Wall panel

Abstract

A wall panel (100) for a safety barrier system (200) and / or warehouse partitioning. The wall panel (100) is a mono-structure formed by a two-stage injection moulding process. The wall panel (100) comprises a panel section (120) and a frame section (130). The panel section (120) is integrally formed from a first polymer material (122). The frame section (130) is integrally formed from a second polymer material (131). The panel section (120) and frame section (130) are integrally formed to provide the monostructure. The frame may be peripheral of the panel and may comprise a thickened portion to act as a handle. The two polymers may comprise a different set of material properties to each other. The properties may include, transparency or opacity, hardness, stiffness and surface finish.

Description

The present disclosure relates to a wall panel. In particular the disclosure is concerned with a wall panel for a safety barrier system and / or warehouse partitioning. Background Partition walls (e.g. walls fabricated from a series of panel elements which are connected together) are used in many ways, for example to create barriers around equipment, define pathways through a particular space and to divide a working space into different areas. Doors may be provided in the partition to allow passage therethrough, which may be lockable to control access. It is common for the panel elements of such partition walls to be made of lengths of material (e.g. metal or wood) which are assembled into a frame which supports a sheet of material (for example plastic, wood, cement board, grills, mesh, metal). The lengths of frame material may be joined using any conventional method (e.g. welding, bonding, screws, nuts and bolts). Such designs, although adaptable, are time consuming to put together, require the production and supply of a large part count, as well as the need to for a skilled worker to put the assembly together correctly. Additionally each part (e.g. the frame lengths, sheet material, fixings) are made by a different manufacturing method, each with their own material supply chain, manufacturing and delivery process. These introduce delay into the supply of panel elements, meaning that a manufacturer may not be able to meet demand for the panel element in a timely fashion, with subsequent financial consequences. Hence a wall panel with a design that enables it to be produced faster than examples of the related art, and a method of manufacture that enables the wall panel to be produced faster than examples of the related art, are highly desirable. Summary According to the present disclosure there is provided an apparatus and method as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows. Accordingly there may be provided a wall panel (100) for a safety barrier system (200) and / or warehouse partitioning (200). The wall panel (100) may be a mono-structure formed by a two-stage injection moulding process. The wall panel (100) may comprise a panel section (120) and a frame section (130). The panel section (120) may be integrally formed from a first polymer material (122). The frame section (130) may be integrally formed from a second polymer material (131). The panel section (120) and frame section (130) may be integrally formed to provide the mono-structure. The wall panel (100) may define an outer edge wall section (110), the outer edge wall section (110) being defined by the frame section (130), the outer edge wall section (110) extending completely around the panel section (120). The frame section (130) may have a first side (133) and a second side (132), the outer edge (134) extending between the first side (133) and the second side (132). The panel section (120) may extend over at least part of at least one of the frame section first side (133) and frame section second side (132). The frame section (130) may define a recess (135). The panel section (120) may span the recess (135). The frame section (130) may comprise a first end sub-section (136), a second end subsection (137), a first side sub-section (138) and a second side sub-section (139) which define the outer edge wall section (110). The first end sub-section (136) and second end sub-section (137) may be spaced apart from one another along the length (L) of the wall panel (100). The first side sub-section (138) and second side sub-section (139) may be spaced apart from one another across the width (W) of the wall panel (100). The first side sub-section (138) and second side sub-section (139) may extend between the first end sub-section (136) and second end sub-section (137). The first side sub-section (138) may define a first widened region which defines a first handle receiving cavity (140). The wall panel (100) may have a length in the range of 0.75 m to 2.5m, and a width in the range of 0.25m to 5.0m. The first