Note: Descriptions are shown in the official language in which they were submitted.
CA 02202077 1997-04-07
ILLUMINATED FASCIA SIGN
Backqround of the Invention
The present invention relates to an improved sign
of the type having an elongated cabinet, the open side of
which is covered with a facing material. Such signs are
often fastened to a horizontal surface, or fascia, of a
commercial establishment for advertising or other purposes.
The facing material for the sign may comprise a flexible
film or fabric, a plastic sheet, or other suitable materi-
al. In many applications the facing material is translu-
cent and the cabinet contains lamps to illuminate the sign.
The aesthetic qualities of fascia signs of the
type described above have led to their increased use in
exterior signage. However, such signs have heretofore, in
many cases, been expensive and difficult to assemble,
install, maintain, and repair, thereby offsetting the
benefits obtainable from their use. Such fascia signs of
the illuminated type have suffered from poor illumination
properties.
SummarY of the Present Invention
It is, therefore, an object of the present
invention to provide a fascia sign that is easy and
economical to install, including retrofit installations and
installations on structures that are not completely square,
level or plumb. The mounting of the sign on the structure
compensates for irregularities in the surface of the
structure to which it is mounted. Once installed, the sign
of the present invention is easy to maintain and repair.
A particular object of the present invention is
to provide a fascia sign, the length of which may be varied
by fine or gross incremental increases to accommodate
measurement errors that may occur when specifying elongated
signs of this type.
A further object of the present invention is to
provide an illuminated fascia sign that provides improved,
uniform illumination throughout the sign and throughout the
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service life of the lamps, thereby to enhance the aesthetic
features of the sign.
A further particular object of the present
invention is to provide a fascia sign exhibiting highly
uniform illumination from spaced, point sources of light
employed in the sign.
A still further particular object of the present
invention is to provide a fascia sign in which uniform
illumination of desired intensity can be obtained from a
relatively small number of relatively widely spaced point
sources of light, thereby reducing the manufacturing and
operating costs of the sign.
Other objects and features of the present
invention will become apparent from the following descrip-
tion, in which same are noted in detail.
The present invention will be further understood
by reference to the following described figures of the
drawing, when taken in conjunction with the following
detailed description.
Brief Description of the Drawings
FIG. 1 is a partial perspective view of the
fascia sign of the present invention;
FIG. 2 is a partial top view of the fascia sign
showing a sign of the illuminated type;
FIG. 3 is a vertical, cross-sectional view taken
along the line 3-3 of FIG. 2 and showing a section of a
multi-section fascia sign;
FIG. 4 is a horizontal, cross-sectional view
taken along the line 4-4 of FIG. 3 showing a section of the
multi-section sign;
FIG. 5 is a vertical, cross-sectional view taken
along the line 5-5 of FIG. 3;
FIG. 6 is a fragmentary cross-sectional view,
similar to FIG. 5, showing disassembly of lighting elements
of the sign for servicing or replacement;
FIG. 7 is a fragmentary, horizontal cross-
sectional view taken along the line 7-7 of FIG. 5;
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FIG. 8 is a vertical, cross--sectional view taken
along the line 8-8 of FIG. 3;
FIG. 9 is a detailed cross-sectional view of the
subject matter shown by the line 9-9 of FIG. 8;
FIG. 9A is a perspective view of a clip suitable
for affixing a facing material of the sign to a cabinet of
the sign;
FIG. 10 is a front view of one element of a
diffuser employed in an illuminated fascia sign of the
present invention;
FIG. lOA shows an additional element added to the
element shown in FIG. 10;
FIG. 11 shows a further element of the diffuser
added to the element shown in FIGS. 10 and lOA, the added
element being diagrammatically shown;
FIG. 12 is a view similar to FIGS. 10 and 11
showing another element added to the diffuser shown in FIG.
