Free-standing window screen fabrication system

Abstract

A free-standing window screen fabrication system for releasably mounting a screen fabric or other pliable sheet material on a free-standing screen frame in such a manner as to self-tighten the fabric or material during installation. A screen is disposed and held securely in place between a screen frame extrusion member and a trim mold. The screen frame extrusion defines a mounting surface disposed below and parallel to an exterior face. The screen frame extrusion further defines an interior channel for receiving one end of a connector, a plurality of screen frame extrusions being secured in an end-to-end fashion to define a free-standing screen frame. A mounting rib extends along the mounting surface and terminates below the exterior face in the preferred embodiment. A bead is defined at the terminal edge of the mounting rib to serve as a locking mechanism. The trim mold defines a channel opening on the bottom surface thereof to closely receive the mounting rib of the screen frame extrusion. A plurality of retention barbs are formed in the channel to engage the mounting rib bead in order to prevent inadvertent removal of the trim mold from the mounting rib.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] 1. Field of Invention

[0004] This invention relates to the field of replaceable window screens. More specifically, the present invention relates to a structure for fabricating a free-standing screen frame and releasably mounting a screen fabric or other pliable sheet material thereto.

[0005] 2. Description of the Related Art

[0006] It is well known that most screens manufactured today include a replaceable screen fabric. In the event the fabric is torn, stretched, or otherwise damaged, the fabric is removed and replaced with another such fabric. Typically this task is accomplished by removing a gasket-type device, commonly referred to as a spline, from within a recess formed around the perimeter of a frame. The spline retains the fabric edges within the recess such that when the spline is removed, the fabric is likewise removed. A new fabric is then stretched across the frame and the spline is replaced within the recess. Excess fabric along the perimeter of the screen—and specifically that material along the perimeter of the fabric and on the side away from the gasket—is then trimmed.

[0007] Although this is a simplistic procedure to describe, it is well known that stretching the fabric and maintaining it in a stretched manner while the gasket is replaced is a difficult task. What typically occurs when the appropriate tools are not available is that as the gasket is forced into place, the fabric loosens or is pulled in a direction such as to create wrinkles. Further, due to the tension on the fabric during installation, it is often difficult to force the spline into the recess without damaging the fabric, or without releasing the tension on the fabric.

[0008] Other devices have been produced to provide a window screen construction. Typical of the art are those devices disclosed in the following U.S. Patents: 1 Pat. No. Inventor(s) Issue Date   918,676 H. W. Johnson Apr. 20, 1909 1,586,708 A. W. Sandelin Jun. 1, 1926 3,469,695 C. D. Greeninger Sep. 30, 1969 3,696,857 F. M. Le Tarte Oct. 10, 1972 3,980,555 M. F. A. Freissle Sep. 14, 1976 4,189,880 G. Ballin Feb. 26, 1980 4,234,035 F. W. Babbs Nov. 18, 1980 4,333,284 D. F. Meadows Jun. 8, 1982 4,658,522 M. L. Kramer Apr. 21, 1987 4,690,192 J. Stilling Sep. 1, 1987 5,666,773 C. J. Librande et al. Sep. 16, 1997 5,904,200 J. E. Agen May 18, 1999 6,032,433 T. Hatziathanasiou Mar. 7, 2000

[0009] Of these patents, the '676 patent issued to Johnson discloses a metal window screen having a metal frame. The interior perimeter of the metal frame defines a bent edge. The screen fabric, or wire netting, is positioned over the frame opening and retaining strips are fastened to the frame over the bent edges, with the wire netting positioned between. The retaining strips are fastened with bolts or screws, the bolts or screws being forced through the netting. The terminal edge of each retaining strip is deformed into a U-shaped configuration to cooperate with the bent edge of the frame such that as the retaining strip is secured to the frame, the netting is tightened. However, because the netting is damaged during installation, the same cannot be removed and reused as desired.

[0010] That device disclosed by Sandelin ('708) is similar to the '676 device in that a retaining frame is screwed onto a screen frame, with a screen fabric disposed therebetween. Similarly, the screen fabric is damaged upon installation by the fasteners.

[0011] Greeninger ('695) discloses a screen tightening apparatus for a vibrating screen. Opposing edges of the screen fabric are mounted on a rotating member, each rotating member being provided with a lever to impart rotation thereon. Such an apparatus, while useful in the environment proposed by Greeninger, is impractical in the environment of the present invention. Specifically, the '695 device is impractical for placing a screen over the opening of a window.

