Abstract:
A stencil system comprising a first stencil body comprising a first stencil aperture and a raised joining protrusion that extends away from a top surface of the first stencil body; and a second stencil body comprising a second stencil aperture and a joining protrusion receiving aperture, wherein said first stencil body and said second stencil body are connectable by a press fit joint between said raised joining protrusion and said joining protrusion receiving aperture.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     Benefit of U.S. Provisional Patent Application Ser. No. 60/565,581, filed Apr. 27, 2004, is hereby claimed and the disclosure incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to stencils, and more particularly to a plurality of stencils which can be assembled in a desired order for transferring letters, numbers and other symbols.  
         [0004]     2. Description of Related Art  
         [0005]     Stencils are useful for creating letters, numbers and other symbols on a surface. Stencils that lock together, or interlocking stencils, may provide for the creation of consistently spaced letters, numbers and other symbols along a desired axis. However, the assembly and disassembly of interlocking stencils may require several complex and time-consuming steps. Interlocking stencils that are suitable for quick and easy assembly and disassembly would be beneficial.  
       BRIEF SUMMARY OF THE INVENTION  
       [0006]     Provided is a stencil system comprising a first stencil body comprising a first stencil aperture and a raised joining protrusion that extends away from a top surface of the first stencil body; and a second stencil body comprising a second stencil aperture and a joining protrusion receiving aperture, wherein said first stencil body and said second stencil body are connectable by a press fit joint between said raised joining protrusion and said joining protrusion receiving aperture.  
         [0007]     Also provided is a stencil system comprising a first stencil body comprising a first stencil aperture and a raised joining protrusion that extends away from a top surface of the first stencil body, said raised joining protrusion comprising a first latching finger and a second latching finger, and a second stencil body comprising a second stencil aperture and a joining protrusion receiving aperture, wherein said first stencil body and said second stencil body are connectable by a resilient latching joint between said raised joining protrusion and said joining protrusion receiving aperture.  
         [0008]     Further provided is a stencil for connection to other stencils, the stencil comprising a stencil body defining a stencil aperture, said stencil aperture comprising a beveled edge having at least one bevel angle, wherein said at least one bevel angle is less than ninety degrees, an offset portion of the stencil body for overlapping a stencil body of another stencil, and a joining structure being provided on the offset portion.  
         [0009]     Further provided is a modular stencil system, comprising a first stencil body comprising a first cylindrical raised joining protrusion that extends away from a top surface of said first stencil body, a second cylindrical raised joining protrusion that extends away from the top surface of said first stencil body, a first offset portion comprising a first lateral projection and a second lateral projection, a first joining protrusion receiving aperture on said first lateral projection, a second joining protrusion receiving aperture on said second lateral projection, and a first stencil aperture, wherein said first stencil aperture is defined by a first beveled edge having a first bevel angle of approximately 45 degrees, and further wherein said first stencil body comprises a polymer and is formed by an injection molding process, and a second stencil body comprising a third cylindrical raised joining protrusion that extends away from a top surface of said second stencil body, a fourth cylindrical raised joining protrusion that extends away from the top surface of said second stencil body, a second offset portion comprising a third lateral projection and a fourth lateral projection, a third joining protrusion receiving aperture on said third lateral projection, a fourth joining protrusion receiving aperture on said fourth lateral projection, and a second stencil aperture, wherein said second stencil aperture is defined by a second beveled edge having a second bevel angle of approximately 45 degrees, and further wherein said second stencil body comprises a polymer and is formed by an injection molding process, and further wherein said first stencil body and said second stencil body are connectable by a press fit joint between said first cylindrical raised joining protrusion and one of said third joining protrusion receiving aperture and said fourth joining protrusion receiving aperture, and further wherein said first stencil body and said second stencil body are connectable by a press fit joint between said second cylindrical raised joining protrusion and the other one of said third joining protrusion receiving aperture and said fourth joining protrusion receiving aperture, and further wherein a surface of said first stencil body and a portion of said second stencil body are substantially coplanar when said first stencil body is connected to said second stencil body. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a perspective view of a stencil according to an embodiment of the present invention;  