11, the element being diagrammatically shown;
FIG. 13 is a view of the diffuser from the side
opposite to that shown in FIGS. 10, 11, and 12, with a
further element added thereto;
FIG. 14 is a view similar to FIG. 13, with
another element added to the diffuser;
FIG. 15 is a horizontal, cross-sectional view
taken along the line 15-15 of FIG. 14;
FIG. 16 is a perspective view of a vertical end
member employed in the fascia sign of the present inven-
tion;
FIG. 17 is a front view of the stretching
apparatus used to stretch flexible facing material of the
sign;
FIG. 18 is a cross-sectional view of the stretch-
ing apparatus taken along the line 18-18 of FIG. 17;
FIG. 19 is a view similar to FIG. 18 showing
stretching of a flexible facing materi.al;
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FIG. 20 is a fragmentary, cross-sectional view
taken along the line 20-20 of FIG. 17 showing the manner of
mounting the stretching apparatus to the sign;
FIG. 20A is a fragmentary Pront view similar to
FIG. 17 showing an alternative way of mounting the stretch-
ing apparatus to the sign;
FIG. 21 is a partial perspective view, similar to
FIG. 1, showing an initial step in a procedure for mounting
the illuminated sign on a fascia;
FIG. 22 is a vertical cross--sectional view taken
along line 20-20 of FIG. 21;
FIG. 23 is a partial top view taken along the
line 23-23 of FIG. 22;
FIG. 24 is a cross-sectional view, similar to
FIG. 22, but showing the sign installed on a fascia;
FIG. 25 is a partial view taken along the line
25-25 of FIG. 24, showing a fastener used to fasten the
sign to the fascia;
FIG. 26 is a fragmentary, perspective view
showing the manner in which portions c)f the fascia sign of
the present invention are joined together at corners of a
fascia;
FIG. 27 is a fragmentary cross sectional view
taken along the line 27-27 of FIG. 26;
FIG. 28 is a fragmentary top view showing an
alternative corner configuration for the fascia sign of the
present invention;
FIG. 29 is a perspective view of an end section
employed in the corner configuration shown in FIG. 28; and
FIG. 30 is a detailed cross sectional view of the
subject matter shown by the line 30-30 in FIG. 28.
Detailed Description of the Preferred Embodiment
The Siqn
As shown in FIG. 1, fascia sign 50 of the present
invention is mounted on supporting structure 52 or fascia.
The supporting structure may typically be an exterior
vertical wall of a building. Or, as shown in FIG. 1, in
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another common application, the sign is mounted on the side
wall of a canopy structure elevated over a service area.
The sign may thus form an elongated decorative trim about
the edge of the canopy. Or, when the sign is of the
illuminated type, it also serves to brighten and draw
attention to the structure. In addition to its decorative
features, sign 50 may typically provide advertising, price,
or other information to the viewer.
As shown in FIGS. 2-8 of the drawing, the fascia
sign 50 of the present invention comprises a cabinet or box
60 covered with a facing material 62.
The Cabinet
Cabinet 60 has top wall 64 and bottom wall 66
extending from back structure 68. Back structure 68 will
typically be a back wall formed of sheet metal and will be
so described herein. However, back structure 68 may also
comprise an open frame work or other suitable elements.
Top wall 64 and bottom wall 66 may include extruded compo-
nents 65, 67 that are fastened to back wall 68 by rivets,
screws, or the like. Back wall 68 may be stiffened by a
plurality of frame members 70 placed at intervals along
cabinet 60. Cabinet 60 is also stiffened by brackets 71
that are mounted between top wall 64 and back wall 68 and
bottom wall 66 and back wall 68 at intervals along the
interior of cabinet 60.
Top wall 64 and bottom wall ~6 also include top
and bottom extruded members, 70 and 72 mounted to compo-
nents 65, 67, respectively. The exact manner of mounting
will depend on the specific configuration of the top and
bottom elements. One manner of mounting is shown in FIGS.
9 and 19 and employs threaded fasteners 74. Extruded
members 70 and 72 grip the edges of facing material 62,
which spans the open, front face of cabinet 60. The manner
in which facing material 62 is secured to extruded members
70, 72 is also shown in FIGS. 9 and 19, and is described in
detail, below.
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Depending on the length of sign 50, cabinet 60
may comprise an integral structure or may be formed of a
plurality of abutting sections which are joined together to
form the cabinet. One such section is shown in FIGS. 3 and
4 by the reference numeral 73. The sections are construct-
ed into section units prior to joinder to form the cabinet.
A typical section may be 7 to 14 ft. long. The use of pre-
fabricated sections facilitates the manufacture, assembly,
and installation of sign 50.
To join the sections together, lengths of square
tubing, one of which is shown by reference numeral 76 in
FIG. 9, are placed in sleeves 78 formed in extruded members
70, 72 of abutting sections of cabinet 60. With the
lengths of tubing extending into each extruded member of
the abutting sections, the tubing is fastened to sleeves
78, as with self-tapping metal screws, to fasten the
sections 73 together. Square tubing 76 also serves to
accurately align two adjacent sections 73 of sign 50
longitudinally. Bars may be fastened to back wall 68
adjacent its upper and lower edges to straddle the joinder
of two adjacent sections 63 and assist in joining the
sections together.
The joinder of the top walls 64 of two abutting
sections 73 may be covered by plate 75, shown in FIG. 2.
Plates 75 are fastened to the abutting sections to streng-
then the joint between the two sections of sign 50 and when
caulked will prevent leakage of light out of the sign or
the leakage of water into the sign at such joints.
