the substitution of equivalents, are contemplated as circumstances may suggest or render expedient; and although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purposes of limitation, the scope of the invention being delineated by the following claims.