Abstract:
A screen track assembly for mounting and tensioning a retractable screen across an opening, the assembly having a generally U-shaped outer track member having an opening; an inner track member received within the outer track member, the inner track member adapted to receive a retractable screen, the inner track member being movable relative to the outer track member; biasing members to present a biasing force to extend the inner track member toward the opening of the outer track member; and adjustable mechanical fasteners to fix the position of the inner track member relative to the outer track member such that the screen may be tightened or loosened as required for proper functionality.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/945,472, filed Feb. 27, 2014, the disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates in general to assemblies and methods of retaining and guiding a retractable screen in an extruded guide track affixed to a fixture or building, or to another fixed guide track. More particularly, the invention relates to such assemblies and methods that are adjustable to increase or decrease tension on the retractable screen. 
     Guiding a screen in a track system is typically accomplished by forming an enlarged edge or bead on opposing sides of the screen and positioning the screen bead within complimentary receiving channels formed within an extruded track, such that the bead is held within opposing track sections in a manner that allows the screen to travel up and down the tracks, the bead and track assembly in combination forming an end retention system to retain the screen under the proper tension. Such an assembly also creates a seal around the screen edges that prevents insects, light, wind and other elements from entering the screened area. Attaching a screen track system to a fixture or building is typically accomplished by directly affixing the track to the fixture or building with mechanical fasteners. 
     The track assembly must be sized within a very narrow tolerance or the screen will not work properly. If the screen is pulled too tight, friction will prevent it from sliding within the track, and if it is too loose it will have a poor appearance. The process of manufacturing a track assembly is not accurate enough to meet the tolerance requirements on its own to achieve a proper fit once installed. As a result, it has become common practice to provide a track assembly that allows for inward and outward adjustment to adjust the screen tension between the installed tracks. Typically, a track assembly is comprised of paired extruded members, an inner track member and an outer track member, wherein the outer track member is fixed directly to the building and the inner track member is received within the outer track member in a manner that allows the inner track member to be adjusted to provide greater or lesser tension on the screen to compensate for irregularities in the building and slight variations in screen dimensions that occur during manufacture. 
     While tension adjustable track assemblies are known in the art, these assemblies are difficult to adjust and typically require professional levels of skill One current method employs an outer channel track with ratchet shaped grooves on the inner surface that engage an inner track with corresponding cogs on the outer surface, with mechanical fasteners to lock the assembly in place. With the outer track installed, the inner track is pushed into the outer track until the screen is properly tensioned, the ratchet teeth and cogs engaging as the track is pushed in such that the inner track is firmly held in its position and cannot be withdrawn without disassembly and special tools. A mechanical fastener is then driven through the two tracks to keep the track from moving further outward. While this presents an effective means for tensioning the screen, this system does not provide an easy means to re-adjust the assembly to release tension from the screen, which may be required when the screen will no longer slide easily within the tracks or the screen gets stuck as a result of shrinkage, settling of the building, temperature changes or other reasons. 
     It is desirable for the professional to be able to install a retractable screen system as quickly as possible. In many cases, however, a building is constructed in a manner that makes fast installation challenging, as the building may have openings that are out of square or out of plumb, or have irregular surface finishes such as siding, stonework, brick, or stucco. Additionally, a building may have another type of track system or fixture already in place on the same opening where an additional screen track is to be mounted. This is common in hurricane zones, where a hurricane shutter track is mounted onto the building across the opening and a screen track would therefore need to be attached to the hurricane shutter track. While a skilled professional can modify, fabricate, and build suitable track systems as necessary to accommodate the requirements of the job, it is time consuming and expensive. 
     It is an object of this invention to provide a screen track assembly that incorporates a structure and method to easily adjust the tension on the screen after installation, whether to tighten or loosen, without requiring professional service, disassembly, or specialized tools. It is a further object to provide a screen track assembly that has a compatible adaptor such that the screen track assembly can be attached to an auxiliary track or building component, such as that of a hurricane shutter or window frame, or where the adapter is designed to overcome a construction irregularity. 
     Other objects and advantages of the present invention include:
         (1) To provide a screen track assembly that is adjustable.   (2) To provide a screen track assembly that has an adjustable inner track member received within a fixed outer track member.   (3) To provide a screen track assembly that incorporates a spring to assist in adjusting tension.   (4) To provide a screen track assembly that can be adjusted by non-skilled individuals.   (5) To provide a screen track assembly that incorporates at least one mating channel.   (6) To provide a screen track assembly that works with adapters to fit to other track systems or building components.   (7) To provide a screen track assembly that works with adapters to solve construction irregularities.   (8) To provide a device that is modular, and can be used in part, as a whole, or in combination with other devices.   (9) To provide a screen track assembly that is durable and weather resistant.   (10) To provide a device that is inexpensive to manufacture.       