The ends of cabinet 60 may each contain an
appropriate end wall or section which has a structure
similar to top and bottom walls 64 and 66. Lengths of
tubing 76 are fastened normal to the end wall and inserted
in sleeves so that the end wall may be affixed to the
cabinet. Or, the cabinet may extend completely around the
building, canopy, etc. on which it is mounted to form an
essentially endless surrounding structure.
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Facing Material
Facing material may comprise a rigid or semi-
rigid plastic material, such as Lexan, having the desired
strength and weather resistance properties. However, the
availability of flexible materials, such as films, fabrics,
fabrics coated or impregnated with p]astic, etc. have led
to the increased use of flexible materials in fascia signs.
This is due to the ease of transport of such material in
rolls, its ease of installation, the absence of visible
seams in the sign, as well as other advantages. Flexible
materials can be stretched taut to provide a smooth
exterior surface without ripples. For these reasons, the
use of such a material is described herein.
Suitable materials for facing material 62 are the
flexible sign and awning membranes made and sold by the 3M
Company of St. Paul, MN, and others. Facing material 62
will typically be colored for aesthetic purposes and may
have designs or alphanumeric indicia printed or otherwise
applied to it to further improve the aesthetic and/or
provide information to the viewer. For illuminated fascia
signs, the facing material is typically translucent.
Material 62 is typically stretched across the
open side of cabinet 60. If cabinet 60 has sections 73,
these are assembled before the stretching of material 62.
A preferred technique for stretching material 62 is shown
in FIGS. 17-20, and described in detail, below. The
stretched material 62 may be retained on cabinet 60 in the
manner shown in FIG. 9. The upper and lower edges of
facing material 62 are folded over. A plurality of short
bars or wedges 78 are inserted between the folds of the
facing material at spaced intervals along the length of
facing material 62. A plurality of clips 79 are placed on
the outside of the folded facing material and aligned with
the bars. One form that clips 79 can take is shown in FIG.
9A. The folded facing material 62, bars 78, and clips 79
are inserted in grooves 80 formed in top and bottom
extruded members 70 and 72 and in similarly formed end
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members. The bars 78 are then driven into grooves 80.
Bars 78 may be provided with slots 82 to receive a screw-
driver or other implement used to drive the wedges into the
grooves. Teeth 84 in grooves 80 engage the bent lips 85 of
clips 79, as well as projection 87 to retain the clip, bar,
and facing material in grooves 80. Projections 89 serve to
retain bars 78 and folded facing material 62 in clips 79.
It is recognized that other fastening technique
may be employed, if desired, and will be required if, for
example, a rigid or semi-rigid material is used in sign 50.
After facing material 62 has been installed on
cabinet 60, a trim piece 91 may be mounted on each of top
and bottom extruded members 70 and 72. FIG. 9 shows trim
piece 91 as used in connection with bottom extruded member
72. Trim piece 91 has a sheet portion 93 which is general-
ly aligned with the top and bottom of surfaces of cabinet
60. A positioning lip 95 fits in a corresponding groove in
the extruded member. Bolts 97 are inserted through holes
spaced along the trim piece and threaded into slot 99 in
the extruded member. Flange 101 extends from sheet portion
93 to embrace a portion of facing material 62. Flange 103
serves as dam for the trim piece mounted on upper extruded
member 70 to lessen or avoid the spillage of rain water
down the face of sign 50.
A piece of thin L-shaped opaque material matching
the color of the trim piece is placed under adjacent ends
of trim pieces 92 and spans the joint between the trim
pieces. The L-shaped material piece lies in the same
orientation as the generally L-shaped trim piece to block
any light leaks and to give the appearance of a continuous
piece of trim.
Lighting System
A lighting system is provided in cabinet 60 for
providing illumination to the inner surface of facing
material 62 when fascia sign 50 is of the illuminated type.
The lighting system includes a plurality of lamps 100
mounted at spaced intervals along cabinet 60. Lamps 100
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may be of halide type. Because of the relatively small
size of such lamps with respect to sign 50 they may be
considered to be point sources of light.
To facilitate installation and servicing of the
lamps, it is a feature of the present invention to provide
the lamps and associated ballasts 102 in modular form. To
this end, and as shown in detail in FIGS. 5 and 6, an
app~opriately sized opening 104 is provided in top wall 64
of cabinet 60. Opening 104 is sufficiently large to allow
ballast 102, and lamp 100, to pass therethrough. A plate
106 is fastened to the top of ballast 102. Top plate 106
is larger than opening 104 and thus can abut top wall 64 of
cabinet 60 when ballast 102 and lamp 100 are inserted
through opening 104.
To facilitate routine maintenance of fascia sign
50, a spring loaded trap door 107 may be provided in bottom
wall 66 of cabinet 60 directly below each lamp 100. The
opening covered by the trap door is sufficiently large to
allow commercially available lamp changers to remove and
replace burned out lamps.
