Frame system

Abstract

The fabric frame system is disclosed to use a minimum number of component parts in order to assemble many types of display systems. The parts are sized with very tight tolerances to form support for specially produced fabric panels.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a frame system and more particularly to a fabric frame system.

2. Background

Frame systems for various materials have been known for hundreds of years. This includes frame systems for art and other materials. Frame systems of the prior art require disassembly and reassembly to accommodate new fabric presentations. For such systems that present fabric for viewing, such disassembly and assembly requires tools, and in many complex systems, mechanics or technicians in order to wield the tools to change the frames. Because frames may be complex, usually some training is required of the persons who disassemble and reassemble them.

It is a first object of the present invention to have a frame system that doesn't require it to be dis-assembled and re-assembled to accommodate new fabric presentation.

It is a second object of the present invention to have a frame system that doesn't require substantial tools for replacement of fabric display.

Is the third object of the present invention to have a frame system for which neither a mechanic nor a technician is needed to replace fabric displays.

Is a fourth object of the present invention to have a frame system that allows anyone, such as a clerk, sales person, laymen, to replace fabric display including utilizing a tongue & groove locking system.

Is a fifth object of the present invention to have a frame system that can achieve an extensive versatility and range of applications.

SUMMARY OF THE INVENTION

A fabric frame is disclosed, which has an extremely unique, flexible framing system designed specifically for displaying custom manufactured, digitally printed polyester fabric panels.

The fabric frame has apparatus and a method by which the fabric is easily affixed to the frame via a special tongue & groove, no tools required method thus eliminating the need to disassemble or re-assemble the frame system in the process of attaching or replacing fabric panels. As set out above “Prior Art” apparatus and methods require that the framing system be disassembled and re-assembled for replacing fabric panels, and thus to effectively accomplish this prior art method, using prior art apparatus, such as in retail and automotive showrooms, an authorized mechanical technician and a large amount of space is needed to achieve the fabric panel change.

The framing system of the present application is supplied in three different variations that awards the customer the capability of permanently mounting to a wall, suspension from ceiling, free standing pillar, dual illuminated pillar or 3 & 4 sided billboard, all for indoor/outdoor use.

The fabric-frame system of the preferred embodiments are comprised of eight distinctively unique and different aluminum extruded components that when connected together in many various configurations can become virtual exhibition booths, banner displays, decorative wall mounted graphic displays, picture frames, theater projection screens, room dividers, posters for entertainment programs, menus and point of purchase displays. The system can also be illuminated as a pillar or three-sided billboard.

Each aluminum extruded profile has to be extruded with a tolerance of no more than ±0.008-0.012 on critical dimensions to ensure accurate and precision integration between each profile. This engineering process ensures consistency so that when changing individual digitally printed fabric panels, it creates fresh new presentations while retaining consistent theme or brand awareness.

To produce a frame (FIGS. 1-A, 2-A & 3-A), each aluminum extruded profile has to be accurately measured and cut on a CNC programmable horizontal cross-cutting table (not shown) that can accurately repeat the machining process at ±0.010 typically. To produce any of the three different fabric display systems, each corner has to be mitre cut at 45° angle with a special saw (not shown) that is equipped with a precision ground cutting blade designed specifically for soft hollow aluminum profiles. The mitre saw cutting system must also be equipped with a fiber optic location beam or its equivalent that will ensure that each cut can be matched to its opposing profile creating a matched 90° angle with a tolerance that must be maintained of no more than ±0.005-0.010. The tolerances mentioned are critical to maintain and ensure that digitally printed graphic panels are accurately stretched into place. The result will be a professional grade presentation, regardless of the fabric and or graphic chosen. See attached FIGS. 1-A, 2-A and 3-A for illustration purposes.

The eight extruded members discussed above, are used to construct all of the substructures, which are used to construct all of the structures for fabric panels as discussed above. In addition to the eight extruded members discussed above, connectors are also used to configure the extruded members into the sub structures discussed above.