polymer material (122) may have a first combination of characteristic material properties. The material properties may comprise: a. being one of transparent, translucent or opaque; b. a first stiffness value; c. a first surface finish; and / or d. a first hardness value. The first polymer material (122) may be chosen from a list comprising Polycarbonate, Polyethylene Terephthalate (PET), amorphous copolyester (PETG) acrylic (PMMA), Poly Vinyl Chloride (PVC), Cyclic Olefin Copolymer, Polyethylene, Liquid Silicone Rubber, Ionomer Resin, Polypropylene, Fluorinated Ethylene Propylene (FEP), Styrene Methyl Methacrylate (SMMA), Styrene Acrylonitrile Resin (SAN), General purpose Polystyrene (GPPS) Transparent ABS (MABS), amorphous polyamides (nylon). The second polymer material (131) may have a second combination of characteristic material properties. The material properties may comprise: a. being one of transparent, translucent or opaque; b. a second stiffness value; c. a second surface finish; and / or d. a second hardness value. The second polymer material (131) may be chosen from a list comprising Polycarbonate and Polycarbonate alloys, Polyethylene Terephthalate (PET), amorphous copolyester (PETG) acrylic (PMMA), Poly Vinyl Chloride (PVC), Cyclic Olefin Copolymer, Polyethylene, Liquid Silicone Rubber, Ionomer Resin, Polypropylene, Fluorinated Ethylene Propylene (FEP), Styrene Methyl Methacrylate (SMMA), Styrene Acrylonitrile Resin (SAN), General purpose Polystyrene (GPPS), Acrylonitrile Butadiene Styrene (ABS), polyamides (nylon). The first combination of characteristic material properties of the first polymer material (122) may be different to the second combination of characteristic material properties of the second polymer material (131). The panel section (120) may be solid. There may be provided a safety barrier system (200) and / or warehouse partitioning comprising a plurality of wall panels (100) according to the present disclosure. The safety barrier system (200) may further comprise an additional panel (202) which is different to the wall panel (100) according to the present disclosure. There may also be provided a method of manufacture of the wall panel (100) according to the present disclosure wherein: the panel section (120) is integrally formed from a first polymer material (122) in one of either a first stage or a second stage of the two-stage injection moulding process; and the frame section (130) is integrally formed from a second polymer material (131) in the other of the first stage or second stage of the two-stage injection moulding process; and the section (120,130) formed by the second stage being formed on the section (120, 130) formed by the first stage; and the section (120, 130) formed in the first stage is only partially cured before the polymer of the section (120, 130) formed in the second stage is provided on the section (120, 130) formed in the first stage so that the panel section (120) and the frame section (130) cure together to form the mono-structure. The panel section (120) may be integrally formed from the first polymer material (122) in the first stage of the two-stage polymer injection moulding process. The frame section (130) may be integrally formed from the second polymer material (131) in the second stage of the two-stage polymer injection moulding process. The stage of the two-stage injection moulding process which forms the panel section (120) may be an injection compression moulding process. After curing is complete, a coating (102) may be applied to the wall panel (100), the coating (102) configured to enhance hardness, surface resistivity and / or chemical resistance of the material of the wall panel (100). Hence there is provided a wall panel with a design that enables it to be produced faster than examples of the related art. There is also provided a method of manufacture that enables the wall panel to be produced faster than examples of the related art. Brief Description of the Drawings Examples of the present disclosure will now be described with reference to the accompanying drawings, in which: Figure 1 shows a plan view of wall panels assembled as a safety barrier system and / or warehouse partitioning according to the present disclosure; Figure 2 is an exploded perspective view of a first side of an assembly of a wall panel and panel support post of the present disclosure; Figure 3 is a view of the first side of the assembly of the panel and panel support post of the present disclosure as shown in figure 2; Figure 4 is a plan view of the assembly shown in figures 2, 3; Figure 5 is a perspective view of the first side of the wall panel according to the present disclosure; Figure 6 is a perspective view of a second side of the wall panel according to the present disclosure; Figure 7 illustrates the steps of a first method of manufacture of