Strap 108 has one end fastened to top plate 106
so that the strap is suspended from top plate 106. The
other end of strap 106 mounts socket 110 for bulb 100.
Insulated wires 112 connect socket 110 to ballast 102.
The mounting for socket 110 includes L-shaped
plate 114. One arm 116 of L-shaped plate 114 is fastened
to, or forms part of, the lower end of strap 108. The
other arm 118 of L-shaped member 11~ is received in U-
shaped bracket 120 mounted on back wall 68 of cabinet 60 to
retain and position the lamp-ballast module in cabinet 60
when the module is lowered from the position shown in FIG.
6 to the position shown in FIG 5. See also FIG. 7. Top
plate 106 is fastened to top wall 64 by fasteners 107 and
sealed with a gasket, not shown.
A vent may be provided in back wall 68 proximate
to each of lamps 100 to assist in removing heat generated
by the lamps.
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--10--
The lighting system for fascia sign 50 also
includes a reflector system for lamps 100. The reflector
system includes a plurality of curved reflectors mounted in
cabinet 60 between each of lamps 100. The reflectors may
best be seen in FIGS. 2, 3 and 4. Part of the reflector
comprises the portion of back wall 68 immediately behind
each of the lamps. This portion is painted a light color,
such as white. In a construction in which the back of sign
50 comprises framework, a partial back wall is positioned
behind each of the lamps. The reflectors also comprise a
plurality of bent sheets 130 of plastic or other material
having a white, or other opaque reflector surface facing
the open face of cabinet 60. For example, sheets of opaque
white styrene plastic may be used to form reflectors 130.
15To form reflectors 130, blocks 132 and 134 having
a groove or cut conforming to the desired curvature of a
reflector 130 may be mounted on top and bottom walls 64 and
66, respectively. For example, a wooden board may be cut
through along the desired curvature for a reflector 130.
The pieces of the cut board are then separated by an amount
equal to the thickness of the reflector to form blocks 132
~ and 134, and affixed to top and bottom walls 64 and 66.
FIGS. 8 and 9 show a block 132 on bottom wall 66 of sign
50.
25The reflectors 130 commence adjacent the portions
of back wall 68 behind lamps 100 and curve outwardly toward
the open face of cabinet 60 intermediate the lamps and
thereafter curve back toward the back wall and an adjacent
lamp. A vertical member 136 is positioned between top and
30bottom walls 64 and 66. See FIGS. 3 and 4, and 8 and 9.
These members assist in positioning blocks 132, 134 and
also stiffen cabinet 60 against the tension of facing
material 62. As shown in FIG. 9, straps 137 may be mounted
to the top and bottom of vertical member 136 so that the
ends of frame member 136 may be mounted to top and bottom
walls 64, 66.
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While FIGS. 3 and 4 show a cabinet section 63
having a standard length, it will be appreciated that the
length of one or more sections of the sign may have to be
altered in accordance with the size of the fascia to which
sign 50 is being applied. This will require a correspond-
ing change in the reflector(s) 130 in the altered section
in order to insure even illumination of facing material 62.
And, it is also possible to change the reflectivity of the
reflectors 130 in certain portions of the sign by using
different materials or coatings to insure the desired
intensity and uniformity of illumination to facing material
62.
A diffuser 140 is provided in front of each of
lamps 100. As shown in FIGS. 10-14, the diffusers 140 are
formed in the following manner. Each diffuser 140 has a
base substrate 142 formed of a sheet of transparent
material, such as plastic, or glass. Substrate 142
preferably has an ultraviolet protective coating (not
shown) applied to the side facing toward lamps 100. An
opaque pattern 144 is applied, as by a silk screening of
black or other colored ink, to the side of substrate 142
not facing lamps 100. Or, a film containing pattern 144
may be applied to base substrate 142. The pattern is shown
in exaggerated thickness in FIG. 15. The form of opaque
pattern 144 is shown in FIG. 10A. Pattern 144 is generally
circular in nature. As the diameter of the pattern is
greater than the height of the substrate 142, the circular
pattern is, therefore, truncated at the top and bottom
edges of substrate 142.
A further layer 146 is applied over the opaque
pattern 144. This layer, which comprises a translucent,
white layer of paint, ink, or film, is shown in FIG. 11.
Layer 146 is in the form of a rectangle superimposed on the
truncated circle of pattern 142. With the diffuser
oriented as shown in FIG. 11, the vertical dimension of
layer 146 is the same as the vertical dimension of pattern
144 at its center.
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Thereafter, an additional layer 148 is applied on
top of layer 146. This pattern is shown in FIG. 12. Layer
146, which may also be a translucent, white layer, is in
the form of a smaller rectangle centrally located in
diffuser 140. The vertical dimension of layer 148 may be
the same as that of pattern 144. The horizontal dimension
is smaller than that of pattern 144.