Thus, with the building blocks, set out above it is possible to construct and modify fabric holders without the need for extensive rebuilding or specialists to do so.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature and objects of the present invention, reference should be had to the following drawings in which like parts are usually given like reference numbers (except the locks) and wherein:

FIG. 1-A is a front view, partially exposed of one of the preferred embodiments of the present invention;

FIG. 1-B is a side cross-sectional view taken along lines 1-1 of FIG. 1-A of a support column;

FIG. 1-C is an enlarged view of an end of the column of FIG. 1-B;

FIG. 1-D is an exploded view of the component parts of FIG. 1-E;

FIG. 1-E is an isometric view of the preferred embodiment of FIG. 1-A with fabric attached;

FIG. 1-F is an exploded view of the locks 2, 8 of the preferred embodiment of FIG. 1-A;

FIG. 1-G is a profile of Item 1;

FIG. 2-A is an isometric view partially exposed for one of the preferred embodiments of the present invention with fabric attached;

FIG. 2-B is a side cross-sectional view taken along lines 2-2 of FIG. 2-I of a support column;

FIG. 2-C is an enlarged view of an end of the column of FIG. 2-B;

FIG. 2-D is an exploded view of the component parts of FIG. 2-A;

FIG. 2-E is an exploded view of the frame of FIG. 2-D;

FIG. 2-F is an exploded view of the locks 2, 8 of the preferred embodiment of FIG. 2-A;

FIG. 2-G is a profile of Item 9;

FIG. 2-H is a profile of the lock 8 in FIG. 2-A;

FIG. 2-I is a front view of a panel of FF System 2000;

FIG. 3-A is a front view, partially exposed of one of the preferred embodiments of the present invention;

FIG. 3-B is a side cross-sectional view taken along lines 3-3 of FIG. 3-A of a support column;

FIG. 3-C is an enlarged view of an end of the column of FIG. 3-B;

FIG. 3-D is an exploded view of the component parts of FIG. 3-B;

FIG. 3-E is an isometric view of the preferred embodiment of FIG. 3-A with fabric attached;

FIG. 3-F is an exploded view of the locks 2, 8 of the preferred embodiment of FIG. 3-A;

FIG. 3-G is a side view of the preferred embodiment of FIG. 3-A showing fabric panels on each side;

FIG. 3-H is an isometric view of the back side of FIG. 3-A;

FIG. 3-I is a profile of Item 7;

FIG. 4 is an illustration of a reinforcing member which may be used with any of aluminum extruded profiles 1, 7 and 9 and is shown illustrated for use in profile 1;

FIG. 4-A is a profile of the reinforcing member;

FIG. 4-B is a profile of splice connecter;

FIG. 4-C is an illustration of connecting two or more profiles;

FIG. 5 is a side view of the male member of Item 1009, 2009, 3009;

FIG. 6 is a side view of the male member of Item 1008, 2008, 3008;

FIG. 7 depicts a side view and front view of lock 8 and an isometric view of lock 2 and an exploded view of lock 2 or lock 8;

FIG. 8 illustrates the inserted panel 6 edge silicone strips 1012, 2012, 3012 into the groove 30; and

FIG. 9 illustrates the connection of panels connected together by use of grooves 4020 to connect corresponding profiles.

DESCRIPTION OF THE INVENTION

Each system has very specific characteristics as it relates to the many applications for which it was designed.

FF System 1000 (FIGS. 1-A-1-G) was designed to be used as a self-supporting, wall mountable or suspended one-sided graphic display system that can be placed virtually anywhere indoor or outdoor. The 0.350 inside dimension cross section 1025 located from the top section 1020 for each of the horizontal and vertical members 1050 becomes the inside perimeter of the profile 1 when assembled into a frame.

As shown in FIGS. 1-A-1-G, only certain of the parts are used in constructing the FF System 1000. This profile 1 is formed by vertical and horizontal members 1050 in conjunction with connectors 2, 3, 4, 5 to make the assembly FF System 1000. For FF System 1000, the component parts may be first assembled into subsystems with components 2, 3, 4, 5 which would form connector parts of the frame of the FF System 1000. To assemble a subsystem, the member 1050 of profile 1 has inserted the female lock 3 and the male lock 2. They are inserted into channels 1004, 1005, on opposite sides of member 1050 of profile 1. The female lock 3 is inserted into channel 1005 and the male lock 2 is inserted into channel 1004 of the same member 1050 of profile 1. The female lock 3 is attached to member 1050 by use of a rivet 5 as is old in the art. The rivet 5 is inserted in opening 1003, provided in member 1050 of the profile 1, which aligns with opening 1002 in female lock 3. The entire assembly then becomes a lock 1001 on one side of member 1050 of profile 1. The male lock 2 inserted into channel 1004 has a threaded opening 1007 in which can be inserted the set screw 4. An opening 1006 is punched in member 1050 of profile 1 and is juxtaposed with threaded opening 1007. Opening 1007 is only formed in one of the two sides of male member 2 (FIG. 1-F).