the wall panel according to the present disclosure; and Figure 8 illustrates the steps of a second method of manufacture of the wall panel according to the present disclosure. Detailed Description The present disclosure relates to a wall panel system 10 for example for forming a partition wall assembly 200 (e.g. a safety barrier system 200 and / or a system / kit for warehouse partitions). The present disclosure also relates to a partition wall assembly 200 comprising a wall panel 100. The present disclosure also relates to a wall panel 100 for forming a partition wall assembly 200. The present disclosure also relates a partition wall assembly 200. Figure 1 shows a plan view of an example partition wall assembly 200 including the wall panel 100 according to the present disclosure. The partition wall assembly 200 comprises a panel 100 and a panel support post 150. In the example shown, the wall panel system 10 comprises a plurality of panels 100 and a plurality of panel support posts 150. The panel support posts 150 are spaced apart from one another, with a panel 100 spanning the gap between each pair of adjacent posts 150. That is to say the wall panel system 10 may comprise at least one pair of panel support posts 150 spaced apart from one another with the panel 100 extending therebetween. The safety barrier system 200 may further comprise an additional panel 202 which is different to the wall panel 100. For example the additional panel 202 may have a different shape, configuration, function and / or structure to that of the wall panel 100. For example the additional panel 202 may be a doorway or provide a hatch. In the example shown in figure 1, the wall assembly 200 extends from a fixed wall 1000 (for example a fixed / structural part of a building) around an apparatus 900. For example, the wall assembly 200 may be provided to limit access to the apparatus 900, or to provide protection from the apparatus 900 within the region defined by the wall assembly 200. That is to say the wall assembly 200 comprises a plurality of panels 100 and panel support posts 150 which are arranged to produce (i.e. define) the partition wall assembly 200 which may be configured to provide controlled access to an area, for example an area which houses an apparatus 900. For example, the apparatus 900 may be a welding unit or machining equipment, and the wall assembly 200 acts as a barrier between the apparatus and anyone and anything breaching the wall assembly 200. However, the wall assembly 200 may be provided to define any shape or configuration - for example to define a walkway through an area, or to extend all of the way around a region (for example to define a work area in a warehouse). Figures 2, 3 illustrate part of the wall assembly 200, namely the wall panel 100 spanning the space between two panel support posts 150. The wall assembly 200 may comprise at least one panel support post 150 and one wall panel 100. The wall assembly 200 may comprise a plurality of panel support posts 150 and a plurality of wall panels 100. Features of the wall panel system 10 may be duplicated / repeated for each panel 100 and post 150 assembly. In the figures the wall panel 100 is shown as being rectangular (e.g. polygonal and elongate) but in practice may have any suitable shape and / or configuration. As illustrated in figure 3 panel 100 is configured to be located at a mount position on the panel support post 150. That is to say the panel 100 is configured to be mounted I fixed to (i.e., located on) the panel support post 150. In the examples shown the wall panel 100 is mounted (e.g., fixed) to two panel support posts 150. In other examples (not shown) the wall panel 100 may be mounted to only one support post 150. The posts 150 to either side of the panel 100 may be substantially identical, and both posts 150 may support the panel 100. As shown in figures 2, 3, 4, 5, the wall panel 100 comprises a panel section 120 and a frame section 130. The wall panel 100 may be formed by a two-stage injection moulding process. The panel section 120 is integrally formed from a first polymer material 122. The frame section 130 is integrally formed from a second polymer material 131. The panel section 120 and frame section 130 are integrally formed with one another such that the wall panel 100 is a mono-structure. That is to say, the panel 100 is manufactured so that there is formed a mechanical and chemical bond between the panel section 120 and frame section 130 to thereby produce the wall panel 100 as a monolithic article (i.e. a mono-structure). Put another way, the way in which the panel 100 is produced results in a mechanical and chemical bond being formed between the panel section 120 and frame section 130 of the panel 100 to thereby produce the wall panel 100 as a monolithic article. That is to say, the panel 100 is manufactured