         [0011]      FIGS. 2A and 2B  are perspective views of a first stencil to be connected to a second stencil according the embodiment of  FIG. 1 ;  
         [0012]      FIGS. 3A and 3B  are perspective views of the first stencil connected to the second stencil of  FIGS. 2A and 2B ;  
         [0013]      FIG. 4  is a plan view of an alternative embodiment of the present invention;  
         [0014]      FIG. 5  is a perspective view showing the detail of a portion of the stencil of  FIG. 4 ;  
         [0015]      FIG. 6  is a perspective view of a first stencil interlocked with a second stencil according the alternative embodiment of  FIG. 4 ;  
         [0016]      FIG. 7  is a side view showing the detail of a portion of the interlocked stencils of  FIG. 6 ;  
         [0017]      FIG. 8  is a perspective view of a first stencil interlocked with a second stencil according to an embodiment of the present invention; and  
         [0018]      FIG. 9  is a perspective view of a first stencil connected to a second stencil according to an embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     As shown in  FIGS. 1-9 , the present invention provides a modular stencil system including reusable interlocking stencils for use in spray painting or otherwise applying numbers, letters or other symbols onto a surface, such as by marking, crayoning, penciling, brush painting, roller painting, or sponge painting, for example. As presently embodied, each stencil  10 ,  10   a ,  10 ′,  10   a ′ comprises a stencil plate or body  12 ,  12   a ,  12 ′  12   a ′ and a design area or stencil aperture  14 ,  14 ′,  14   a ′ in the shape of a particular symbol. Further, the apertures  14 ,  14 ′,  14   a ′ are not limited to a textual symbol, as described herein, and can be provided in any desired shape in accordance with the present invention. The stencils  10 ,  10   a ,  10 ′,  10   a ′ shown in  FIGS. 1-3B  and  FIG. 9 , by way of example, have apertures  14 ,  14 ′ shaped as the numbers “7” and “0” and the stencils  10 ,  10   a ,  10 ′,  10   a ′ shown in  FIGS. 4-8 , by way of example, have apertures  14 ,  14 ′,  14   a ′ shaped as the number “1” 
         [0020]     In the embodiment of  FIGS. 1-3B , two upwardly raised cylindrical joining protrusions  116  and two corresponding cylindrical joining protrusion receiving apertures  118  are provided for the purpose of interconnecting a stencil  10  with an adjacent stencil  10   a  having corresponding raised joining protrusions  116  and joining protrusion receiving apertures  118 . Each protrusion receiving aperture  118  is provided on an offset portion  22  that is raised upwardly from a top surface of the stencil body  12 . As best shown in  FIGS. 2A-3B , two adjacent stencils  10 ,  10   a  can be lockingly interconnected by inserting the raised joining protrusions  116  of the first stencil  10  into the respective protrusion receiving apertures  118  of the second stencil  10   a . The respective protrusions  116  and apertures  118  are sized to provide a substantially tight fit to hold the adjacent stencils  10 ,  10   a  together (see  FIGS. 3A and 3B ) during the intended use, while allowing the stencils  10 ,  10   a  to be separated (see  FIGS. 2A and 2B ) as necessary.  
         [0021]     The offset portion  22  is shown as having a generally C-shape and comprising lateral projections  120  on which the joining protrusion receiving apertures  118  are located. The offset portion  22  is not limited to a generally C-shape, and can be provided in any desired shape, for example, rectangular, semi-circular, or an asymmetrical shape, in accordance with the present invention.  
         [0022]     The joints formed between respective protrusions  116  and apertures  118  that hold the stencils  10 ,  10   a  together are press fit joints. As used herein, the terms “press fit joint” refers to a connection formed by static friction forces due to the mutual pressure acting on the contact surfaces between a protrusion and a corresponding aperture into which the protrusion is inserted. The protrusions  116  and corresponding apertures  118  are adapted to permit the manual connection and disconnection of stencils  10 ,  10   a . For example, the protrusions  116  and corresponding apertures  118  are adapted to permit the manual insertion of a protrusion  116  on a stencil  10 ,  10   a  into an aperture  118  on another stencil  10 ,  10   a  to a depth at which the stencils are substantially coplanar and connected by a press fit joint. Furthermore, stencils  10 ,  10   a  so connected by a press fit joint are adapted to be disconnected by manually, for example, by pulling apart so connected stencils  10 ,  10   a . Alternatively, protrusions  116  and corresponding apertures  118  can be adapted to require the assistance of a tool, for example, a weight, a hammer, pliers, or a manual or powered vise, for connection and disconnection of the press fit joint. The cylindrical protrusions  116  and apertures  118  of the embodiment of  FIGS. 1-3B  can be replaced with protrusions and corresponding apertures of any other suitable shape, such as frustoconical or polygonal protrusions and apertures, for example.  
         [0023]     As an alternative, as shown in  FIG. 9 , the relative locations of the raised joining protrusions  116 ′ and joining protrusion receiving apertures  118 ′ are reversed. so that the raised joining protrusions  116 ′ project downward from the offset portion  22 ′. Thus situated, the joining protrusions  116 ′ can engage the protrusion receiving apertures  118 ′ located on the stencil body  12 ′ by insertion from above.  