The two sides of the male lock 2 are interlocked by corresponding male and female spirals 1008, 1009, respectively, on one end of male lock 2. The two interlocked spirals 1008, 1009 form a channel 1010 at the base 1013 of the male spiral 1008 and at the outer end 1014 of the female spiral 1009. Elastomer 1011 is provided to be inserted in channel 1010 transversely and is locked in place in that manner. Locks 8 work in a similar manner but are cut straight instead of at an angle. Locks 2 are cut at the angle of forty-five degrees (FIG. 7).

FF System 2000 (FIGS. 2-A-2-I) was designed as a graphic display system, one side only, to accomplish not only everything embodied in FF System 1000, but also to serve as a free-standing display system for applications such as pop-up display, automotive showrooms, divider walls, illuminated pillars and 3-sided billboards for profile 2. Shown in FIGS. 2-A-2-I, the dimension 2060 (FIG. 2-G) of 0.350 in the upper left corner of the profile 9 becomes the female receptor for spacer 12, both of which are connected together with a locking device 8 (FIG. 2-D). A horizontal stand member on foot 4000 is then horizontally attached with a male locking device 8 to a vertical stand structure or support to form the stand-alone support structure for profile 9. This is accomplished by providing opening 2070 in foot 4000 to fit one end of lock 8, the other end being inserted into a channel 2030 of vertical strut 11. The other end of channel 2030 is sized to receive a cap end plug 7. Spacers 12 with male lock 8 then attach vertical support 11 to vertical member 2050.

As shown in FIGS. 2-A-2-I, only certain of the parts are used in constructing the FF System 2000. This profile 9 is used in conjunction with components 2, 3, 4, 5, 7, 8, 10, 11, 12, 4000 which would form connector parts of the frame of FF System 2000. For FF System 2000, the component parts may be first assembled into subsystems which would form connector parts of the frame of the FF System 2000. To assemble the subsystem, the vertical and horizontal members 2050 of profile 9 has inserted into them the female lock 3 and the male lock 2. They are inserted into channels 2004, 2005 on opposite sides of members 2050 of profile 9. The female lock 3 is inserted into channel 2005 and the male lock 2 is inserted into channel 2004 of the same member 2050 of profile 9. The female lock 3 is attached to member 2050 of profile 9 by use of a rivet 5 as is old in the art. The rivet 5 is inserted in opening 2003, provided in the member 2050 of profile 9, which is aligned with opening 2002 in female lock 3. The entire assembly then becomes a lock 2001 on one side of member 2050 of profile 9. The male lock 2 is inserted into channel 2004 and has a threaded opening 2007 in which can be inserted the set screw 4. An opening 2006 is punched in member 2050 of profile 9 and is juxtaposed with threaded opening 2007. Opening 2007 is only threaded on one of the two sides of male lock 2 (FIG. 2-F).

The two sides of the male member 2 are interlocked by corresponding male and female spirals 2008, 2009, respectively, on one end of male lock 2. The two interlocked spirals 2008, 2009 form a channel 2010 at the base 2013 of the male spiral 2008 and at the outer end 2014 of the female spiral 2009. Elastomer 2011 is provided to be inserted in channel 2010 traversely and is locked in place in that manner.

For the foot 4000, plastic plug caps 10 must be used and seal the foot 4000.