so that there is formed a mechanical and adhesive bond between the panel section 120 and frame section 130 of the panel 100 to thereby produce the wall panel as a monolithic article (i.e. a mono-structure). Put another way, the way in which the panel 100 is produced results in a mechanical and adhesive bond between the panel section 120 and frame section 130 of the panel 100 to thereby produce the wall panel 100 as a monolithic article. That is to say, all of the panel section and frame section of the panel 100 are processed in such as way as to form both a mechanical, chemical and / or adhesive bond between them to thereby produce a homogeneous structure and / or monolithic article. The monolithic article (i.e. the wall panel formed to be a mono structure) may have a homogeneous structure. That is, the panel section 120 and frame section 130 are produced as a single article / part. Hence the wall panel 100 is produced as a single layer of material. The panel section 120 may be solid. That is, the panel section 120 may not comprise any hollow sections or spaced apart sheets / section of material. As shown in figures 2, 3, 4, 5 the wall panel 100 defines an outer edge wall section 110 and inner edge section 112. The outer edge wall section 110 and inner edge section 112 are defined by the frame section 130 and extend completely around the panel section 120. As indicated in figures 2, 3, 4, 5, the frame section 130 has a first side 133 and a second side 132, the outer edge 134 extending between the first side 133 and the second side 132. As best illustrated in figure 5 (and also shown in figures 2, 3, 6) the frame section 130 comprises a first end sub-section 136, a second end sub-section 137, a first side subsection 138 and a second side sub-section 139. The first end sub-section 136, second end sub-section 137, first side sub-section 138 and second side sub-section 139 define the outer edge wall section 110 and the inner edge section 112. The first end sub-section 136 and second end sub-section 137 are spaced apart from one another along the length L of the wall panel 100. The first side sub-section 138 and second side sub-section 139 are spaced apart from one another across the width W of the wall panel 100. The first side sub-section 138 and second side sub-section 139 extend between the first end sub-section 136 and second end sub-section 137. The first end sub-section 136 and second end sub-section 137 extend between the first side subsection 138 and second side sub-section 139. The frame section 130 defines a recess (i.e. cavity) 135. The recess 135 is a region between the first end sub-section 136 and second end sub-section 137, and between the first side sub-section 138 and second side sub-section 139. Hence the inner edge section 112 extends around the perimeter of the recess 135. That is to say, the inner edge section 112 of the frame section 120 defines the extent of the recess 135 in the length L direction and width W direction. The panel section 120 spans the recess (i.e. cavity) 135. That is to say, the panel section 120 closes the recess (i.e. cavity) 135. Put another way, the frame section 130 defines an aperture 135, and the panel section 120 spans, closes and / or covers the aperture 135. The panel section 120 may extend from the inner edge section 112 of the frame section 130 across the full width W and length L of the frame section 130. At least part of the panel section 120 may extend from the inner edge section 112 of the frame section 130 across the full width W and length L of the frame section 130. The first end sub-section 136, second end sub-section 137, first side sub-section 138 and second side sub-section 139 are integrally formed with one another. The first end sub-section 136, second end sub-section 137, first side sub-section 138 and second side sub-section 139 extend continuously around the panel section 120. That is, the first end sub-section 136, second end sub-section 137, first side sub-section 138 and second side sub-section 139 form an unbroken whole, and extend without interruption / break around the panel 120 to define the outer edge section 110 of the wall panel 100. That is, the first end sub-section 136, second end sub-section 137, first side sub-section 138 and second side sub-section 139 extend without interruption / break around the panel 120 to define the outer edge wall section 110. As shown in figures 2, 3, a handle 300 (or handles) may be provided as part of the wall panel system 10, the handle (or handles) 300 being provided to engage with, and lock into, the wall panel 100 to provide a way of lifting the wall panel 100. The frame section 130 may extend with constant width around at least some of the panel section 120. The first side sub-section 138 may define a first handle receiving cavity 140 on the first side 133 of the frame section 