Note: Descriptions are shown in the official language in which they were submitted.
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CHANNEL SIGN ASSEMBLY AND RETAINING TRIM CAP
BACKGROUND
Channel sign assemblies are used to provide signage for buildings, shopping
malls, and
the like where it is desirable that the signage comprise illuminated letters
or any other
shapes that are easily seen, even at great distances, day or night. Each
channel sign
assembly comprises an enclosure, usually a metal box, having a rear surface
which is
positioned against a raceway, or the wall of a building. The channel sign
assemblies
further comprise signage which is mounted along a plurality of sides which
define the
figuration of a letter, number, etc. The letters or numbers can comprise a
lens which
makes up a front portion or front wall of the sign. A light source, such as a
neon tube or
LED lights, is positioned within the walls of the enclosure and attached
proximal to the
rear surface to provide illumination (of the lens) for the channel sign
assembly.
The light sources used in existing channel sign assemblies that comprise neon
bulbs or
tubes require high voltage power with transformers built into the metal
enclosures. To
prevent injury to those servicing such channels sign assemblies many
municipalities
require that such sign assemblies be inspected to ensure that they are
adequately sealed
using standards set by the Underwriters Laboratories (UL).
The light sources used in existing channel sign assemblies that comprise low
voltage
LED type light sources provide a very long lasting bright light without
requiring the high
voltage and transformers needed for neon lighting. It is expected that channel
sign
assemblies employing the LED type light sources will not be required to meet
the same
standards set by the UL for neon tubes, but rather other (i.e. less onerous)
standards.
In addition to the lighting, the channel sign assembly can also include a
planar
transparent or translucent lens, the outer shape of which corresponds to the
figuration of
the sign assembly or any other shape defined by the sides of the enclosure.
The lens of
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existing channel sign assemblies have a trim cap glued to the outer edges
thereof which
form a border around the lens. The trim cap, heretofore developed, also has a
lip which
when assembled to the enclosure, is shaped to fit around the forward ends of
the walls
thereof for retaining the lens to the enclosure and for maintaining the water
resistant seal
required by the UL. Screws are threaded through the sides of the trim cap and
into the
metallic walls in order to retain the lens and trim cap across the forward
opening of the
enclosure.
SUMMARY
The present disclosure is embodied in a channel sip assembly. For the purposes
of this
description, a channel sign assembly is defined as an illuminated contoured
fixture in the
shape of a letter of the alphabet, a numeral, an element of punctuation such
as a comma,
an exclamation point, or any other shape or form intended to constitute a
portion of a
sign.
The channel sign assembly of the present disclosure has a rear surface for
mounting
against a raceway, a wall, or any other structure suitable for supporting the
signage. The
walls defining the figuration of the sip assembly or shape to be depicted can
be made of
sheet metal having a given thickness. A lighting element, such as a strip of
LEDs
according to the newly available technology or any other light source, can be
positioned
against the rear surface of the enclosure to provide illumination therefore.
To retain the lens to the open front of the enclosure, a shoulder can be
provided around
the inner surface of the sides thereof wherein the shoulder defines a plane
parallel to the
outer ends of the side walls but is recessed therefrom. In accordance with the
present
disclosure, a planar transparent or translucent lens having an outer edge
which is in the
shape of the sign assembly and sized to fit within the side walls of the
enclosure is
retained against the shoulder by retainer cap and a plurality of retaining
tabs which are
intermittently spaced around a forward end of the sheet metal side walls.
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In accordance with the present disclosure, a channel sign assembly is provided
comprising an enclosure having at least two opposing walls made of sheet metal
or
similar. The at least two opposing walls define the shape of the sign wherein
the sign has
an open front. The at least two opposing walls have an inner surface and a
forward end.
The walls include a series of intermittent tabs punched outward through the
walls,
wherein the tabs are aligned with and offset from the forward end. The
assembly further
comprises a planar transparent lens having a forward surface. The lens
includes an outer
edge in the defined shape of the sign and is sized to fit within the at least
two opposing
walls of the enclosure. A retainer cap is provided and mounted against the
forward
surface of the lens for retaining the lens within the enclosure and against
the walls. The
retainer cap comprises an extrusion readily formable into a variety of shapes.
The retainer
cap includes an interior face having a first edge and an opposing second edge.
The first
edge has an overhang welded to the forward surface of the lens; and, the
second edge has
a channel, wherein the channel is adapted to securely engage a plurality of
the tabs along
an outer surface of the enclosure walls.
In accordance with the present disclosure, the tabs can be spaced
intermittently and
aligned along the forward end of the metal walls of the enclosure for securing
and
retaining a retainer cap. The retainer cap can include an extrusion readily
formable into a
variety of shapes. The retainer cap can include an interior face having a
first edge and an
opposing second edge. The first edge can include an overhang welded to the
forward
surface of the lens, and the second edge can have a channel wherein the
channel is
adapted to securely engage a plurality of the tabs along an outer surface of
the enclosure
walls.