FF System 3000 (FIG. 3-A-3-I) was designed to display graphics on both sides of the frame. Its variety of uses include free-standing illuminated pillars, wall dividers, exhibition booths, two-sided banner stands and virtual building structures that enable the creation of outside walls, inner walls, ceilings, windows and roofs using digitally printed fabric panels for replication. As shown in FIGS. 3-G and 3-I, the dimension 4020 of 0.350±0.010 inches located at the bottom of the member 3050 of profile 7 becomes the channel 3005 to receive female angle lock 3 (FIG. 3-D). The male angle lock 2 is received in the opposite member 3050 of profile 7 side of channel 3004, for each profile 7 in FIG. 3-F is then horizontally attached with the male locking device 8 as shown in FIG. 3-F to form the stand alone support structure of profile 7 for FIG. 3-D.

As shown in FIGS. 3-A-3-I, only certain components are used in constructing the FF System 3000. The components that are used for profile 7 are connectors and locks 2, 3, 4, 5, 8, 4001, 4002, 4010 to make the assembly of FF System 3000. For FF System 3000, the component parts may be first assembled into subsystems which would form parts of the frame of the FF System 3000.

To assemble the subsystem, the member 3050 of profile 7 has inserted into it the female locking insert 3 and the male locking insert 2. They are inserted into channels 3005, 3004 on opposite sides of member 3050 of profile 7. The female locking insert 3 is inserted into channel 3005, and the male locking insert 2 is inserted into channel 3004 of the same profile 7. The female locking insert 3 is attached to member 3050 of profile 7 by use of a rivet 5 as is old in the art. The rivet 5 is inserted in opening 3003, provided in the member 3050 of profile 7, which is aligned with opening 3002 in female locking insert 3. The entire assembly then becomes a lock 3001 on one side of member 3050 of profile 7. The male locking insert 2 inserted into channel 3004 has threaded opening 3007 in which can be inserted the set screw 4. An opening 3006 is punched in member 3050 of profile 7 and is juxtaposed with threaded opening 3007. Opening 3007 is only threaded in one of the two sides of male locking insert 2 (FIG. 3-F). The two sides of the male locking insert 2 are interlocked by corresponding male and female spirals 3008, 3009, respectively, that form a channel 3010 at the base 3013 of the male spiral 3008 and at the outer end 3014 of the female spiral 3009. Elastomer 3011 is provided to be inserted in channel 3010 traversely and is locked in place in that manner.

Profile 7 is supported by vertical members 4010. One end of each vertical member 4010 is locked in channel 4020 of member 3050 to horizontal member 3050 by lock 8, and the other end of member 4010 is connected by a lock 8 to an opening 3070 formed in horizontal foot 4001. The ends of foot 4001 are closed by caps 4002.

The invention's use is also unique as it allows, if necessary, as discussed below, for a large structure that requires rigid substructure members 1050 for profile 1 (and for profiles 7, 9 are members 3050, 2050, respectively) to be locked into place when constructing frames that are large enough that deflection becomes a consideration, e.g., a rectangular structure thirty feet in length by twenty feet in height. For the use of substructure profiles 1050, a straight locking device 8 (FIGS. 1-F, 2-F, 3-F, 7) would be permanently attached to the top and bottom of substructure 1050 of the structure profile 1 (and for profiles 7, 9 are members 3050, 2050, respectively) as discussed below. Location of locking device 8 is where inside the opening 1035 of FIG. 1-G (and for profiles 7, 9 openings 3035, 2035 respectively) the opening dimension is 0.594+0.030-0.000. The locking device 8 is then attached to the opening 1025 (and for profiles 7,9 openings 3025, 2025 respectively) which has a 0.350 inside dimension in the critical areas where deflection could be problematic.

The vertical support structure 1030, 2030, 3030 shown in FIG. 4-4-C is used as a stud support structure for FF System 1000, 2000 and 3000 frames across the span of much larger frames.

The splice connector profile 20 shown in FIG. 4 is used to achieve long lengths and enables one to connect and expand the size of a frame structure to much larger lengths than the profile 1, 7, 9 can have their members 1050, 2050, 3050 extruded, which currently is available in ten foot lengths. The profile 20 has a member 1050, 2050, 3050 cut on a 45° angle on only one side and straight cut on the other side. Thus, the angled cuts of the members 1050, 2050, 3050 form the angles to lock to other members. The two straight cuts 110, 120 are adjacent to each other. A splice 130 is inserted in channel 1005, 2005, 3005 of the adjacent straight cuts 110, 120 and locked in place by locking screws 4. This provides modular expansion capability.