FIG. 15 shows the orientation of diffuser 140
with respect to lamps 100 with pattern 144 and layers 146,
148 on the side of the diffuser away from lamp 100.
Screening of aluminum, or other suitable materi-
al, is applied to the opposite side of diffusers 140 from
pattern 144 and layers 146, 148, i.eO on the side facing
lamp 100. The screening may be in the nature of typical
window screening. As shown in FIG. 13, one layer 150 of
screening may be dimensionally co-extensive with substrate
142. As shown in FIG. 14, a second layer of screening 152,
applied over screening layer 150, is formed as a smaller,
centrally located rectangle. Screening 150, 152 may be
fastened to substrate 142 by suitable means, such as pop
rivets.
The manner in which diffusers 140 are placed in
front of lamps 100 is shown in FIGS. 3, 5, and 6. A pair
of upper and lower brackets 71 are provided on either side
of each of lamps 100. Diffusers 140 are suspended in front
of lamps 100 by chains 160, or other suitable means, having
one end coupled to brackets 71 and the other end coupled to
diffusers 140. The lower portions of diffusers 140 are
fastened to brackets 71 by springs 162, or other suitable
means, having a hook at one end connected to the diffuser
and the hook at the other end connected to one of brackets
71. Diffusers 140 and lamps 100 are positioned so that
lamps 100 are centered, horizontally and vertically, with
respect to the diffuser.
Reflectors 130 and diffusers 140 provide a
distribution of the light of point light source lamps 100
in a manner that provides uniform il]umination to facing
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-13-
material 62. They also assist in maintaining the appear-
ance of sign 50, notwithstanding the loss of light output
from lamps 100 due to aging. The use of reflectors 130/
diffusers 140 enables lamps 100 to be more widely spaced
along the direction of elongation of fascia sign 50, while
at the same time maintaining the desired levels and
uniformity of illumination. The wider spacing of lamps 100
reduces the number of lamps that are required in sign 50
and the manufacturing and operating costs for the sign.
The use of diffusers 140 and reflectors 130 also
make it possible to obtain the desired uniform illumination
of fascia sign 50 even though, in a typical fascia sign,
the spaced lamps 100 are rather close to facing material
62. This proximity would otherwise tend to make for non-
uniform illumination of the facing material. For example,
a typical fascia sign of the type t:o which the present
invention is concerned may be approximately 11"-12" deep.
While the foregoing description of the lighting
system contemplates illumination of fascia sign 50 along
its entire length, it will be appreciated that only
selected portions of the sign 50 may be illuminated, if
desired, by appropriate positioning of lamps 50 and
modification of the reflectors 130 and diffusers 140, if
necessary. Further, while specific types of light sources
have been described above, other types of light sources,
such as fluorescent lighting tubes may be used, if desired,
with appropriate modification of the lighting system
elements.
Assembly and Mountinq
As noted above, the fascia sign 50 of the present
invention is formed of one or more sections. The sign may
be mounted on the fascia in such a section or sections.
Or, the sections may first be assembled into larger units
of the sign and the larger units then mounted on the
fascia. In either case, the installation of fascia sign 50
is greatly facilitated over prior art signs that are
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constructed piece-by-piece directly on the fascia as the
sign is installed.
For a fascia sign 50 formed of plurality of
sections, cabinet sections 73 may be assembled into the
cabinet 60 prior to installation. Or one section 73 of the
cabinet may first be mounted on the fascia and the assembly
of the sections carried out as a subsequent, abutting
section is being mounted to the fascia. The assembly of
the sections is carried out in the manner described above
in which lengths of square tubing 76 are placed in sleeves
78 formed in extruded members 70, 72 of abutting sections
73 of cabinet 60 and fastened to the sections.
A feature of the present invention is the ability
to provide both gross adjustments and fine adjustments to
the length of the cabinet to accommodate the often occur-
ring differences between the design length of the cabinet
and the length actually required for proper installation on
a specific building or other fascia. Such difference may
occur from difficulties in obtaining accurate measurements
of large structures on which the sign is installed.
To increase the length of one or more sections up
to 3-4", sections of top and bottom walls 64, 66, are cut
to the desired width and slid on square tubing 76 between
adjacent cabinet sections. The intermediate section of the
walls may be fastened to square tubing 76 in the same
manner as the cabinet sections. The joinder of the top
wall and bottom wall sections to the adjacent cabinet
sections may, if desired, be covered by plates 75, in the
manner shown in FIG. 2, to provide strength and prevent
leakage.
It will be appreciated that a size adjustment of
the type described above can be provided between each pair
of adjacent cabinet sections 73 of a multiple section
fascia sign 50 to increase the total amount of adjustment
available.
