GB2395657A

GB2395657A - A plastic twin-sheet hollow panel structure

Info

Publication number: GB2395657A
Application number: GB0326753A
Authority: GB
Inventors: Stephen Hayes; Stephen Hollyoak
Original assignee: Huntleigh Technology Ltd
Current assignee: Huntleigh Technology Ltd
Priority date: 2002-11-19
Filing date: 2003-11-17
Publication date: 2004-06-02
Anticipated expiration: 2023-11-17
Also published as: AU2003302010A1; GB0226918D0; GB2395657B; GB0326753D0; WO2004045342A1

Abstract

A panel structure comprises a twin-sheet thermoformed hollow panel 1 and a support frame 2. The panel 1 is welded around its periphery and around any desired internal features, eg. handles 3 or can be brought together and heat welded to add rigidity and strength. Apertures 14 are cut in the panel 1, 10 to allow the insertion of a hollow support frame 2 which may be secured within the hollow panel 1 by injecting foam/adhesive through the frame 2. The injected foam or adhesive is forced out though holes 8 within the frame to diffuse inside the panel 1 to anchor the frame 2 rigidly to the panel 1 thereby providing a solid structure. The frame can also be fixed by rivets or screws. The panel structures can be used to provide support surfaces on beds, trolleys or couches, bed headboards/footboards and safety sides.

Description

Panel Assembly The present invention relates to the manufacture of panels

for hospital beds or similar, in particular those 5 formed by twin sheet process.

A known method of producing such panels as headboards and footboards for hospital beds involves cladding a metal armature with two vacuum-formed plastic covers as shown in Figure 6. The plastic covers are fixed 1() to the metal armature using double-sided tape and the two plastic covers are lap jointed together. This lap joint is then fully sealed, for example with adhesive to obtain a strong watertight joint required for hospital beds.

This method requires a large amount of labour and is 15 difficult to produce with consistent quality. Also, the need for a substantial armature and a large labour input in assembly results in an expensive product. Furthermore, the structure relies entirely on the metal armature for its strength.

20 The present invention seeks to make improvements.

Accordingly, the present invention provides a panel structure for a bed or similar, including a panel of thermoformed twin sheet hollow plastic welded substantially around the periphery, and a support frame, 25 the support frame inserted within the hollow panel by means of apertures located on the panel, wherein the frame is secured within the hollow panel.

Preferably, the panel structure comprises a bed headboard having a handle feature, more preferably, the 30 frame comprises a hollow tubular frame of an 'H' construction wherein the two legs of the frame are inserted into apertures on the hollow panel. Preferably, the frame is secured within the panel by means of foam or adhesive forcefully fed through the hollow tubular legs

of the frame, the legs having openings at their ends within the panel.

In a preferred embodiment, the panel structure comprises a bed headboard and footboard. In another s preferred embodiment, the panel structure is a section of a platform for a bed. Preferably, each such section has a frame comprising a metal frame inserted into the hollow panel after thermoforming and incorporating the hinge points about which the panel structure can pivot. More 10 preferably, the frame is secured within the panel by means of rivets or screws. In another embodiment, the panel structure is a side rail for a bed.

The present invention is described below, by way of examples only, with reference to the accompanying 15 drawings in which: Figure l shows a plan view of a panel structure as a headboard for a bed according to the present invention; Figure 2 shows a plan view of the components of the panel structure in Figure l; 20 Figure 3 shows a plan view of a panel structure as a section of a platform for a bed according to the present invention; Figure 4 shows a plan view of the components of the panel structure in Figure 3; 25 Figure 5 shows a plan view of a panel structure as a side rail for a bed according to the present invention.

Referring to the drawings, Figures l and 2 show a panel structure consisting of a twin-sheet thermoformed hollow panel l and a support frame 2, the support frame 2 30 preferably provided with location spigots to enable the panel structure to be mounted as a headboard for a bed.

The twin-sheet process produces a hollow plastic panel l welded around its periphery and around any desired internal features such as handles 3 or similar

aperture. As shown in Figure 3, the two sheets comprising the panel can be brought together and heat welded by the process in order to add rigidity and strength. The resulting panel 10 results in a strong, rigid but 5 lightweight structure. Apertures 14 are cut through the bottom edge of the panel 1, 10 in order to allow the insertion of a support frame 2. The support frame is of an 'H' construction where the two legs 4, 5 of the frame 2 are inserted deep into the hollow panel 1 leaving the 10 two shorter legs 6, 7 to project beyond the panel 1.