BRIEF DESCRIPTION OF THE DRAWINGS
A better and more complete understanding of the present disclosure will be had
after a
reading of the following detailed description taken in conjunction with the
drawings
wherein:
FIG. 1 is a front elevational view of a prior art channel sign assembly;
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FIG. 2 is an enlarged cross sectional view of the channel sign assembly shown
in FIG. 1;
FIG. 3 is an enlarged cross sectional view of a channel sign assembly in
accordance with
the present disclosure;
FIG. 4 is an elevational view of the channel sign showing the retainer cap and
channel
sign enclosure (prior to attaching the retainer cap to the enclosure);
FIG. 5 is an enlarged cross sectional view of the mounting of the lens to the
enclosure
shown in FIG. 4 employing the retainer cap (after attaching the retainer cap
to the
enclosure);
FIG. 6 is a side view of the retainer cap and enclosure shown in FIG. 5;
FIG. 7 is an elevational view of a punch tool in accordance with the present
disclosure;
FIG. 8 is a further enlarged perspective view of the punch tool;
FIG. 9 is a fragmentary enlarged side view of the punch tool in operation;
FIG. 10 is a perspective view of a second tool for detaching the retainer cap
from the
enclosure in accordance with the present disclosure; and,
FIG. 11 is an enlarged view for channel sign assembly with the second tool
detaching the
retainer cap from the enclosure.
DETAILED DESCRIPTION
The subject embodiments to follow relate to channel sign assemblies and
related store
front signs, especially those that are illuminated by neon or LED and the
like, and include
selective wording identifying the store by name or can include other
descriptive
figurations or shapes. The embodiments have particular applications to sign
installation
systems that are simple and quick to install and maintain, by including a wide
variety of
figurations.
As discussed above, signs fabricated with plastic faced letters for
disposition within a
lighted channel to create a three dimensional illuminated sign are well known.
A product
often referred to as trim cap in the sign industry, can be used for securing
the plastic
faced letters to the lighted channel. The trim cap can be manufactured by
extruding
essentially a thin flat strip 1 inch to 2 inches wide of vinyl plastic that
has been embedded
with a metallic foil for strength and formability.
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Trim cap can come in rolls and may be cut to any length. It can essentially be
shaped to
any figuration or size and is used to trim Plexiglas letters or shapes by
chemically
welding the trim to the plastic shapes. The letters or shapes can then be
placed on a
channel which would contain neon or LED lighting to illuminate the letters or
shapes.
The result is a three-dimensional illuminated letter or shape. Prior
attachment means for
securing the trim cap to the outside of the metallic channel comprises holes
drilled
through the trim cap and the metal channel followed by screws driven through
the trim
cap into the metallic channel (i.e. for securing the trim cap thereto).
Referring to FIGS. 1 and 2, a channel sign assembly 10 according to the prior
art is
mounted on a supporting structure (not shown). The channel sign assembly 10
includes a
metal enclosure 14 having a rear surface 16 and a plurality of side walls 18,
19 which are
contoured to define the edges of a sign assembly 10 . The forward edges 20 ,
21 of the
sidewalls 18 , 19 define a plane and fitted across the forward edges 20 , 21
is a
transparent lens 24 having a shape corresponding to that defined by the walls
18 , 19 of
the enclosure 14 . Retained to the rear surface 16 of the enclosure 14 is a
light source 30,
which can extend through the length of the channel sign assembly 10 and
thereby
illuminate the entire surface of the lens 24 .
Referring further to FIG. 2, in accordance with the prior art, the lens 24 is
retained to the
side walls 18 , 19 of the enclosure 14 by the trim cap 34 , a plastic border
member which
can be glued or welded to the outer edges of the lens 24 . The trim cap 34 has
a
rearwardly extending lip 36 that fits over the forward edges 20 , 21 of the
side walls 18,
19 and the lens 24 . The assembly is then secured to the enclosure member 14
by a
plurality of screws 38.
The use of screws 38 is undesirable for a number of reasons. Screws 38 are not
aesthetically acceptable and they create depressions in the trim cap. The
screws 38 peel
when painted to match the trim cap and can rust and freeze making it difficult
to remove
for servicing the sign assembly. The screws 38 cause staining and often crack
the trim
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cap. Thus, there is a need for an improved system for assembling trim cap
letters and
numbers to a supporting channel.
The manufacture of a channel sign assembly 10 involves the construction of the
enclosure 14 , the manufacture of a light fixture 30 and the lens 24 .