Fine adjustments to the length of cabinet 60 may
be provided through the use of vertical end members
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-15-
provided at each end of the assembled cabinet. As noted
above, when fascia sign 50 has exposed ends, the vertical
end members may be resemble top and bottom walls 64 and 66
having lengths of tubing 76 fastened normal thereto. In
many cases fascia sign 50 will extend entirely around a
commercial establishment or other structure. Section end
pieces suitable for use in fascia sign 50 at the corners of
a building or other structure are shown in FIG. 16.
In applications in which an end of one cabinet
section 73 abuts an adjacent cabinet section 73 around a
corner of a building or other structure, the ends of each
of the cabinet sections are cut away at an angle, as shown
in FIG. 26. For a 90~ corner, the ends of the cabinet
sections are cut away at a 45~ angle. Vertical end members
180, for use in the configuration described in FIG. 26,
include an extruded vertical member 182 having a configura-
tion similar to top and bottom extruded members 70, 72.
See FIG. 16. A plate 184 is fastened to each of the top
and bottom of vertical member 182. A strap or length of
square tubing 186 is fastened to each of plates 184 at an
angle so that end members 180 may be mounted on the ends of
a cabinet section in alignment with the angled cut away
ends.
The use of tubing, such as tubing 186 on end
section 180, permits the vertical end members to be moved
outwardly from the ends of cabinet 60 by a small amount to
make fine adjustments to the length of fascia sign 50. The
vertical end members may also be tilted in a vertical plane
normal to the direction of extension of cabinet 60 so as to
cant the ends of cabinet 60 to compensate for any irregu-
larities in the building or fascia structure to which sign
50 is being mounted.
The fine adjustment provided by vertical end
members, such as end members 180, thus ensures that signs
positioned on two orthogonal or other angularly displaced
building walls may be brought into alignment or abutment to
ensure a highly aesthetic appearance to fascia sign 50.
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-16-
To complete the assembly of sign 50, the lighting
system installed in cabinet sections 73 in the manner shown
in FIGS. 5 and 6.
Prior to fastening facing material 62 to the
cabinet, the vertical end members 180, are removed from the
cabinet. One technique by which a fabric facing material
62 may be stretched across the open side of cabinet is
shown in FIGS. 17 through 2OA of the drawing. As noted
above, facing material 62 is commonly provided in roll
form. A length of material 62 approximating, but longer
than, the length of assembled cabinet 60 is unrolled from
the roll and cut off. One end of the piece of material is
clamped to one end of cabinet 60, as by means of the frame
200 shown in FIGS. 18 through 20.
Frame 200 includes frame member 202. Frame
member 202 has square tubing sections 204 extending normal
thereto. Square tubing sections ~04 are inserted in
sleeves 78 in the ends of a cabinet section 73. A second
frame member 206 is loosely fastened to frame member 202,
as by bolts 208.
One end of the length of facing material 62 is
inserted between frame members 202 and 208. A clamping
means, which may be in the nature of a pair of locking
pliers, pinches the end of facing material 62 between frame
members 202 and 206 to retain the material at the end of
the sign.
At the other end of cabinet 60, tensioning frame
210 is provided. Tensioning frame 210 includes framework
212 having square tubing sections 214 for mounting the
tensioning frame at the other end of the assembled cabinet
60. A clamping frame 216, similar to clamping frame 200 is
provided in conjunction with tensioning frame 210.
Clamping frame 216 includes frame members 218 and 220 and
clamping means 222. Clamping frame 216 is mounted on rods
224 that extend from clamping frame 216 through a pair of
movement mechanisms, such as ratchet or screw mechanisms
226.
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The other end of facing material 62 is placed in
clamping frame 216 and clamped between members 218 and 220
by the locking means 222. Ratchet mechanisms 226 are then
operated to draw clamping frame 216 to the right as shown
in FIGS. 17 through 19, as indicated by the arrow in FIG.
19, to tension facing material 62. When the desired amount
of tension has been applied to facing material 62, the
upper and lower edges of facing material 62 are fastened to
top and bottom walls 64 and 66 of cabinet 60 by the clips
76 shown in FIG. 20 and described above in connection with
FIG. 9.
When the top and bottom edges of facing material
62 have been fastened to top and bottom walls 64 and 66 of
cabinet 60, ratchet mechanisms 226 are operated to move
clamping frame 216 to the left as shown in FIGS. 17 through
19. Clamping frames 200 and 216 are opened and the ends of
facing material 62 removed from the frames. Clamping frame
200 and tensioning frame 210 are then removed from the
cabinet 60.
The vertical end members, such as members 180 are
installed on the ends of cabinet 60 and fastened to the
ends of the cabinet. The ends of facing material 62 may be
fastened to vertical end members 180 using wedges 78, as
shown in FIG. 20, at this stage of the assembly process.