     BRIEF SUMMARY OF THE INVENTION 
     In general the invention comprises in various embodiments a screen track assembly for mounting and tensioning a retractable screen across an opening, the assembly comprising a generally U-shaped outer track member having an inward-facing opening, an inner track member received within the outer track member, the inner track member adapted to retain a retractable screen, the inner track member being movable relative to the outer track member, biasing members to present a biasing force to extend the inner track member toward the opening of the outer track member; and adjustable mechanical fasteners to fix the position of the inner track member relative to said outer track member such that combination of the fasteners and the biasing members enables the screen to be tightened or loosened as required for proper functionality. In further embodiments, the invention comprises adaptors that enable the outer track member to be affixed to various building surfaces or auxiliary track. 
     In alternative language, the invention is a screen track assembly adapted to mount a retractable screen across an opening, the assembly comprising a generally U-shaped outer track member having an opening; an inner track member received within said outer track member, said inner track member adapted to retain a retractable screen, the position of said inner track member relative to said outer track member being adjustable to adjust the tension on the retractable screen; biasing members to present a biasing force to extend said inner track member toward said opening of said outer track member; and adjustable mechanical fasteners to fix the position of said inner track member relative to said outer track member. 
     Additionally, the invention is a screen track assembly comprising a generally U-shaped outer track member comprising an outer face member, two parallel exterior walls, an opening and mating flanges extending from said exterior walls; an inner track member positioned within said outer track member, the position of said inner track member within said outer track member being adjustable, said inner track member comprising a bead channel, a pair of mounting fins, and a rail member; a screen comprising a bead, said bead being retained within said bead channel in a manner whereby said bead is axially movable within said bead channel; biasing members positioned between said inner track member and said outer track member to present a biasing force to extend said inner track member toward said opening of said outer track member; and adjustable mechanical fasteners connecting said mounting fins of said inner track member to said mating flanges of said outer track member, whereby the combination of said biasing members and said adjustable mechanical fasteners fix the position of said inner track member relative to said outer track member in an adjustable manner to properly tension said screen. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of the inner track member of the screen track assembly. 
         FIG. 2  is an end view of the inner track member embodiment of  FIG. 1 . 
         FIG. 3  is a perspective view of an embodiment of the outer track member of the screen track assembly. 
         FIG. 4  is an end view of the outer track member embodiment of  FIG. 3 . 
         FIG. 5  is an exploded view of an embodiment of the track assembly comprising the inner track member embodiment of  FIGS. 1 and 2  and the outer track member embodiment of  FIGS. 3 and 4 . 
         FIGS. 6A, 6B and 6C  show the assembled track assembly of  FIG. 5  as adjusted for an intermediate, fully tensioned and fully relaxed configuration, respectively. 
         FIG. 7  is a side view of an embodiment of the spring member. 
         FIG. 8  is a top view of the spring member embodiment of  FIG. 7 . 
         FIG. 9  is a perspective view of an embodiment of the track adaptor. 
         FIG. 10  is an end view of the track adaptor embodiment of  FIG. 9 . 
         FIG. 11  is an exploded view showing the track assembly of  FIGS. 5 and 6 , adaptor of  FIGS. 9 and 10 , and an auxiliary track member. 
         FIG. 12  shows the track assembly of  FIGS. 5 and 6 , adaptor of  FIGS. 9 and 10  and an auxiliary track member in an assembled configuration. 
         FIG. 13  is an exploded view of the outer track member and an alternative embodiment of an adaptor. 
         FIG. 14  shows the outer track member and the alternative adaptor embodiment of  FIG. 13  in an assembled configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     This invention, as described and shown in the drawings in various embodiments that are not meant to be limiting, is in general a tension adjustable retractable screen assembly, the assembly being a screen track assembly  100  comprised of paired extruded aluminum profiles, an inner track member  10  and an outer track member  20 , springs  91 , and adjusting fasteners  92  that interact to allow easy adjustment of the retractable screen. The inner track member  10  is structured to receive the peripheral bead or edge structure of a retractable screen such as used in covering an opening to prevent passage of insects, debris, light, etc. The inner track member  10  is received by and cooperatively mates in adjustable manner with the outer track member  20 , which is typically affixed directly to the inward facing side of an opening in a building. The assembly  100  may further comprise an adaptor member  30  to allow the screen track assembly  100  to be affixed to other extruded aluminum profiles, such as another track member  40  already affixed to an opening, to a lateral face or wall of a building, or to compensate for irregularities in the mounting surface. 