These shorter legs 6, 7 are used to attach the panel structure to a bed, for example as a headboard or footboard. The support frame 2 is secured within the hollow panel 1 by injecting a foam or adhesive through l5 the open ends of the upright hollow tubular legs 4, 5 of the frame 2. The ends of the upright legs 4, 5 are crimped closed and holes 8 are cross- drilled in the upper part of the legs. The injected foam or adhesive is forced to extrude out though the cross-drilled holes 8 and 20 subsequently diffuse out into the void inside the panel 1. The foam or adhesive then anchors the frame 2 rigidly to the panel 1 providing a solid structure. The amount of foam/adhesive can be varied so that only sufficient is used to anchor the frame 2 to the panel 1 or 25 alternatively, the whole void of the panel 1 is filled to generate a stiffer structure. The open ends of the upright legs 6, 7 are plugged with a plastic cap 9 to prevent ingress of fluid.

Figures 3 & 4 show a panel structure 10 as a section 30 of a bed platform to provide a lightweight, rigid and easily cleaned structure. In this example, the two sheets comprising the panel 10 are brought together in certain areas and heat welded to add rigidity and strength. The resulting panel 10 results in a strong, rigid but

lightweight structure. Apertures 14 are cut through the bottom edge of the panel 10 in order to allow the insertion of the metal frame 11. The frame 11 further incorporates hinge points 12 about which the panel 5 structure 10 can pivot. Instead of the foam or adhesive as in the previous example, the frame 11 is fixed in place by using rivets or screws 13 going through one of the walls of the panel and into the metal frame 11. The metal frame is shown as a tubular construction but can lo take the form of metal pressings or plates. The inserted metal frame 11 can include additional metal plates to allow for the attachment of other structures or items to the panel structure by fastening through the wall of the panel into the plates.

15 Figure 5 shows a panel structure consisting of a twin-sheet thermoformed hollow panel 15 and a support frame 16, the support frame 16 located on the bed frame to enable the panel structure to be mounted as a side rail for a bed. As with the headboard or footboard above, 20 the twin-sheet process produces a hollow plastic panel 15 welded around its periphery and around any desired internal features such as handles 17 or similar aperture.

The above examples of panel structures incorporating hollow panels and support frames can be used to provide 25 any support surface on beds, trolleys or couches or similar as well as the manufacture of headboards and footboards and also safety sides.

Claims

Claims:

1. A panel structure for a bed or similar, comprising a 5 panel of thermoformed twin sheet hollow plastic welded substantially around the periphery, and a support frame, the support frame inserted within the hollow panel by means of apertures located on the panel, wherein the frame is secured within the hollow panel.

lo

2. A panel structure as claimed in claim 1 wherein the frame comprises a hollow tubular frame of an 'H' construction wherein the two legs of the frame are inserted into apertures on the hollow panel.

3. A panel structure as claimed in claims 1 or 2 wherein the frame is secured within the panel by means of foam or adhesive forcefully fed through the hollow tubular legs of the frame, the legs having openings at 20 their ends within the panel.

4. A panel structure as claimed in claims 1, 2 or 3 wherein the panel structure comprises a bed headboard.

25

5. A panel structure as claimed in claim 4 wherein the bed headboard has a handle feature.

6. A panel structure as claimed in claims 1, 2 or 3 wherein the panel structure comprises a bed footboard.

7. A panel structure as claimed in claims 1, 2 or 3 wherein the panel structure is a section of a platform for a bed.

8. A panel structure as claimed in claim 7 wherein the panel structure has a frame incorporating hinge points about which the panel structure can pivot.

5

9. A panel structure as claimed in claim 7 or 8 wherein the frame is secured within the panel by means of rivets or screws.

10. A panel structure as claimed in claims 1, 2 or 3 10 wherein the panel structure is a side rail for a bed.

11. A panel structure substantially as hereinbefore described and with reference to the accompanying drawings.