As shown in FIG. 9, adjacent profiles 7 may be interlocked in the same way as the legs 4010 are presently interlocked to profile 7. The difference would be that legs 4010 would be smaller in length and would be mounted horizontally instead of vertically. Thus, FIG. 9 shows horizontal spacers 12. Spacers 12 are located at the grooves 4020 of each profile 7. Inserted into such spacers 12 are locks 8 to lock into grooves 4020, such as the vertical grooves 4020 of member 3050. In addition, if vertical expansion were required, then the spacers 12 would be inserted with their locks 8 to the upper horizontal groove 4020 and have the locks 8 locked in place.

Each aluminum extruded profile has to be extruded with a tolerance of no more than ±0.008-0.012 on critical dimensions to ensure accurate and precision integration between each profile. This engineering process ensures consistency so that when changing individual digitally printed fabric panels, it creates fresh new presentations while retaining consistent theme or brand awareness.

To produce a frame (FIGS. 1-A, 2-A & 3-A), each aluminum extruded profile has to be accurately measured and cut on a CNC programmable horizontal cross-cutting table (not shown) that can accurately repeat the machining process at ±0.010 typically. To produce any of the three different fabric display systems, each corner has to be mitre cut at 45° angle with a special saw (not shown) that is equipped with a precision ground cutting blade designed specifically for soft hollow aluminum profiles. The mitre saw cutting system must also be equipped with a fiber optic location beam or its equivalent that will ensure that each cut can be matched to its opposing profile creating a matched 90° angle with a tolerance that must be maintained of no more than ±0.005-0.010. The tolerances mentioned are critical to maintain and ensure that digitally printed graphic panels are accurately stretched into place. The result will be a professional grade presentation, regardless of the fabric and or graphic chosen. See attached FIGS. 1-A, 2-A and 3-A for illustration purposes.

The Digitally Printed Fabric Panel Assembly

Essential for completing a fabric frame system, the digitally produced and printed fabric panel 6 (FIGS. 1-A, 2-A and 3-A) is the single most important element. There is only one method presently known for producing a fabric panel, and that is by utilizing a large format inkjet printer equipped with dye-sublimation toners. The dye-sublimation process is very unique in that the toners are printed onto a paper media via an inkjet printer. The paper (donor) is then merged with a polyester fabric (receiver) with an applied pressure range of 6-25 psi and a temperature of 400° F. or 204° C. for 25-45 seconds. The molecular structure of both toner and fabric are the same mylar/polyester. When subjected to heat and pressure for a period of time, the toners morph from a solid to a gas. The gas then cross links with each individual fiber and then immediately returns back to a solid state, thus giving the appearance of a permanent dyed effect to the fabric. The dyes permeate each fiber and become colorfast. The fabric panels can be constructed from three distinctively different types of 100% polyester fabrics. The three styles of fabrics were chosen because of the critical tolerance that must be maintained in the warp and weft of the fabrics during the heat setting process. Any other fabrics known at the present time are unacceptable due to memory and shrinkage characteristics of the fabrics.

The size of the frame dictates the finished size of the fabric panel by using a mathematical formula as illustrated by the following example: To accommodate a frame with an outside dimension of 24″×36″, the inside dimension of the frame then becomes 23.527″×35.527″. To ensure that fabric panels are made to fit perfectly, the following methodology and calculations must be followed. Step I: The fabric must be pre-shrunk, printed and cut with a hot knife to an exact size of 1.023″ larger than the frame's inside dimension to ensure a perfect fit into the frame every time. Step II: Once the fabric panel has been printed, and all four edges sealed with a hot knife, a silicone strip material 1012, 2012, 3012 ⅛″ thick×½″ wide, must then be cut to a size 1% smaller than each side of the printed fabric panel 6. Each piece of silicone strip 1012, 2012, 3012 has to be sewn flush to the outside of all four sides of the fabric panel 6 using a single needle lock stitch with a minimum of 8-10 stitches per inch.

