This application relates to a longitudinal frame member and spline for use in attaching fabric, for example, to a frame.
Frames used for windows, doors and office furniture, such a cubical dividers, have fabric attached to a frame in some fashion. Other applications include ceiling panels, air/water filter panels, and acoustic tiles. In the example of window frames and doors using screens, typically the frame includes longitudinal frame members having channels to which the screen is secured. The longitudinal members are joined to one another in some fashion to provide the frame. During assembly, the screen is positioned over the frame and a rubber spline having a generally circular cross section is inserted into the channels thereby retaining the screen between the spline and longitudinal frame members. Other approaches have been used to secure the screen to the frame. Typically, a separate retaining member is pressed or snapped into the frame, securing the screen between the frame and retaining member. However, manipulating and inserting a separate retaining member, like a rubber or plastic spline into the frame members while controlling the woven fabric, is labor intensive and costly.
Installation of fabric using the spline arrangement described above or other manners of screen attachment are typically labor intensive and costly. In the example of the splines described above, a special tool having rollers must be run along the length of longitudinal member. Moreover, the frame tends to “hourglass” as a result of the screen assembly process. Pre-bowing the frame members and blocking of the assembled frame for squareness is typically used to prevent this undesired result, which adds cost to assembly.
Another approach for securing screens has been to use a hinged retaining member integral with and movable relative to the frame, as disclosed in U.S. Pat. No. 3,379,237. The arrangement disclosed in the '237 patent has at least two problems. First, the frame is not structurally stable such that it will deflect and permit the retaining member to open, thus releasing the screen. Second, the retaining member does not keep sufficient force on the screen to maintain the screen in tension. Third, there is a sharp edge on the retaining member that is the primary and only point of engagement with the screen, which will tend to tear the screen when force is applied to it.
Window and door screens must pass an industry “push out” test. One industry standard requires that the screen be held through the longitudinal frame members for at least forty pounds of applied force. The standard can sometimes be difficult to meet using rubber or plastic splines.
What is needed is an improved frame that requires less labor and cost to manufacture while meeting or exceeding the present industry standard for “push out” and improving the hour glass specifications.
These and other features of the disclosure can be best understood from the following specification and drawings, the following of which is a brief description.
An example frame of the disclosure includes longitudinal members secured to one another, for example by using corner locks, to form the frame. The longitudinal members support an integral spline that is normally open prior to assembly to expose a cavity that receives a fabric. A fabric, such a mesh screen, is arranged over the frame so that the perimeter of the screen is received within the cavities of the longitudinal members.
In one example, the frame is retained on a fixed platen by stops. A movable platen is actuated to engage the spline. The splines are forced into the cavities or channels to a closed position in which the perimeter of the screen is pinched between a nose of the spline and the longitudinal members. The nose provides three engagement features, in one example, that ensure that screen is securely retained without tearing it. The first engagement feature is provided by a curved portion of the nose that engages and pushes the screen down into the cavity as the spline is moved from the open to the closed position. The second engagement features is provided by a corner of the nose that pinches the screen against a base wall of the channel. The third engagement feature is provided by a ridge that extends from the base wall to support the perimeter of the screen so that it wraps about the corner thereby enhancing retention. The spline profile is designed to deflect about a fulcrum hinge point away from the engagement features of the surrounding frame to prevent the frame from distorting during assembly.
The spline is generally S-shaped in one example. The spline may be integral with the longitudinal member or separately secured to the longitudinal member, for example, by snapping or sliding the spline into a recess in the longitudinal member.
Accordingly, the disclosed frame requires less labor and cost to manufacture while meeting or exceeding the present industry standard for “push out.” Further, the frame members do not require pre-bowing or blocking during the assembly process.
An example longitudinal frame member 10 is shown in the Figures. Like numerals are used to refer to like elements between some Figures.
Referring to
The example member 10 shown in
For roll-formed members, the member 10 includes a first edge 16 provided on the spline 14 and a second edge 18 provided on the tubular portion 12, best seen in
Opposite the flange 20 is a wall 22 having a slot 24 for receiving a corner lock 28. The corner lock 28 includes first and second legs 30 and 32. The first leg 30 is received in the tubular portion 12, and the leg 32 extends from the slot 24.
The arrangement shown in
Referring to
Another example assembly process is shown in
According to one example method of assembly, referring to
The machine 34 includes a movable platen 50 having a flat profile 52. By utilizing a flat profile 52, the tooling costs are drastically reduced since a platen of particular profile requiring machining is not required, and alignment issues between the movable platen 50 and frame 42 are eliminated.
The tubular portion 12, or base portion, is generally quadrangular in one example and includes a base wall 58 that provides a bottom surface of the channel 26. The base wall 58 extends between and interconnects spaced apart first and second outer walls 59, 61, in one example. In the example shown in
The movable platen 50 is moved downward into engagement with the spline 14 moving the spline 14 from the first or open position PI (see also
The nose 46 has a sharp corner 56, for example, on the first edge 16 that pinches the fabric 44 to retain the perimeter of the screen between the corner 56 and the surface of the base wall 58, thus providing a second engagement feature. The corner 56 not likely to tear the fabric 44 as force is applied to it since the fabric at this location will experience a smaller force that at the first engagement feature. In the third position P3, the arch 48 has a larger radius than it did in first position P1, and the nose 46 has smaller radius than it did in the first position P1. The deflected spline 14 applies sufficient retaining force on the fabric 44 to prevent “push-out” of the fabric. The fabric 44 begins to tear, which occurs at around 125 pounds of applied force for typical insect screen materials, without it pulling out of the channel 26.
To further improve retention of the fabric 44, a third engagement features, such as barbs 54, may extend upward from the base wall 58 into the channel 26, as is show in
Referring to
In another example, the spline 14 can be adhered to the tubular portion 12 by any suitable process, such as by laminating or over-molding, as shown in
The example longitudinal frame member 10 permits easy replacement of the screen. The spline 14 may be “zippered” open and the damaged screen removed and replaced. With the new screen positioned as desired, the spline 14 can be manually forced back into the channel 26 using a block of wood and hammer or a roller, for example.
Referring to
As an alternative configuration to the end 216, edges 218 may be laser welded to one another using a weld bead 222 to form the end 216 shown in
The example embodiments have been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the disclosed examples are possible in light of the above teachings. For that reason, the following claims should be studied to determine their true scope and content.
This application claims priority to provisional application No. 60/885,426 filed on Jan. 18, 2007. This application is also a continuation-in-part of application Ser. No. 11/233,640 filed on Sep. 23, 2005, now abandoned which claims priority to provisional application No. 60/615,794 filed on Oct. 4, 2004, and a continuation-in-part of application Ser. No. 10/825,525 filed on Apr. 15, 2004, now U.S. Pat. No. 7,316,758 which claims the benefit to provisional application Nos. 60/485,579 and 60/492,698 respectively filed on Jul. 9 and Aug. 6, 2003.
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Number | Date | Country | |
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20070256800 A1 | Nov 2007 | US |
Number | Date | Country | |
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60885426 | Jan 2007 | US | |
60615794 | Oct 2004 | US | |
60485579 | Jul 2003 | US | |
60492698 | Aug 2003 | US |
Number | Date | Country | |
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Parent | 11233640 | Sep 2005 | US |
Child | 11760231 | US | |
Parent | 10825525 | Apr 2004 | US |
Child | 11233640 | US |