130. The first side sub-section 138 may define a second handle receiving cavity 142 on the second side 132 of the frame section 130. The second side sub-section 139 may define a third handle receiving cavity 144 on the first side 133 of the frame section 130. The second side sub-section 139 may define a fourth handle receiving cavity 146 on the second side 132 of the frame section 130. The first side sub-section 138 of the frame section 130 may define a first widened region 160 which defines the first handle receiving cavity 140. The first widened region 160 may extend from the first side 133 to the second side 132. The first widened region 160 may define the second handle receiving cavity 142. The second side sub-section 139 of the frame section 130 may define a second widened region 162 which defines the third handle receiving cavity 144. The second widened region 162 may extend from the first side 133 to the second side 132. The second widened region 162 may define the fourth handle receiving cavity 146. As set out above, the panel section 120 extends from the inner edge section 112 of the frame section 130. Additionally, the panel section 120 may extend over at least part of at least one of the frame section first side 133 and frame section second side 132. For example, the panel section 120 may extend over at least part of the first widened region 160 and / or second widened region 162. For example, the panel section 120 may extend over at least part of the first widened region 160 and / or second widened region 162 on the first side 133 and / or second side 132 of the wall panel 100. The wall panel 100 may have a length in the range of 0.25 m to 5m, and a width in the range of 0.25m to 5.0m. The wall panel 100 may have a length in the range of 0.75m to 2.5m, and a width in the range of 0.25m to 5.0m. The wall panel 100 may have a length in the range of 1,0m to 2.5m, and a width in the range of 0.25m to 1,5m. The wall panel 100 may have a length in the range of 1.5m to 2.5m, and a width in the range of 0.25m to 1.5m. The first polymer material 122 of the panel section 120 has a first combination of characteristic material properties. That is to say, when cured, the first polymer material 122 of the panel section 120 has a first combination of characteristic material properties. The first combination of characteristic material properties may comprise: a. being one of transparent, translucent or opaque; b. a first stiffness value; c. a first surface finish (for example having a gloss, matt, smooth or rough surface finish; and / or d. a first hardness value. The first polymer material 122 may be chosen from a list comprising Polycarbonate, Polyethylene Terephthalate (PET), amorphous copolyester (PETG) acrylic (PMMA), Poly Vinyl Chloride (PVC), Cyclic Olefin Copolymer, Polyethylene, Liquid Silicone Rubber, Ionomer Resin, Polypropylene, Fluorinated Ethylene Propylene (FEP), Styrene Methyl Methacrylate (SMMA), Styrene Acrylonitrile Resin (SAN), General purpose Polystyrene (GPPS) Transparent ABS (MABS), amorphous polyamides (nylon). The second polymer material 131 of the frame section 130 has a second combination of characteristic material properties. That is to say, when cured, the second polymer material 131 of the frame section 132 has a second combination of characteristic material properties. The second combination of characteristic material properties may comprise: a. being one of transparent, translucent or opaque (which may be the same or different to the first polymer material 122 when cured); b. a second stiffness value (which may be the same or different to the first stiffness value); c. a second surface finish (for example having a gloss, matt, smooth or rough surface finish, which may be the same or different to the first surface finish); and / or d. a second hardness value (which may be the same or different to the first hardness value). The second polymer material 131 may be chosen from a list comprising Polycarbonate and Polycarbonate alloys, Polyethylene Terephthalate (PET), amorphous copolyester (PETG) acrylic (PMMA), Poly Vinyl Chloride (PVC), Cyclic Olefin Copolymer, Polyethylene, Liquid Silicone Rubber, Ionomer Resin, Polypropylene, Fluorinated Ethylene Propylene (FEP), Styrene Methyl Methacrylate (SMMA), Styrene Acrylonitrile Resin (SAN), General purpose Polystyrene (GPPS), Acrylonitrile Butadiene Styrene (ABS), polyamides (nylon). The first combination of characteristic material properties of the first polymer material 122 of the panel section 120 when cured may be different to the second combination of characteristic material properties of the second polymer material 131 of the frame section 130 when cured. The wall panel 100 may further comprise a coating. That is to say, after curing is complete, a coating 102 may be applied to the wall panel 100. The coating 102 may