Manufacture of the
lens 24 involves cutting a transparent acrylic material into the shape of the
channel sign
assembly 10 and attaching the trim cap 34 around the edges thereof. The trim
cap 34 can
be welded to the outside plastic face 25 of the lens 24 using chemical bonding
material,
for example, Rez-N-Bond. The trim cap 34 , heretofore developed, is intended
to meet
the present sealing standards set by Underwriters Laboratories, but the same
such
standards may not be needed for channel sign assemblies which employ the new
LED
technology. It would, therefore, be desirable to provide an easier and less
expensive
method of attaching/detaching/reattaching a lens 24 and trim cap 34 to the
enclosure of
the channel sign assembly 10 .
Referring to FIGS. 3-6, a channel sign assembly 100 in accordance with the
present
disclosure can be attached to a supporting structure and includes a metallic
enclosure 114
having a rear surface (not shown) and a plurality of sheet metal side walls
118 , 119
similar to the prior art. Fitted within the enclosure 114 is a suitable light
source (not
shown). A retainer or snap cap 134 can be attached, i.e. firmly glued to the
lens 24 . The
lens 24 and retainer cap 134 provide lateral support to the walls 118 , 119 .
After
assembly, the lens 24 and the retainer cap 134 prevent the walls 118, 119 from
moving
towards each other and from bowing outward away from each other.
With reference again to FIGS. 3-6, the system for fabricating and installing a
retainer cap
134 without screws is shown. A tool 200 (FIGS. 7-9) can punch, cut, and bend a
tab 140
outward away from the outside surface or wall 118 of the channel enclosure 114
as
shown in FIGS. 3-6. In exemplary embodiments, the tab 140 can be from about
1/4" to
about IA" long and from about 1/2" to about 1" wide. The lower edge 144 of the
tab
extends outward away from the wall of the channel and can engage a foot 150 of
the
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retainer cap 134 (i.e. in a 'snap cap' or friction engagement arrangement).
The foot 150
of the retainer cap 134 can be in the form of a receiver edge 152 angled from
about 4
degrees to about 9 degrees 151 from a horizontal plane 153 perpendicular to a
vertical
plane 154 comprising a leg 156 of the retainer cap 134 . In one arrangement,
the receiver
152 can be angled from about 5 degrees to about 7 degrees 151 from the
horizontal plane
153.
The tabs 140 can be punched into the channel walls 118, 119 at random
positions around
the letter or shape at the discretion of an installer. The number and
intermittent spacing of
the tabs 140 will be dependent upon the size and design of the channel sign
100 .
Referring to FIG. 5, the interlocking effect of the foot 150 of the retainer
cap 134 to the
lower edge 144 of the tabs 140 will enable secure attachment of the plastic
lens 24 and
retainer cap 134 to the metallic channel enclosure 114 (without the use of
screws, et al.).
The punch tool 200 (FIGS. 7-9) can be utilized in order to accomplish and
create the tabs
140 for securing the retainer cap 134 to the metallic walls 118 , 119 . The
tool 200 can
punch, cut, and bend the tabs 140 to any desired size to the outside surface
of the channel
walls 118 as shown in FIGS. 3-6. The lower edge 144 of the tab can engage the
second
edge 152 and foot 150 of the retainer cap 134 (i.e. in a snap or friction fit
arrangement).
As discussed, the tabs 140 can be punched along the channel walls 118 at
predetermined
spaced positions, while aligning with the forward edge 120 of the metallic
walls 118 ,
around the letter or shape. The interlocking effect enables a positive
engagement of the
plastic retainer cap 134 to the forward edge 120 and forward side portions 118
of the
metallic enclosure 114 . FIG. 3 shows a side view of the tab 140 as it would
be aligned
with the front edge 120 of the side walls 118 . FIG. 6 shows an elevational
view of a side
wall 118 of a formed sign assembly shown with a tab 140 extending from the
side wall.
Referring now to FIGS. 7-9, the punch tool 200 can comprise a male component
204 and
a female component 206 wherein the male component 204 is adapted to cut tabs
140
from the channel side walls 118 , 119 and bend the tabs 140 outward at an
angle away
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from the side walls 118 , 119 as the male component 204 is pushed through the
open
channel of female component 206 . The tabs 140 can be positioned such that
they are
proximal to the front edge 120, 121 of the side walls 118, 119 and aligned
with the front
edge 120 of the side walls 118 . The tool 200 can include a stop 210 which
provides the
offset for aligning and spacing the tabs 140 parallel to the forward end 120
of the side
walls 118 . The punching of the tabs 140 can be done by the manual tool 200 or
can be
incorporated into a pneumatic punch press (not shown) as part of an automated
channel
letter forming machine.
In furtherance of the above described retainer cap 134 , another tool 250 has
been
developed to facilitate the detachment or removal of the plastic retainer or
snap cap 134
from the metallic walls 118 , 119 . The retainer cap 134 can be detached from
the tabs
140 using this separate tool 250 which can be manually lever driven. The lever
tool 250
includes a pair of prongs 252 , 254 for prying underneath the foot 150 of the
retainer cap
134 to detach the attached portion of the retainer cap 134 from the tab 140 .