[0012] The '857 patent issued to Le Tarte discloses a more conventional screen frame wherein a fabric is stretched across an opening in the frame. A plastic, generally Y-shaped, strip is then oriented and pressed into place in the frame such that the edges of the fabric are pressed into a recess defined by the frame, thus holding the fabric in place.

[0013] Freissle ('555) discloses a replaceable screen having a frame, but does not disclose a frame having a construction to allow for the replacement of the screen fabric itself.

[0014] Babbs ('035) discloses a trim lock for holding the edge of one or two pieces of trim fabric in relation to a frame member of upholstered furniture. Similar to conventional screens, the trim lock is forced into a channel with the trim fabric being disposed between the trim lock and the channel. The '433 device disclosed by Hatziathanasiou is similar to the '035 device disclosed by Babbs.

[0015] The '522 device taught by Kramer is used for tensioning a piece of fabric for needlework. A frame defines a circular cross-section, while a plurality of clamps define an arcuate configuration. The clamps are configured to closely receive the frame such that the clamps may pivot over the frame when attached. The fabric is tensioned by so rotating the clamps over the frame. However, Kramer does not disclose a manner in which the fabric is maintained in a tensioned state.

[0016] The '773 device disclosed by Librande et al., includes a screen frame to which is releasably mounted a screen. A plurality of rail operators is provided for accomplishing the mounting of the screen on the frame. However, such operators are not disclosed for self-tightening the screen fabric while installing the same on the frame.

[0017] The Agen device ('200) is an improvement to the convention screen installation system, wherein a number of barbs extend inwardly and downwardly in alternating succession on either side of a channel defined by the frame. The screen fabric is inserted into the channel, with the barbs serving to retain the fabric therein. However, as in other conventional screens, there is no provision for self-tightening of the screen fabric as it is installed on the frame.

[0018] Those devices disclosed by Ballin ('880), Meadows ('284), and Stilling ('192) each include a receptor in which is received the screen fabric or film and a spline. The spline is forced into the receptor as in conventional screens. However, the spline includes a head disposed above the receptor and the screen.

[0019] In U.S. Pat. No. 6,378,267, the inventor of the present invention disclosed a unique system for installing screens and films over window openings. The disclosure of the '267 patent is incorporated herein. However, what was disclosed in that patent was directed toward a screen mounted on a window opening. The '267 patent did not disclose a device for forming a free-standing screen. More specifically, the '267 patent does not disclose a device for forming a screen frame across which is stretched a screen fabric to thus form a free-standing screen.

BRIEF SUMMARY OF THE INVENTION

[0020] The present invention is designed for releasably mounting a screen fabric or other pliable sheet material to a free-standing screen frame in such a manner as to self-tighten the fabric or material during installation. While a hammer may be used to secure a trim mold to the screen frame, tightening of the screen or fabric is accomplished without the use of any tools. Moreover, in the preferred embodiment the screen frame and trim mold are designed to allow for the mounting of the fabric or material without damaging the same such that it may be removed and reused as required. The present invention is designed to allow for the replacement of the screen fabric with any other suitable sheet material such as vinyl.

[0021] A screen is disposed and held securely in place between a screen frame and a trim mold. To accomplish the disposition and retention of the screen, the screen frame and trim mold are each extruded members. The screen frame extrusion defines a mounting surface disposed below and parallel to an exterior face. A vertical surface extends between and perpendicular to the exterior face and the mounting surface. A mounting rib extends along the mounting surface parallel to the vertical surface. The screen frame extrusion defines an interior channel for receiving one end of a connector. A plurality of screen frame extrusions are secured in an end-to-end fashion to define a screen frame. The mounting rib terminates below the exterior face in the preferred embodiment. A bead is defined at the terminal edge of the mounting rib to serve as a locking mechanism.

[0022] The trim mold is configured to closely receive the mounting rib of the screen frame extrusion. To this extent, the trim mold defines a channel opening on the bottom surface thereof and extending into the trim mold a depth substantially equal to the height of the mounting rib. A plurality of retention barbs disposed at an upward angle with respect to the mounting rib are formed in the channel to engage the mounting rib bead in order to prevent inadvertent removal of the trim mold from the mounting rib. The trim mold is configured to be received within a volume defined generally by the vertical surface and the mounting surface of the screen frame extrusion. The trim mold defines an exterior face which is disposed substantially co-planar with the screen frame extrusion when installed.

