Abstract:
A fan blade and color display fan deck provide a changeable color display product because the fan deck blades can be added to and removed from the fan deck without opening the fastener to which the fan blades are pivotally attached. Despite being removable from the fan deck, the blades can withstand the normal wear and tear associated with use in a color fan deck such as supporting the weight of the whole fan deck when a user holds an individual fan blade.

Description:
RELATED APPLICATION(S) 
     This application claims the benefit of U.S. Provisional application No. 61/972,192 filed Mar. 28, 2014, which is incorporated by reference in its entirety herein. 
    
    
     TECHNICAL FIELD 
     The present invention relates to color sample display devices in the form of a color fan deck for paint products where paint is illustrated on one or both sides of the fan blades of the fan deck. 
     BACKGROUND 
     Paint colors often are displayed on color swatches mounted on a flat planar base, multiple ones of which are joined together to form a deck or a fan deck with fan blades that are pivotally spread or fanned to display color. Each blade in the deck has one or more color swatches or painted areas that display one or more colors. The blades with the paint coated swatches or painted areas on one or both sides of the blades form a fan deck with potentially large numbers of blades and colors. The blades are held at one end of the deck and pivot around a fastener such as a screw or rivet such that the blades can swivel around a longitudinal body of the fastener to display colors to the user. A fan deck is an effective way to display large numbers of colors and color tones. 
     Advantageously, a fan deck can display many colors with many blades. Users typically will swivel one fan blade out from the fan deck and hold the fan deck by that blade when evaluating a color such as by holding the fan blade up to a wall or other surface to be painted. A problem exists in that the fastener pivotally holding the blades has to be removed, sometimes by destroying the fastener and/or the blades, to free the blades to add new or revised blades with revised colors to the fan deck or to replace blades already in the fan deck. Hours can be spent in unfastening and then re-fastening the fastener to slip in a new blade or revised blade, and care must be taken to not lose or misarrange fan blades during the time the fastener is not secure. Moreover, the fan blades themselves must have sufficient strength to withstand the rigors of use including supporting the weight of the fan deck during color evaluation by a user. 
     An object of the fan deck described herein is to provide fan blades for a changeable color fan deck with a plurality of blades that can be changed by adding to the fan blades of the deck or removing fan blades of the deck without removing the fastener holding the individual blades pivotally together. 
     Other objects will become more apparent with reference to the description set forth below. 
     SUMMARY 
     Generally speaking, pursuant to these various embodiments, the fan blade and color display fan deck described herein provide a changeable color display product because the fan deck blades can be added to and removed from the fan deck without opening the fastener to which the fan blades are pivotally attached. Despite being removable from the fan deck, the blades can withstand the normal wear and tear associated with use in a color fan deck such as supporting the weight of the whole fan deck when a user holds an individual fan blade. 
     In one approach, the blades have openings or holes surrounding the fastener which has a body width. The fastener, for example, may be a post with heads at each end of the posts or a ring. A planar connector of the fan blade defines a channel extending from a first channel end at the opening around which the blade pivots to a second channel end at an edge of the fan blade through which the fastener body moves when adding or removing a fan blade. The channel permits removal and/or addition of the fan blade from/to the fastener to effect a changing of the color display fan deck without the fastener being opened or removed from the color display fan deck. In other words, the channel provides a reusable path for the fastener to slide to and from the opening when adding the blade to and removing the blade from the fan deck. In one aspect, an overlay flap may extend from the connector and fold over at least a portion of the channel without covering the opening in the planar connector around which the blades pivot. 
     In one aspect, a portion of the channel (such as a shoulder in the channel) has a width less than the width of the body of the fastener to keep the fan blade from sliding off of the fastener and inadvertently separating from the fastener. This portion also has sufficient stiffness to keep the blade from twisting away from the fastener. The planar connector has flexibility and resiliency to flex sufficiently to permit opening the channel to a width larger than the body width of the fastener to allow removal and/or addition of the fan blade from/to the fastener when desired. The planar connector has a deformation strength sufficient to hold the fan deck&#39;s weight without deformation to prevent separation of the fan deck from the fastener when the fan deck is held by one blade having the opening and channel. This feature allows the fan deck to be updated with new or different color tones as may be available from a given paint supplier without dismantling the whole fan deck, risking mixing or losing fan blades. 
     In one example, the planar connector will hold a fan deck when the fan deck has a weight of from about 1.5 to about 30 ounces excluding the weight of the blade by which the fan deck is held. Such strength thereby allows a user to hold a fan blade apart from the other fan blades, for example to evaluate a color, without the fan blade separating from the fan deck. In one aspect, the planar connector may comprise an extension adhered to the planar base of the fan blade. 
     In a further aspect, a polymeric film may be added to the fan blade, surrounding the opening and/or the channel without covering the opening around which the blade pivots, to provide additional strength to the planar connector to support the fan deck. In another aspect, the film can provide an overlay flap that folds over itself, for example, along a score line, to releasably adhere to, cover, and secure at least a portion of the channel to further prevent inadvertent removal of the fan blade from the fan deck. 