Or, if desired, the ends may be fastened in the same manner
at a later stage, after sign 50 has been mounted on the
building or other structure. Excess facing material is
trimmed from the ends of sign 50.
While the foregoing has described fastening
facing material 62 to cabinet 60 prior to mounting fascia
sign 50 on fascia 52, it will be appreciated that it is
also possible to fasten the facing material to the cabinet
after the sign has been mounted on the fascia.
It will also be appreciated that, in some cases,
instead of using clamping frame 200, a vertical end member
may be installed at one end of cabinet 60 and one end of
the facing material fastened to the vertical end member and
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adjacent portion of top and bottom extruded members 70 and
72 to hold one end of facing material 62 as the material is
stretched. Further, and as shown in FIG. 20A, either or
both of clamping frame 200 and tensioning frame 210 may be
formed so that tubing sections 204a, 214a extend along the
exterior of top and bottom extruded members 70 and 72. The
tubing sections may be removably attached to the extruded
members by screws extending through the tubing sections and
into slots 99 of extruded members 70 and 72. Such an
arrangement avoids the need for sleeves 78 to be accessible
in order to mount the frames. Vertical end members 180 can
thus be mounted on cabinet 60 prior to stretching facing
material 62, if desired. And facing material 62 can be
stretched in configurations of sign 50 in which sleeves 78
are blocked due to corners formed in the sign to correspond
to thQse of the struc-ture to .whiGh the fasGia sign is
mounted.
The installation of the sign may proceed as
follows and is shown in conjunction with a canopy 52
extending over a service area in FIGS. 21 through 26. Such
a canopy 52 will typically have an exposed framework 250 to
which fascia sign 50 is to be fastened. As shown in FIG.
22, the framework 250 has vertical member or members 252
supported by struts 254.
To mount fascia sign 50, a T-shaped molding 256
is employed. As shown in FIGS. 22, 24, and 25, straps 258
are fastened to molding 256 at intervals along the molding
so that the straps will be aligned with vertical frame
members 252 when molding 256 is placed on canopy 52. T-
shaped molding 256 is preliminarily installed on canopy 52
by a small number of screws passing through the vertical
leg of the T-shaped molding. Thereafter the molding 256 is
secured on canopy 52 by fastening the free ends of straps
258 to vertical members 252 of canopy 52.
The use of molding 256 provides the following
advantages in installing fascia sign 50. First, during the
attachment of molding 256, a level may be placed on the
CA 02202077 1997-04-07
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exposed horizontal flange 259 of the molding and the
position of the molding adjusted, as it is attached, to
insure that horizontal flange 259 on which sign 50 will
rest is level. Second, the vertical flange of molding 256
ensures the sign will be mounted on a smooth surface and
not be subjected to the irregularities likely to be present
on the exposed surface to which the sign is being mounted.
These features are particularly advantageous when sign 50
is mounted on a structure that is uneven or out-of-square
due to poor construction, settling, the removal of earlier
signs, or the like. For example, the structure may present
a mounting surface that is rough and irregular or which
undulates in a horizontal or vertical manner.
Fascia sign 50 is then lifted into place so that
a portion of bottom wall 66 rests on T-shaped molding 256.
To this end, lifting tool 260 shown in FIGS. 21-23 is
employed. Lifting tool 260 is generally U-shaped having a
member 262 that is generally vertical when the tool is in
use and a pair of spaced arms 264 and 266 mounted at
opposite ends of vertical member 262. Arms 264 and 266 are
generally horizontal when the tool is in use. The spacing
between arms 264 and 266 is sufficient to accommodate
fascia sign 50. For example, the spacing between arms 264
and 266 may be a half inch greater than the height of the
sign.
The length of lower arm 266 is less than the
length of upper arm 264. The length of upper arm 264 is
preferably equal to the depth of fascia sign 50 from the
outer front surface of fascia sign 50 to the outer surface
of back wall 68. The lesser length of lower arm 266
accommodates T-shaped molding 256. Flanges 268 on the side
of lifting device 260 are fastened to top and bottom walls
64 and 66 of cabinet 60 with temporary fasteners 270 to
retain the fascia sign in lifting device 260.
As shown in FIG. 21, a pair of lifting devices
260 are typically used to raise fascia sign 50 into
position. A lifting lug 272 is provided on the upper
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surface of upper arm 264 of each of lifting devices 260.
Lifting lug 272 includes one or more holes 274 for receiv-
ing a hook, shackle pin, or the like fastened to the lift
strap 276 leading to a crane or other elevating device.