be configured to enhance hardness, surface resistivity and / or chemical resistance of the material of the wall panel 100. The first polymer material 122 and / or second polymer material 131 may comprise additives configured to enhance hardness, surface resistivity and / or chemical resistance of the material of the wall panel 100. The panel support post 150 may comprise a third material 151 having a third combination of characteristic material properties. That is to say, when cured, the third material 151 of the support post 150 has a third combination of characteristic material properties. The third combination of characteristic material properties may comprise: a. being one of transparent, translucent or opaque; b. a third stiffness value (which may be the same or different to the first and / or second stiffness value); c. a third surface finish (for example having a gloss, matt, smooth or rough surface finish, which may be the same or different to the first surface finish and / or second surface finish); d. a third hardness value (which may be the same or different to the first and / or second hardness value). The third material 151 may be chosen from a list comprising: steel, aluminium, or a composite comprising resin and a continuous long fibre reinforced plastic, where the fibre can be glass, steel, natural (for example flax or hemp), oriented polymer (oriented plastic fibres or tapes wherein the melting point of the tape is above the melting point of (thermoplastic) or endotherm (thermoset) of the resin), stone (basalt or granite) or any other high stiffness and strength fibre or tape. Resin can be any thermoset or thermoplastic that can be processed to the required shape. Example methods of manufacture of the wall panel 100 are illustrated in figures 7, 8. The method of manufacture may comprise a two-stage injection moulding process. In summary, the panel section 120 may be integrally formed from the first polymer material 122 in one of either a first stage or a second stage of the two-stage injection moulding process. The frame section 130 may be integrally formed from a second polymer material 131 in the other of the first stage or second stage of the two-stage injection moulding process. The section 120, 130 formed by the second stage may be formed on the section 120, 13 formed by the first stage. The section 120, 130 formed in the first stage is controlled / allowed to only partially cure before the polymer of the section 120, 130 formed in the second stage is provided on the section 120, 130 formed in the first stage so that the panel section 120 and the frame section 130 cure together to form the mono-structure. In one example, as illustrated by figure 7, in a first step 1001 as part of the first stage of the two-stage polymer injection moulding process, the panel section 120 is integrally formed from the first polymer material 122. In a second step 1002 of the first stage, the panel section 120 is then allowed / controlled to partially cure. In a third step 1003, which defines the second stage of the two-stage polymer injection moulding process, the frame section 130 is integrally formed from the second polymer material 131, and at the same time (i.e. as it is injected) the second polymer material 131 is brought into contact with a region of the partially cured first polymer material 122 of the panel section 120. In a fourth step 1004 the panel section 120 and the frame section 130 cure together to form the mono-structure. Optionally, in a fifth step 1005, after curing is complete, the coating 102 is applied to the wall panel 100. The coating 102 is configured to enhance hardness, surface resistivity and / or chemical resistance of the material of the wall panel 100. In a further example, as illustrated by figure 8, in a first step 2001 as part of the first stage of the two-stage polymer injection moulding process, the frame section 130 is integrally formed from the second polymer material 131. In a second step 2002 of the first stage, the frame section 130 is then allowed / controlled to partially cure. In a third step 2003, which defines the second stage of the two-stage polymer injection moulding process, the panel section 120 is integrally formed from the first polymer material 122, and at the same time (i.e. as it is injected) the first polymer material 122 is brought into contact with a region of the partially cured second polymer material 131 of the frame section 130. In a fourth step 2004 the first polymer material 122 of the panel section 120 and the second polymer material 131 of the frame section 130 cure together to form the monostructure. Optionally, in a fifth step 2005, after curing is complete, the coating 102 is applied to the wall panel 100. The coating 102 may be configured to enhance hardness, surface resistivity and / or chemical resistance of the material