[0023] In order to install a screen in the screen frame of the present invention, the screen is laid over the screen frame extrusion at approximately the point to be attached. The trim mold is then placed over the mounting rib and pressed toward the screen frame extrusion such that the screen is deformed over the mounting rib and the mounting rib and screen are both received within the trim mold channel. The screen is thus tightly received between the mounting rib and the channel, with the retention barbs assisting in the retention thereof. In order to remove the screen, the trim mold is simply pried away from the screen frame extrusion. After the trim mold is snapped into place, the opposing trim mold is snapped into place. Prior to snapping the trim mold into place, the screen is gently pulled to remove excess slack. A similar procedure is then performed on the trim mold on either side of the frame.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0024] The above-mentioned features of the invention will become more clearly understood from the following detailed description of the invention read together with the drawings in which:

[0025] FIG. 1 is a perspective illustration of a free-standing window screen constructed in accordance with several features of the present invention;

[0026] FIG. 2 is an elevation view, in section, of the free-standing window screen taken at 2-2 of FIG. 1;

[0027] FIG. 3 is an exploded top plan view of a corner of the free-standing window screen of the present invention, showing one means for joining the corners of the free-standing screen frame;

[0028] FIG. 4 is a top plan view of the window screen installation screen showing a first trim rail mounted thereon;

[0029] FIG. 5 is a top plan view of the window screen installation screen showing a second trim rail mounted thereon;

[0030] FIG. 6 is a top plan view of the window screen installation screen showing a third trim rail mounted thereon; and

[0031] FIG. 7 is a top plan view of the window screen installation screen showing a fourth trim rail mounted thereon.

DETAILED DESCRIPTION OF THE INVENTION

[0032] A free-standing window screen fabrication system incorporating various features of the present invention is illustrated generally at 10 in the figures. The free-standing window screen fabrication system 10, which comprises primarily includes a screen frame 12 and trim mold 14, is designed for releasably mounting a screen fabric 16 or other pliable sheet material in such a manner as to self-tighten the fabric or material during installation. While a hammer may be used to secure the trim mold 14 to the screen frame 12, tightening of the screen or fabric 16 is accomplished without the use of any tools. Moreover, in the preferred embodiment the screen frame 12 and trim mold 14 are designed to allow for the mounting of the screen or fabric 16 without damaging the same such that it may be removed and reused as required.

[0033] In the preferred embodiment of the present invention, a screen fabric 16 may be installed for use in such applications as a storm door or a window screen, or for larger applications such as screened-in porches. However, in colder seasons, it may be preferable to replace the screen fabric 16 with a transparent sheet material 16′ such as vinyl. Accordingly, the present invention is designed to allow for the replacement of the screen fabric 16 with the sheet material 16′, and vise versa. For ease of description, use of the term “screen 16” is intended to include a conventional screen fabric 16, a conventional transparent sheet material 16′, or any other pliable sheet that may be used as a membrane in the screen frame 12 of the present invention.

[0034] Illustrated in FIG. 1 is a perspective view of a screen frame 12 of the present invention. In order to illustrate the various uses of the screen frame 12, a portion of a screen fabric 16 is shown in the lower portion of the frame 12, while a portion of a transparent sheet material 16′ is shown in the upper portion of the screen frame 12. Thus it is clearly seen that the screen frame 12 and trim mold 14 of the present invention are designed for use in various environments and applications.

[0035] As more clearly illustrated in FIG. 2, the screen 16 is disposed and held securely in place between the screen frame 12 and the trim mold 14. To accomplish the disposition and retention of the screen 16, the screen frame 12 and trim mold 14 are each extruded members. The screen frame extrusion 12 defines a mounting surface 18 preferably disposed below and parallel to an exterior face 26. A vertical surface 24 extends between and perpendicular to the exterior face 26 and the mounting surface 18. A mounting rib 20 extends along the mounting surface 18 and parallel to the vertical surface 24. The mounting rib 20 terminates below the exterior face 26 in the preferred embodiment. A bead 22 is defined at the terminal edge of the mounting rib 20 to serve as a locking mechanism. An interior channel 28 is defined along the length of the screen frame 12 extrusion. As will be discussed in greater detail below, the interior channel 28 is useful for securing two segments of the screen frame 12 together to form the free-standing screen frame 10.

[0036] The trim mold 14 is configured to closely receive the mounting rib 20 of the screen frame extrusion 12. To this extent, the trim mold 14 defines a channel 30 opening on the bottom surface thereof and extending into the trim mold 14 a depth substantially equal to the height of the mounting rib 20. A plurality of retention barbs 32 disposed at an upward angle with respect to the mounting rib 20 are formed in the channel 30 to engage the mounting rib bead 22 in order to prevent inadvertent removal of the trim mold 14 from the mounting rib 20.