The lever
tool 250 can release the retainer cap much as a bottle opener locks under the
lid to pop a
lid off.
When a channel sign assembly 100 is assembled using the tabs 140 as described,
the
finished product will present a more attractive appearance than one assembled
using
screws. In addition, when it is time to service the sign assembly 100 to
replace LEDs, or
other devices, the snap/retainer cap 134 can be pried off using the simple
lever device
250 , via movement of the lever in the direction 260 shown in FIG. 11. The
lever device
250 can reach between the retainer cap 134 and the side wall 118 which then
enables
pulling of the receiver edge 152 of the retainer cap 134 outward in order to
free the edge
152 from the terminal end 144 of the tab 140. This prying process can be
continued for
several tabs which will allow the service technician to free the entire
perimeter, or a
desired portion thereof, of the retainer cap 134 from the forward end 120 of
the channel
sign enclosure 114 without the use of a screwdriver and the cumbersome removal
of
screws.
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In accordance with one embodiment of the aforementioned disclosure, the
channel sign
assembly 100 comprises the enclosure 114 having at least two opposing walls
118, 119
made of sheet metal. The enclosure 114 defines the shape of the sign assembly
100
wherein the sign has an open front 102 . The at least two opposing walls 118 ,
119 have
an inner surface 122, 123 and forward ends 120, 121 , respectively. The walls
118, 119
include a series of intermittent tabs 140 punched outward through the walls
118 , 119 ,
wherein the tabs 140 are aligned with and offset from the forward ends 120 ,
121 . The
assembly 100 further comprises a planar transparent or translucent lens 24
having a
forward surface or outside face 25 . It is to be appreciated that the lens 24
includes an
outer edge 26 in the defined shape of the sign and is sized to fit within or
adjacent to the
at least two opposing walls 118 , 119 of the enclosure 114 . A retainer cap
134 can be
mounted against the forward surface 25 of the lens 24 for retaining the lens
24 with the
enclosure 114 and against the walls 118 , 119 . The retainer cap 134 can
include an
interior face 157 having upper or first edge 158 and an opposing lower or
second edge
160 . The first edge 158 has an overhang 159 welded to the forward surface 25
of the lens
24 ; and, the second edge 160 has the foot or channel 150 , wherein the
channel 150 and
receiver edge 152 is adapted to securely engage a plurality of the tabs 140
along an outer
surface of the enclosure 114.
In accordance with another embodiment of the aforementioned disclosure, a
method is
provided for forming the channel sign assembly 100 . The method comprises
making an
enclosure 114 with at least two opposing walls 118 , 119 made of sheet metal
or similar.
The walls 118 , 119 can be bent to any figuration and will form the enclosure
114 which
in turn will define the shape of the sign assembly 100 . The enclosure 114 can
have an
open front 102 . The at least two opposing walls 118 , 119 will have inner
surfaces 122 ,
123 and forward ends 120, 121 , respectively. The method further provides for
a tool 200
used for punching a series of intermittent tabs 140 through the walls 118, 119
, such that
the tabs protrude outward and are aligned with and offset from the forward
ends 120 ,
121 of walls 118, 119 . The method further comprises cutting a lens 24 to fit
within or
adjacent to, the at least two opposing walls 118, 119 of the enclosure 114 . A
retainer cap
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134 that has been cut to length can be mounted against the forward surface 25
of the lens
24 for retaining the lens 24 to the enclosure 114 and against the walls 118 ,
119 . The
retainer cap 134 comprises an interior face 157 having upper or first edge 158
and an
opposing lower or second edge 160 . The first edge 158 has an overhang 159
that can be
welded to the forward surface 25 of the lens 24 ; and, the second edge 160 has
the foot or
channel 150 , wherein the channel 150 and receiver edge 152 is adapted to
securely
engage a plurality of the tabs 140 along an outer surface of the enclosure
walls 114 . The
retainer cap 134 can be 'snapped' into position by pressing the foot 150 over
the terminal
edges 144 of the respective tabs 140 . This step can be repeated around the
entire
circumference of the enclosure 114 , thereby securing the lens 24 and retainer
cap 134 to
the walls of the enclosure 114 . Another tool 250 can be used for detaching
the retainer
cap 134 from the enclosure 114 (see FIG. 1)) in order to remove the retainer
cap 134 for
servicing the lights (or other maintenance) within the enclosure 114 .
While embodiments of the present disclosure have been disclosed, it will be
appreciated
that many modifications or variations may be made without departing from the
true spirit
and scope of the disclosure. It is, therefore, the intent of the pending
claims to cover all
such variations and modifications which fall within the true spirit and scope
of the
disclosure.