The hole 274 to be used is selected, with respect to the
center of gravity of fascia sign 50, such that when fascia
sign 50 is positioned in lifting device 260 with facing
material 62 generally adjacent vertical member 262, fascia
sign 50 will be tipped in the manner shown in FIG. 22 in
which the corner of bottom wall 66 and back wall 68 is
positioned closer to fascia framework 250 than the corner
of top wall 64 and back wall 68.
With the sign so positioned, sign 50 is lowered
toward T-shaped molding 256 mounted on framework 250. The
above described tipping of sign 50 enables the corner of
bottom wall 66 and back wall 68 to be conveniently placed
on T-shaped molding 256. The reduced length of lower arm
266 of lifting device 260 also facilitates this placement.
With cabinet 60 of fascia sign 50 resting on the
exposed horizontal flange 259 of T-shaped molding 256, the
cabinet is fastened to the molding, as by self-tapping
metal screws, blind rivets, or other suitable fasteners 276
extending through flange 259 of T-shaped molding 256 and
bottom wall 66 of the cabinet.
Attachment straps 280 are fastened along the
upper edge of back wall 68 of cabinet 60 at locations
aligned with struts 254 of framework 250. The free ends
282 of straps 280 are fastened to struts 254 to complete
the mounting of fascia sign 50 on canopy 52.
The use of straps 280 allows the vertical plumb
of fascia 50 to be established notwithstanding irregulari-
ties of canopy 52 since the mounting position of the straps
with respect to struts 254 is adjustable so that, for
example, sign 50 is mounted in a vertical position, even if
canopy 62 is not. This feature, when combined with the
leveling features provided by the use of T-shaped moldings
CA 02202077 1997-04-07
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256, provides for particularly advantageous mounting of
fascia sign 50.
With fascia sign 50 mounted on canopy 52,
fasteners 270 may be removed from flanges 268 to release
lifting tool 260 from the sign. The lifting tool is then
pulled away from sign 50.
It will also be appreciated that, in some cases,
instead of lifting an entire assembled fascia sign, the
appropriate sections may be lifted in place one at a time
and assembled one to another as described previously and
fastened to the supporting structures as described below.
With this approach it would be possible to lift the
sections into place on a scissors lift or similar device
without the use of lifting brackets or a crane.
FIG. 26 shows a fascia sign 50 in which sections
73 of cabinet 60 abut at corners of the structure to which
the fascia sign is mounted. As noted above, when sections
73 of cabinet 60 abut at a corner, the ends of the sections
are cut away. For the 90~ corners shown in FIG. 26, the
ends of the sections are cut away at a 45~ angle slanting
toward the center of the sign from front to back. End
pieces 180 shown in FIG. 16 may be mounted at the ends of
the abutting sections.
At a "outside" corner as shown in FIG. 27, such
as corner 52A of structure 52, a small gap is provided
between the abutting sections. This permits the fastening
of facing material 62 to vertical end pieces 180 of
sections 73. Trim piece 300 covers the gap to maintain the
aesthetics of the sign. A cover plate 302 is fastened to
top walls 64 of sections 73 of the cabinet to provide
strength and prevent the leakage of light out of the sign
or water into the sign.
Instead of fastening facing material 62 to the
end pieces of the adjacent sections, it is also possible to
wrap an extended length of facing material around a corner
of sign 50. The facing material is held in place by
affixing it to the top and bottom walls 64 and 66 of the
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adjacent, abutting sections. This provides a continuous
piece of facing material around the corner.
At "inside" corner 52B, the adjacent sections of
the sign are brought into abutment. With the ends of the
cabinet sections 73 cut away at a 45~ angle slanting toward
the center of the cabinet, front to back, there will be
sufficient space to allow a worker to insert the ends of
facing material 62 into end pieces 180 of the abutting
sections by means of wedges 78. The abutting portions of
section 73 are covered with plate 304 to strengthen the
joinder and prevent leakage at the corner.
FIGS. 28-30 show an end member 350 that may be
used in place of end member 180 shown in FIG. lG. End
member 350 may be used when it is desired to provide a more
rigid structure at the ends of fascia sign 50. End member
350 is formed of top and bottom walls 352, 354, respective-
ly, that may be of the same construction as top and bottom
walls 64, 66 of cabinet 60. Post-like members 356, 358
extend between top and bottom walls 352, 354. Extruded
vertical member 360, which may be formed similar to
extruded vertical member 182, is fast:ened to post 358, as
by bolts 362.
End member 350 is fastened to the end of cabinet
60 in the same manner in which the sections 73 of the
cabinet are fastened together. That is, lengths of square
tubing 76 are placed in sleeves 78 of end member 350 and
end section 73 of cabinet 60 and fastened with screws 79.
Other modifications and alternatives will be
apparent to those skilled in the art. Such modifications
and alternatives should be considered to be within the
scope of the following claims.