[0037] As illustrated in FIG. 3, several segments of the screen frame 12 extrusion are used to form the entire screen frame 12. Adjoining ends of the screen frame 12 extrusion are mitered to form the selected angle. Most standard screens define a rectangular configuration. Accordingly, the illustrated screen frame 12 extrusions are mitered at 45° to form a right angle when joined. However, the ends may be mitered at any selected angle to fabricate a free-standing screen frame 10 for any shaped opening. For example, although not illustrated, a trapezoid having corners measuring 120° and 60° requires the pairs of adjoining ends to be mitered at 60° and 30°, respectively. For ease of fabrication, the trim mold 14 is received on the screen frame 12 extrusion when the ends are mitered, thereby insuring that the trim mold 14 is cut to the appropriate length. The trim mold 14 is then removed from the screen frame 12 extrusion for assembly of the freestanding screen frame 10.

[0038] A connector 36 is provided for securing each pair of adjoining screen frame 12 extrusion ends in a fixed relationship. The connector 36 of the illustrated embodiment defines two elongated members 38 configured to be received within the interior channel 28 of the screen frame 12 extrusion. In the illustrated embodiment, the locking members 40 are compression springs which, when inserted into the screen frame extrusion interior channel 28, are compressed and tightly engage the walls of the interior channel 28. The angle between the elongated members 38 determines the angle formed by the two screen frame 12 extrusions. Accordingly, for the illustrated rectangular free-standing screen frame 10, the elongated members 38 are disposed at a right angle.

[0039] While a mitered joint has been illustrated and described, other conventional connectors may be used as well. For example, although not illustrated, another conventional connector defines a corner member that remains exposed after construction of the screen frame. Such a connector does not require the screen frame 12 to be mitered.

[0040] In order to install a screen 16 in the screen frame 12 of the present invention, the screen 16 is laid over the screen frame extrusion 12 at approximately the point to be attached. The trim mold 14 is then placed over the mounting rib 20 and pressed toward the screen frame 12 extrusion such that the screen 16 is deformed over the mounting rib 20 and the mounting rib 20 and screen 16 are both received within the trim mold channel 30. The screen 16 is thus tightly received between the mounting rib 20 and the channel 30, with the retention barbs 32 assisting in the retention thereof. In order to remove the screen 16, the trim mold 14 is simply pried away from the screen frame extrusion 12 with, for example, a flat head screwdriver. Thus, mounting and removal of the screen 16 typically do not damage the screen 16 as a result of not requiring the use of conventional fasteners such as screws.

[0041] FIGS. 4-7 illustrate in a step-by-step fashion the installation of a screen 16 on a screen frame 12. As illustrated in FIG. 4, a screen 16 dimensioned at least slightly larger than the opening 40 defined by the screen frame 12 is positioned on top of the screen frame 12 and the trim mold 14 corresponding to a first screen frame extrusion 12 is snapped into place. Then as illustrated in FIG. 5, the opposing trim mold 14 is snapped into place. Prior to snapping the trim mold 14 into place, the screen 16 is gently pulled to remove excess slack. However, slack approximately equal to the height of the mounting rib 20 is automatically removed from the screen 16 when the second trim mold 14 is placed. By placing opposing trim molds 14 in this manner, slack is removed from the screen 16 in an end-to-end fashion, with some slack remaining side-to-side. FIGS. 6 and 7 illustrate a similar procedure from side to side to remove the remaining slack and to complete the screen mounting process. With the placement of each of the third and fourth trim molds 14, slack approximately equal to the height of the mounting rib 20 is taken from each side of the screen 16, leaving a tightened screen mounted on the screen frame 12. Once all pieces of trim mold 14 have been securely placed on the respective screen frame 12 extrusions, the selvage is trimmed to yield the free-standing screen of FIG. 1 which is ready for placement in a selected opening.

[0042] From the foregoing description, it will be recognized by those skilled in the art that a free-standing window screen fabrication system offering advantages over the prior art has been provided. Specifically, the free-standing window screen fabrication system is designed for releasably mounting a screen fabric or other pliable sheet material in such a manner as to self-tighten the fabric or material during installation. Tightening of the screen or fabric is accomplished without the use of any tools. The screen frame is designed to be free-standing such that it may be selectively removed and replaced as required. Moreover, the screen frame is designed to allow for the mounting of the fabric or material without damaging the same such that it may be removed and reused as required.

[0043] While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept.