As shown in FIG. 8, panels 6 are attached to profiles 1, 7, 9. A groove 30 is formed in the members 1050, 2050, 3050, the dimension (width) of which is 0.150 inches±0.020. The edges of the panel 6 are folded at the four ends and these folds, having silicone strips 1012, 2012, 3012 (detalced 60 durometer) facing the folded material, is inserted into grooves 30 on all four edges. The back of groove 30, being a little wider, permits the silicone expansion after insertion and in conjunction with the durometer of the silicone strip 1012, 2012, 3012 acting with the annodized aluminum surface of members 1050, 2050, 3050, holds the panel 6 tautly in place without being forced out of the groove 30. Thus, the fabric being taut and flush mounted on the frame may hold any pattern on the fabric at the panel 6 for display and ease to change for a new panel 6.

Because many varying and different embodiments may be made within the scope of the invention concept taught herein which may involve many modifications in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.

Claims

1. A graphic display system for a panel, comprising:

a set of pieces assembled into a frame;

said frame having main sections;

each of said main sections having a face and having a groove on its face to receive the edge of the panel and hold the panel against falling out of said groove; and

each of said grooves having a centerline that is orthogonal to each of the adjacent grooves of adjacent main sections.

2. The display system of claim 1, wherein said groove is in the shape of a tongue and groove.

3. The display system of claim 2, wherein said tongue and groove has a channel opening to a wider cavity.

4. The display system of claim 3, wherein there is further included a panel having a perimeter larger than the perimeter of said groove, said perimeter of said panel being inserted into said groove.

5. A graphic display system, comprising:

a set of no more than eight different extruded members;

said components are assembled into a frame;

said components including removable locks; and

said frame being held by said locks in the shape of a rectangle with substantially right angles.

6. The system of claim 5, wherein said components are aluminum extruded.

7. The system of claim 5, wherein said locks are removable.

8. The system of claim 7, wherein said locks include a set screw and are removable by rotation of said set screw.

9. The system of claim 5, wherein said frame has main members with a channel therein and said lock is inserted into a portion of said channels of said main members, each of said portions, being at 45° angle, said portions interfacing at said faces.

10. The system of claim 5, wherein said there is further included a base, said base being formed out of said eight extruded members.

11. A frame for use with graphic display units, comprising:

a set of horizontal members, having a first of slots;

a set of vertical members, having a second set of slots;

a set of first locks inserted in said first and second slots;

a connector insertable into two of said first set of slots;

a second connector insertable into the other two of said first set of slots; and

a set of holders to hold said connectors in place in said first set of slots.

12. The frame of claim 11, wherein there is included a vertical support structure removably connected to said two horizontal members.

13. The frame of claim 11, wherein said support structures connect to said horizontal members at a juncture of said first set of slots.

14. A dual sided graphic display system for use with two panels, comprising:

a frame, said frame having main sections;

each of said main sections having two faces, one on each side of said main sections;

each of said faces having a groove on said face, said grooves sized to receive the edge of the panel;

each of said groove having a centerline that is orthogonal to each of the adjacent grooves of adjacent main sections.

15. The display system of claim 14, wherein there is included a base, said base attached to the lowest main section of said frame.

16. The display system claim 14, wherein there is included an outer periphery channel on each of said mainframes.

17. A panel for a mounting frame, comprising:

a digitally produced and printed fabric surface;

said fabric is preshrunk, printed and cut with a hot knife, said size being set relative to the mounting frame;

said fabric having an outer silicon strip applied to it, flush to the outside of the entire perimeter of said fabric.

18. The panel of claim 17, wherein said fabric is produced by a large format ink jet printer onto paper using dye sublimation toners and said paper is merged with polyester fabric.

19. The panel of claim 18, wherein said paper and said plastic fabric have pressure applied at elevated temperatures for periods of time.

20. The panel of claim 19, wherein the pressure range is 6 to 25 psi.

21. The panel of claim 19, wherein the temperature is in the range of 400° F.

22. The panel of claim 19, wherein the time period is 25 to 45 seconds.

23. The panel of claim 17, wherein said silicone strips are detalced 60 durometer.

24. The process of making a panel comprising:

producing a printed fabric by large format ink jet printer onto paper using dye sublimation toners;

merging said paper with polyester fabric;

pressure inking said fabric and cutting it to a size relative to the mounting frame;

applying an outer silicone strip to said fabric flush to the outside of the entire perimeter of said fabric.