     The outer track member  20 , an embodiment of which is shown best in  FIGS. 3 and 4 , forms the affixed and static base for the screen track assembly  100 . It is preferred that the outer track member  20  be generally U-shaped in cross-section such that the inner track member  10  and screen  60  is received through the inwardly facing opening  28  of the “U”. The outer track member  20  comprises two parallel exterior walls  26  (the legs of the “U”) and an outer face member  24  (the base of the “U”) joined to the two exterior walls  26 . The outer track member  20  further comprises an interior guide channel  21 , likewise generally U-shaped, formed by parallel interior walls  25  extending from the outer face member  24 , with the opening  27  of the interior guide channel  21  defined by the two interior walls  25  facing in the same direction as the opening  28  of the outer track member  20  defined by the exterior walls  26 . A mounting flange  22  extends inwardly from the middle portion of each exterior wall  26 , the opposing mounting flanges  22  extending toward each other in the same plane and dimensioned so as to leave a central gap  29  between the two mounting flanges  22 . The combination of the exterior walls  26  and the mounting flanges  22  defines an exterior guide channel  51 , which is wider than the interior guide channel  21 . The outer track members  20  are preferably extruded metal members and are affixed in known manner to opposite sides of an opening in a building or the like, typically by mechanical fasteners extending through the outer face member  24 , with openings  28  facing each other. 
     The inner track member  10 , an embodiment of which is shown in  FIGS. 1 and 2 , is the inner adjustable component of the screen track assembly  100  that is received within the outer track member  20 . The size and structure of the inner track member  10  is such that it is able to be adjusted and moved in the ward and outward directions to differing positions within the outer track member  20 . It is preferred that the inner track member  10  be approximately I-shaped or T-shaped in cross-section in a broad sense, and comprising a rail member  11  sized and adapted to be received within the outer track guide channel  21 , the rail member  11  being mounted onto an extension flange or member  15  extending from a generally C-shaped in cross-section bead channel  12 . Bead channel  12  is adapted to receive the peripheral bead  61  of the screen  60  to be positioned between the opposing outer track members  20  in a manner that allows the screen  60  to be retracted and extended along the inner track member  10 , the bead  61  sliding axially within the bead channel  12 . The combination of the rail member  11  and the extension member  15  is generally T-shaped in cross-section, and the width of the rail member  11  is structured to be slightly smaller than the width of the interior guide channel  21  between the interior walls  25 , such that the interior guide channel  21  allows relative movement of the rail member  11  in the inward or outward direction but limits lateral movement of the rail member  11 . 
     The inner track member  10  further comprises mounting flanges or fins  13  that extend in a single plane laterally to either side of the bead channel  12 , the fins  13  serving as the abutting surface for the head of the adjusting fastener  92 . The mounting fins  13  are sized such that the distance between their outer edges is only slightly smaller than the width of the exterior guide channel  51  between the opposing exterior walls  25 , such that the exterior guide channel  51  limits lateral movement of the mounting fins  13 . The combination of the rail member  11  and the mounting fins  13  received within the interior guide channel  21  and exterior guide channel  51  allows the inner track member  10  to be moved and adjusted inwardly and outwardly relative to the outer track member  20 , while preventing the inner track member  10  from moving laterally, pivoting or rotating within the outer track member  20 , such that the inner track member  10  remains in proper alignment under any tension. 
     In use the inner track member  10  is positioned within the outer track member  20 , the rail member  11  extending through the gap  29  and beyond the mounting flanges  22  such that it resides within the interior guide channel  21  between the interior walls  25 , and the mounting fins  13  residing within the external guide channel  51  between the exterior walls  26 . In the embodiments as shown, the gap  29  is sized such that the bead channel  12  may pass through the gap  29  as well. 
     The rail member  11  is preferably formed to comprise a slotted channel  14  that is sized to accept biasing or spring members  91 . The biasing member  91  is preferably a leaf spring type, as shown in  FIGS. 7 and 8 , adapted to reside within the outer track guide channel  21  to abut the rail member  11  of the inner track member  10 , as shown in  FIG. 5 . The embodiment of the biasing member  91  as shown comprises a widened portion defining mounting flanges  93  that are received within the slotted channel  14  of the end member  11 . It is a preferred embodiment that the spring is stainless steel. With this design, the biasing members  91  exert a bias force against the inner track member  10 , forcing or extending it in the direction of the opening  10  of the outer track member  20 . Alternative configurations for the biasing members  91  and/or positioning of the biasing members  91  between the inner track member  10  and the outer track member  20  will also be suitable to provide the biasing force. 