of the wall panel 100. In both examples of figure 7, 8 the stage of the two-stage injection moulding process which forms the panel section 120 may be an injection compression moulding process. The two-stage injection moulding process may take a few minutes to complete. By way of non-limiting example the two-stage injection moulding process may take 1 to 5 minutes to complete. Hence there is provided a wall panel with a design that enables it to be produced faster than examples of the related art. There is also provided a method of manufacture that enables the wall panel to be produced faster than examples of the related art. The result of the two-stage manufacturing process is that the frame section and panel section are integrally formed (i.e. that the wall panel 100 is provided as a monostructure). Advantageously, the two-stage process enables the mechanical properties of the frame section and panel section to be configured according to their function in the wall panel. That is to say, the two-stage process enables the mechanical properties of the frame section to be different to that of the panel section by virtue of their different composition. For example the panel section 120 may be configured to be resilient to impact (and hence be well suited to act as a safety barrier) while extending over the desired span / area and still be within a desired weight limit (e g. so it is still liftable by a user). The panel section 120 may be provided as a relatively thin sheet of material. However, the frame section 130 may be configured to have greater stiffness than the panel section 120 so the frame section 130 can support the panel section 120. Hence the frame section 130 may be thicker than the panel section, have a cross-sectional shape area to provide a stiff structure, and be made from a material which is stiffer when cured than the panel section 120. Since the frame section 130 and panel section 120 are integrally formed, only one manufacturing process is required to produce the wall panel (e.g. as set out in figures 7, 8). Hence compared to the fabrications of the related art which use several materials which are manufactured separately and brought together by a skilled fabricator, the wall panel 100 of the present disclosure may be made significantly more quickly, and using less equipment, than the examples of the related art. Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A wall panel (100) for a safety barrier system (200) and / or warehouse partitioning (200),5the wall panel (100) being a mono-structure formed by a two-stage injection moulding process; the wall panel (100) comprising a panel section (120) and a frame section (130), wherein:10 the panel section (120) is integrally formed from a first polymer material (122) having a first combination of characteristic material properties;the frame section (130) is integrally formed from a second polymer material (131) having a second combination of characteristic material properties; and15the first combination of characteristic material properties of the first polymer material (122) is different to the second combination of characteristic material properties of the second polymer material (131); and20 the panel section (120) and the frame section (130) are integrally formed to provide the mono-structure.

2. A wall panel (100) as claimed in claim 1 wherein the wall panel (100) defines an outer edge wall section (110), the outer edge wall section (110) being defined by the frame25 section (130), the outer edge wall section (110) extending completely around the panel section (120).

3. A wall panel (100) as claimed in claim 2 wherein the frame section (130) has a first side (133) and a second side (132), the outer edge (134) extending between the first30 side (133) and the second side (132); and the panel section (120) extends over at least part of at least one of the frame section first side (133) and frame section second side (132).26 10 234. A wall panel (100) as claimed in any one of the preceding claims wherein the frame section (130) defines a recess (135), and the panel section (120) spans the recess (135).5   5. A wall panel (100) as claimed in any one of claims 2 to 4 wherein the framesection (130) comprises a first end sub-section (136), a second end subsection (137), a first side sub-section (138) and a second side sub-section (139) which define the outer edge wall section (110);the first end sub-section (136) and second end sub-section (137) being spaced apart 10 from one another along the length (L) of the wall panel (100);the first side sub-section (138) and second side sub-section (139) being spaced apart from one another across the width (W) of the wall panel (100); andthe first side sub-section (138) and second side sub-section (139) extending between the first end sub-section (136) and second end sub-section (137).