Claims

1. A free-standing screen frame comprising:

a plurality of screen frame extrusions secured in an end-to-end fashion and cooperating to form a frame opening, each said screen frame extrusion defining at least one mounting surface and at least one mounting rib extending upwardly from said mounting surface and parallel to an interior edge of said screen frame extrusion, said mounting rib defining a bead along a terminal edge of said mounting rib, each said screen frame extrusion further defining an interior channel defined along a length thereof;

a plurality of connectors for securing said plurality of screen frame extrusions in a fixed relationship to define a screen frame, each of said plurality of connectors defining a first elongated member and a second elongated member, said first elongated member for being received within said interior channel defined by a one of said plurality of screen frame extrusions, said second elongated member for being received within said interior channel defined by another of said plurality of screen frame extrusions;

a screen disposed across said frame opening; and

a plurality of trim mold extrusions configured to closely receive said mounting rib of said screen frame extrusion, each of said plurality of trim mold extrusions defining a bottom surface and a channel opening thereon and extending into said trim mold extrusion a depth substantially equal to a height of said mounting rib, said channel defining a plurality of retention barbs for engaging said mounting rib bead, whereby said trim mold extrusion is prevented from inadvertent removal when said screen frame extrusion mounting rib is received within said trim mold extrusion channel and said screen is retained from movement therein, and further whereby said screen is self-tightened as said trim mold is engaged with said screen frame extrusion.

2. The free-standing screen frame of claim 1 wherein said screen frame extrusion further defines an exterior face above and parallel to said mounting surface, and a vertical surface extending between and perpendicular to said exterior face and said mounting surface, whereby said mounting rib is disposed substantially parallel to said vertical surface, and whereby said mounting rib terminates below said exterior face.

3. The free-standing screen frame of claim 2 wherein each of said plurality of trim mold extrusions further defines an exterior face disposed substantially co-planar with said screen frame extrusion exterior face when said screen frame extrusion mounting rib is received within said trim mold extrusion channel.

4. The free-standing screen frame of claim 1 wherein said screen frame extrusion defines a symmetrical configuration having a first said mounting rib for mounting a first said screen and a second said mounting rib for mounting a second said screen.

5. The free-standing screen frame of claim 1 wherein said screen is fabricated from a mesh-type screen selected to allow air flow therethrough.

6. The free-standing screen frame of claim 1 wherein said screen is fabricated from a sheet material selected to prevent airflow therethrough.

7. The free-standing screen frame of claim 1 wherein said screen is interchangeable and is fabricated from either of a mesh-type screen selected to allow air flow therethrough and a sheet material selected to prevent airflow therethrough.

8. A method for fabricating a free-standing screen including a screen frame and at least one trim mold extrusion, said screen frame constructed from a plurality of screen frame extrusions, each said screen frame extrusion cooperating to form an opening across which is positioned said screen, each said screen frame extrusion defining at least one mounting surface and at least one mounting rib extending upwardly from said mounting surface and parallel to an interior edge of said screen frame extrusion, said mounting rib defining a bead along a terminal edge of said mounting rib, each said screen frame extrusion further defining an interior channel defined along a length thereof, said plurality of screen frame extrusions being secured one to another in an end-to-end fashion using a plurality of connectors, each of said plurality of trim mold extrusions being configured to closely receive said mounting rib of said screen frame extrusion said screen, said trim mold extrusion defining a bottom surface and a channel opening thereon and extending into said trim mold extrusion a depth substantially equal to a height of said mounting rib, said channel defining a plurality of retention barbs for engaging said mounting rib bead, said method comprises the steps of:

a) connecting each of said plurality of screen frame extrusions using said plurality of connectors to fabricate a screen frame defining a frame opening;

b) positioning said screen over said opening defined by said screen frame;

c) placing a one of said at least one trim mold extrusion over said mounting rib of a cooperating one of said at least one screen frame extrusion to position said channel over said mounting rib;

d) pressing said trim mold to engage said mounting rib in said channel with said screen positioned between;

e) pulling said screen to gently tighten said screen over said screen frame opening;

f) placing a further of said at least one trim mold extrusion over said mounting rib of a cooperating one of said at least one screen frame extrusion to position said channel over said mounting rib;

g) pressing said further trim mold extrusion to engage said mounting rib in said channel with said screen positioned between;

h) repeating steps e) through g) until each of said at least one trim mold has been pressed into engagement with a cooperating one of each of said at least one screen frame extrusion mounting rib, whereby as said further of said at least one trim mold and each subsequent said at least one trim mold is engaged, said screen is self-tightened.

9. The method of claim 8, after said step of repeating steps e) through g), further comprising the step of:

i) trimming excess of said screen from around an exterior perimeter defined by each of said at least one trim mold extrusion.