         [0024]     Referring to  FIGS. 4-7 , to the extent that an alternative embodiment shown therein has features which substantially correspond to the above description of  FIGS. 1-3B , the same reference characters will be used. Two locking tabs  16  and two tab-receiving apertures  18  are provided. Each locking tab  16  comprises two diverging hook-like projections or latching fingers  20  extending upwardly from the top surface of the stencil body  12 . Each tab-receiving aperture is provided on the offset portion  22  that is raised upwardly from the top surface of the stencil body  12 . Two adjacent stencils  10 ,  10   a  can be lockingly interconnected by inserting the locking tabs  16  of the first stencil  10  into the respective tab-receiving apertures  18   a  of the second stencil  10   a . The latching fingers  20  engage or latch onto the stencil body  12   a  near the tab-receiving apertures  18   a , thereby connecting the stencil bodies  10 ,  10   a . The latching fingers  20  are resilient and bendable, which allows the latching fingers to be momentarily moved to a disengaging position. When the latching fingers  20  are in the disengaging position, two connected stencil bodies  10 ,  10   a  can be separated. In one embodiment of the invention, the movement of one or both of the two latching fingers  20  of each of the two locking tabs  16  to the disengaging position allows two stencil bodies  10 ,  10   a  to be disconnected. In another embodiment, the movement of both of the latching fingers  20  to disengaging positions is required for the stencil bodies  10 ,  10   a  to be disconnected.  
         [0025]     During use, the hook-like latching fingers  20  of the locking tabs  16  prevent the locking tabs  16  from being inadvertently removed from the tab-receiving apertures  18   a . In order to disconnect the stencils  10 ,  10   a , the user squeezes or compresses the hook-like latching fingers  20  together, that is, to the disengaging position, allowing the tabs  16  to clear the tab-receiving apertures  18   a.    
         [0026]     The outside edge  24  of the stencil aperture  14  of the stencil  10  is tapered inward, or beveled, at exactly a 45 degree angle or at an approximately 45 degree angle from front to back. As used herein, the term “approximately” refers to an inclusive range beginning slightly below, and ending slightly above. For example, angles of 41, 43, 46 and 49 degrees are each approximately 45 degrees. This bevel enhances the sharpness of the edges of the stenciled symbol, especially when spray painted. Alternatively, the outside edge  24  can be tapered at any desired angle less than 90 degrees or can be perpendicular to the front surface of the stencil body  12 . Beveled edges can be provided on the outside edges of the stencil apertures of all embodiments disclosed herein.  
         [0027]     As shown in  FIGS. 6 and 7 , the offset portion  22   a  of the stencil body  12   a  overlaps the adjacent stencil body  12  and allows both of the stencils  10 ,  10   a  to lie flat, such that they have perfectly coplanar, or at least substantially coplanar, back surfaces when interconnected. As used herein, the terms “substantially coplanar” refer to planes in space that nearly, but not exactly, coincide, and which intersect to form small acute angles. An unlimited number of stencils  10 ,  10   a  can thus be interconnected in a serial fashion. Returning to  FIGS. 3A and 3B , it can be seen that the interconnected stencils  10 ,  10   a  of the shown embodiment also have substantially coplanar back surfaces.  
         [0028]     As an alternative, as shown in  FIG. 8 , the relative locations of the locking tabs  16 ′,  16   a ′ and tab-receiving apertures  18 ′,  18   a ′ are reversed. Accordingly, locking tabs  16   a ′ project downward from the offset portion  22   a ′. Thus situated, the locking tabs  16   a ′ can engage the tab-receiving apertures  18 ′ located on the stencil body  12   a ′ by insertion from above. Downward projecting lips  26 ,  26   a  surround the stencil apertures  14 ′,  14   a ′. The lips  26 ,  26   a  preferably project downward at least the same distance as the locking tabs  16 ′,  16   a ′. The lips  26 ,  26   a  prevent a liquid, for example, spray paint, that is applied to a surface through the stencils  10 ′,  10   a ′ from migrating under the stencil bodies  12 ′,  12   a ′ and contain the liquid within the stencil apertures  14 ′,  14   a′.    
         [0029]     The stencils  10 ,  10   a ,  10 ′,  10   a ′ of the disclosed embodiments are injection molded from a polymer material such as a plastic, for example, acrylonitrile-butadiene-styrene, phenolic, polyvinyl chloride, polyethylene, or polycarbonate. Alternatively, the stencils  10 ,  10   a ,  10 ′,  10   a ′ can be fabricated by blow molding, centrifugal molding, die cutting, stamping, pressing, cutting by hand or machine tool, or other known processes. Further, other suitable materials, including paper, cardboard, rubber, or metals, can be used to construct all or desired portions of the disclosed invention.  
         [0030]     It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.