156. A wall panel (100) as claimed in claim 5 wherein the first side sub-section (138) defines a first widened region which defines a first handle receiving cavity (140).

7. A wall panel (100) as claimed in any one of claims 5, 6 wherein the wall panel (100)20 has a length in the range of 0.75 m to 2.5m, and a width in the range of 0.25m to 5.0m.

8. A wall panel (100) as claimed in any one of the preceding claims wherein the first combination of characteristic material properties comprises:a. being one of transparent, translucent or opaque;b. a first stiffness value;c. a first surface finish; and / ord. a first hardness value; andthe second combination of characteristic material properties comprises:a. being one of transparent, translucent or opaque;b. a second stiffness value;35 c. a second surface finish; and / or26 10 23d. a second hardness value.

9. A wall panel (100) as claimed in claim 8 wherein the first polymer material (122) is chosen from a list comprising Polycarbonate, Polyethylene Terephthalate (PET), 5 amorphous copolyester (PETG) acrylic (PMMA), Poly Vinyl Chloride (PVC), Cyclic Olefin Copolymer, Polyethylene, Liquid Silicone Rubber, Ionomer Resin, Polypropylene, Fluorinated Ethylene Propylene (FEP), Styrene Methyl Methacrylate (SMMA), Styrene Acrylonitrile Resin (SAN), General purpose Polystyrene (GPPS) Transparent ABS (MABS), amorphous polyamides (nylon).1010. A wall panel (100) as claimed in claim 8 wherein the second polymer material (131) is chosen from a list comprising Polycarbonate and Polycarbonate alloys, Polyethylene Terephthalate (PET), amorphous copolyester (PETG) acrylic (PMMA), Poly Vinyl Chloride (PVC), Cyclic Olefin Copolymer, Polyethylene, Liquid Silicone 15 Rubber, Ionomer Resin, Polypropylene, Fluorinated Ethylene Propylene (FEP), Styrene Methyl Methacrylate (SMMA), Styrene Acrylonitrile Resin (SAN), General purpose Polystyrene (GPPS), Acrylonitrile Butadiene Styrene (ABS), polyamides (nylon).20   11. A wall panel (100) as claimed in any one of the preceding claims wherein the panelsection (120) is solid.

12. A safety barrier system (200) and / or warehouse partitioning comprising a plurality of wall panels (100) as claimed in any one of claims 1 to 11.2513. A safety barrier system (200) as claimed in claim 12 further comprising an additional panel (202) which is different to the wall panel (100) claimed in claims 1 to 11.

14. A method of manufacture of the wall panel (100) as claimed in any one of 30 claims 1 to 11 wherein:the panel section (120) is integrally formed from a first polymer material (122) in one of either a first stage or a second stage of the two-stage injection moulding process; and26 10 23the frame section (130) is integrally formed from a second polymer material (131) in the other of the first stage or second stage of the two-stage injection moulding process; and5 the section (120,130) formed by the second stage being formed on the section (120, 130) formed by the first stage; andthe section (120, 130) formed in the first stage is only partially cured before the polymer of the section (120, 130) formed in the second stage is provided on the 10 section (120, 130) formed in the first stage so that the panel section (120) and the frame section (130) cure together to form the mono-structure.

15. A method of manufacture as claimed in claim 14 wherein:15 the panel section (120) is integrally formed from the first polymer material (122) in the first stage of the two-stage polymer injection moulding process; andthe frame section (130) is integrally formed from the second polymer material (131) in the second stage of the two-stage polymer injection moulding process.2016. A method of manufacture as claimed in claim 14 or claim 15 wherein the stage of the two-stage injection moulding process which forms the panel section (120) is an injection compression moulding process.25   17. A method of manufacture as claimed in any one of claims 14, 15, 16 wherein aftercuring is complete, a coating (102) is applied to the wall panel (100), the coating (102) configured to enhance hardness, surface resistivity and / or chemical resistance of the material of the wall panel (100).

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