     Adjusting fasteners  92 , shown herein as a screw, serve to hold the inner track member  10  and outer track member  20  together in the desired relationship to properly tension the screen. The adjusting fasteners  92  pass through apertures provided in the mounting fins  13  of the inner track member  10  and the mounting flanges  22  of the outer track member  20 , thereby securing the inner track member  10  to the outer track member  20  and limiting its inward movement toward opening  28 , as shown in  FIG. 6A . This combination enables the tension on the screen  60  extending between opposing track assemblies  100  to be adjusted as required to properly tension the screen  60 . Tightening the adjusting fastener  92 , as shown in  FIG. 6B , increases tension on the screen  60  by moving the inner track member  10  further into the outer track member  20 , while loosening the adjusting fastener  92 , as shown in  FIG. 6C , allows the biasing member  91  to push inward the inner track member  10  away from the outer face member  24  of the outer track member  20 , thereby decreasing tension on the screen  60 . 
     To mount and tension the screen  60  within an opening, the outer track members  20  are attached directly to the building by mechanical fasteners, mechanical interlocking, bonding or other suitable means. The biasing members  91  are slid into the slotted channel  14  of the inner track member  10  and the inner track members  10  are positioned in the outer track member  20 . Fasteners  92  are run through holes placed on the mounting fins  13  of the inner track member  10  and through aligned holes in the mounting flanges  22  of the outer track member  20 , thereby securing the assembly  100  together. The bead  61  of the screen  60  is fed into the bead channels  12  of the inner track member  10  of the track assembly  100  and the adjusting fasteners  92  are adjusted inwardly or outwardly to set the required screen tension for proper screen function and appearance. 
     It is contemplated that in most situations the track assembly  100  will be mounted directly to a building by mechanically fastening the outer track members  20  to the inwardly facing walls of the building opening. Alternatively, the outer track member  20  may be mounted utilizing an adaptor  30  as shown in  FIGS. 9-14 , either to the building, such as when the building wall has an irregular surface, or to a window frame, or to an auxiliary track member  40 , such as the track of a hurricane already installed on the opening of the building. In this case a generally L-shaped adaptor member  30  is utilized, which as shown in the embodiment of  FIGS. 9-12  comprises a first face  32  and a second face  33  joined at a right angle. The adapter member  30  further comprises mating flanges or catches  31  extending from the first face  32  and second face  33  to engage one or more longitudinally extending, external mating channels  23  disposed on or within the outer face  24  of the outer track member  20 , and at the same time to engage one or more longitudinally extending, mating channels  41  of the auxiliary track  40 . 
     In the alternative embodiment shown in  FIGS. 13 and 14 , the L-shaped adaptor  30  has a first face  32  structured to be mechanically fastened to a wall or window frame member. With the outer track member  20  affixed to the adaptor  30 , the first face is in parallel with the exterior walls  26  of the outer track member  20 . The second face  33 , perpendicular to the first face  32 , is provided with a mating flange  31  that is received by the longitudinally extending mating channel  23  on the closed end of the outer track member  20 . The first face  32  is provided with a longitudinally extending hook flange  34  that receives and mates with the free edge of the abutting exterior wall  26 . In this manner the adaptor  30  is first fastened to the wall or frame and the outer track member  20  is then snapped into the adaptor  30 . 
     The extrusion profiles are of such size as to accomplish the goals of the invention. However, the profiles could be made larger or smaller, profile elements can be longer or shorter, and multiple profiles can be connected as required by the application. It is preferred that the track members  10  and  20  forming the assembly  100  and the adaptors  30  be made of extruded aluminum. 
     It is preferred to use common fasteners such as self-drilling screws, however any suitable type fastener may be used. It is preferred to use materials resistant to UV and other forms of degradation. While these materials and methods are preferred embodiments of the invention, other materials and methods maybe used to more efficiently produce the parts and the future may yield new materials that may enhance performance. Any of these improved items may be incorporated into the invention without altering the spirit of the invention. 
     The invention enables the professional installer to quickly adjust the tension of the screen track assembly inwardly or outwardly to achieve the best screen appearance and functionality and it provides the end user or homeowner the ability to make minor adjustments as required to maintain appearance and functionality with common household tools such as a screwdriver. The invention further allows the professional installer a selection of adapters that can be used to quickly attach the screen track assembly to an existing track or solve a construction irregularity. 
     While the invention offers a solution primarily for use in the installation of retractable screens such as insect and shade screens to protect windows and patio areas and other openings, the assembly has many other uses in many fields of endeavor where textiles screens are used; such as projector screens, temporary barriers, and billboards. Nothing should be construed from this description to limit the scope of this invention. It is understood that equivalents and substitutions for elements set forth above may be obvious to those of skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims.