Joints and connections – Interfitted members – Interfitted angle or channel bars
Reexamination Certificate
1999-04-28
2002-04-09
Browne, Lynne H. (Department: 3629)
Joints and connections
Interfitted members
Interfitted angle or channel bars
C403S335000, C040S549000
Reexamination Certificate
active
06368011
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to a device for joining two or more surfaces, and more particularly to a joining device for joining two or more extrusion members of a sign box.
BACKGROUND OF THE INVENTION
In the past, it is known to have a sign box with illuminated signs having a rectangular housing containing a light source typically in the form of one or more fluorescent tube bulbs. The sign faces may be in the form of a single, translucent sheet, painted or marked as desired, or the sign face may be divided into a number of horizontal rows to receive interchangeable panels bearing alphanumeric characters or other symbols.
A rectangular sign box is suited for mounting a sign in front of a row (or rows) of fluorescent tubes that most commonly constitute the interior source of illumination. Moreover, the cabinet-type framework accommodates a weatherproof internal raceway in which lamp ballasts and connecting wiring may be disposed. Whatever the interior construction, the framework must be extremely rugged to support the weight of larger signs and to withstand gale winds.
Although the rectangular sign box housing or cabinet continues to be used, there are significant problems associated with the size of the sign box and its ease of construction and assembly. Several unsuccessful attempts have been made in the past to address the need for a box having alternate shapes and sizes that are easy assembly and construct at a reasonable cost.
For example, large signs must be strong and rugged. Accordingly, they have long been known to be fabricated of steel or aluminum frameworks. Either angle or channel members are employed to form inwardly facing U-shaped channels which are mitered or otherwise joined successively one to the next in order to form a rectangular cabinet. Combinations of slots, ledges, clamps and the like have then been used to secure the rigid panels, that form the display faces, to the resulting framework.
More successful improvements in sign framework construction have been made in recent years through the use of aluminum extrusions to form the cabinet and the mounting components for display faces. A leading example of such improvements is to be found in the disclosure of U.S. Pat. Nos. 4,926,605 and 5,647,1.
Extruded sign box members are typically made from a primary extrusion that is used to form all four sides of a sign cabinet, including the provision of a weather-resistant and accessible wiring raceway. On the past a sign box extrusion has been joined to another through the use of internal steel structural supports causing large and unsightly gaps between the two or more extrusion members. Sometimes these gaps are covered with additional applications of thin metal sheets which are known to require considerable labor and materials for assembly. A combination of a groove and a shelf defined on a sidewall of the extrusion may be used in several different ways to hang and/or hold the marginal edge portions of a rigid plastic display face.
A significant undesirable limitation of prior sign box construction is that the depth of the primary extrusion forming the sign box is dictated by the limitations associated with the extrusion process. Typically, extrusions are limited in width to 14 inches, and more typically to 6 and 12 inch widths. An extrusion is limited by the physical limitations of die size and extrusion press capacity. Accordingly, this deficiency also limits the size and depth of the sign construction.
Accordingly, a new type of sign box construction allowing for more flexible size and depth using existing extrusion components is needed. Further, the new sign box construction must produce a strong framework and support for the sign material at a minimized cost.
SUMMARY OF THE INVENTION
The present invention solves many of the problems by association with conventional sign boxes by providing a joining device that makes it possible to join two or more sign box extrusions or entire cabinets to create a finished sign box with a shape, size and depth as may be desired. The sign box in accordance with the present invention includes a very clean and uniform appearance relative to the outer surfaces of the sign box without the need for expensive new extrusion materials. Further, since standard sign box extrusion forms can be used, more efficient and cost-effective use of existing materials can be achieved to produce a more attractive and desirable sign box.
In accordance with the present invention a sign box joining device is provided in the form of an elongated member having a c-shaped cross section. The sign box joining device includes an elongated, flat, first top wall and a pair of elongate downwardly extending side walls integral to opposite sides of the first top wall, the side walls being substantially parallel to one another and being at right angles to the first top wall. The side walls may include flat, curvilinear, and other complex shapes as required to mate with the extrusion member. In addition the relationship of the side walls with the top wall may be other than perpendicular. Further, the side walls need not be parrallel to each other or have the same shape as, or be mirror images of the other. In addition, each side walls may be double sided. The joining device conformably fills the space formed by mating extrusion members such that the joining device engages and interlocks the extrusion members togther.
The invention also includes a method for joining a sign box, having the steps of mating a pair of elongated extrusion members so that a space having a predetermined shape is formed therebetween. The method also including at least partially filling the predetermined space formed between the elongated extrusion members with a joining member having a shape at least partially corresponding to the predetermined shape formed between the elongated extrusion members.
More specifically, the joining device includes an elongated, flat, first top wall having a pair of elongate downwardly extending side walls that are integral to opposite sides of the first top wall. The side wall may also be flat as required. The downwardly extending side walls are parallel to one another and at right angles to the top wall. The downwardly extending side walls include a pair of elongate, inwardly extending bottom wall flanges integral to the bottom ends of the downwardly extending side walls. The inwardly extending bottom wall flanges extend toward one another generally parallel to the first top wall and at right angles to the downwardly extending side walls.
The sign box joining device slidably engages and interlocks at least one extrusion member of a sign box to form a sign box assembly in accordance with the present invention. Each extrusion member of the sign box has an elongate, flat bottom wall having a first and a second elongate, flat, upwardly extending side wall. The upwardly extending side walls are integral to opposite sides of the bottom wall. The upwardly extending side walls are parallel to one another and at right angles to the bottom wall.
One upwardly extending side wall includes an elongate, flat, inwardly extending top wall integral to a distal free end of the respective side wall. The inwardly extending top wall extends in parallelism to the bottom wall at a right angle to the respective side wall. The other upwardly extending side wall has an elongate, flat, outwardly extending top wall integral to a distal free end of the respective side wall. The outwardly extending top wall extends in parallelism to the bottom wall and at a right angle to the respective side wall. However, it is understood that the side walls, outwardly and inwardly extending walls may have any angular relationship to each other as required to mate with an extrusion member.
The joining device slidably engages and interlocks at least one of the extruded members when a portion of the top wall, one downwardly extending side wall and one inwardly extending bottom wall of the joining device is in contact respectively with a portion of the inwardly extending
LaFountain Steven
Milliken K. Blair
Bochna David E.
Browne Lynne H.
Dann Dorfman Herrell & Skillman P.C.
Milliken Industries
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