     Also disclosed herein is a method of revising a color fan deck having a plurality of fan blades as described above without removing the fastener that pivotally holds the fan blades together. The method includes moving the fastener through the channel in the planar connector so that the planar connector surrounds the fastener, where the planar connector has sufficient strength to hold the fan deck&#39;s weight without deformation to prevent separation of the fan deck from the fastener when the fan deck is held by one blade having the opening and channel. 
     A method for making the fan blades is also described herein. 
     The blades of the fan decks described herein may be any known in the art including a swatch bearing blade including a flat elongated base paper laminated on one or both sides with a paint coated polymeric film as described in U.S. Pat. No. 8,007,621, or the blade may be a paint coated paper blade as described in United States Patent Application Publication No. 2014/0045149 filed Aug. 5, 2013, both of which are incorporated by reference as if fully rewritten herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of a fan deck with the individual blades precisely aligned on top of each other. 
         FIG. 2  is a top view of a color fan deck with the blades rotatably or pivotally moved so that the color on each side of the blade can be seen. 
         FIG. 3  is a side plan view of one example fan blade according to various embodiments of the invention. 
         FIG. 4  is a side view of one example fan deck according to various embodiments of the invention. 
         FIG. 5  is a top view of one example fan blade according to various embodiments of the invention. 
         FIG. 6  is a top view of one example fan blade having a polymeric film according to various embodiments of the invention. 
         FIG. 7  is a schematic view showing dimensions of one example design for the film layer of the example fan blade of  FIG. 6 . 
         FIG. 8  is a schematic view showing dimensions of one example design for the film layer having the optional foldable flap of the example fan blade of  FIG. 6 . 
         FIG. 9  is a side plan view of one example fan blade according to various embodiments of the invention. 
         FIG. 10  is a top view of one example fan blade having a polymeric tongue extending from a fan blade according to various embodiments of the invention. 
         FIG. 11  is a side plan view of one example fan blade according to various embodiments of the invention. 
         FIG. 12  is a schematic view showing dimensions of one example design for the polymeric tongue of the example fan blade of  FIG. 10 . 
         FIG. 13  is a schematic view showing dimensions of one example design for the polymeric tongue having the optional foldable flap of the example fan blade of  FIG. 10 . 
         FIG. 14  is a flow diagram of example methods of making fan blades according to various embodiments of the invention. 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein. 
     DETAILED DESCRIPTION 
     Turning now to the drawings and, in particular,  FIGS. 1-4 , an example color display fan deck  100  will be described in accordance with various aspects of the invention. The color display fan deck  100  includes a plurality of fan blades  105 , individual ones  107 ,  108 , and  109  of which include a planar base  115  with a top surface  120  and a bottom surface  130 . In one example, the fan blades can be between about one and four inches wide and between about two and eight inches in length. The planar base  115  illustrates paint color on at least one side of the fan blade  107 . The fan blade  107  further includes a planar connector  150  at an edge  152  of the at least one individual fan blade  107 . 
     The fan blade  107  itself can be constructed in any number of ways, including any of those known in the art. With reference to  FIGS. 3 and 9 , two such examples will be described. In  FIG. 3 , the planar base  115  of the fan blade includes a top surface  120  and a bottom surface  130 . The top surface  120  includes a paint layer  125  suitable to display the paint color when the fan blade  107  is swiveled away from the other fan blades  108  and  109  of the fan deck  100 . The paint layer  125  is disposed on a paper layer  140 . Similarly, a separate paint layer  135  is disposed on a bottom surface  130  of the planar base  115 . The second paint layer  135  may be the same color as the first paint layer  125  or a different color. United States Patent Application Publication No. 2014/0045149 describes one method of making a paint chip or fan blade according to the example of  FIG. 3 , which document is incorporated by reference herein. Another example fan blade is described with reference to  FIG. 9 . In this example, the planar base starts with a film layer  142 . A layer of adhesive  144  is applied to the film layer  142  so that a paper layer  146  can be adhered to the film layer  142 . The paper may be a 10 point paper sufficient to provide a stiffness to the fan blade and provide sufficient color backing so that the displayed paint color is true. Accordingly, a paint layer  148  is applied to the paper layer  146 . A clear top coat  149  is applied to the paint layer  148  to help maintain the color integrity of the paint layer  148 . U.S. Pat. No. 8,007,621 describes in more detail one approach to creating a fan blade such as in the example of  FIG. 9 , which patent is incorporated by reference herein as though fully rewritten. 
     A fan deck  100  includes a fastener  160 , which, as illustrated in  FIG. 4 , includes a body  162  and ends  164 . The fastener  160  ends or heads  164  are wider than the fastener body  162  to secure the fan blades  105  within the fan deck  100 . In a different approach, the fastener  160  may instead be a ring similar to a key ring to secure the plurality of fan blades  105  within the fan deck  100 . 
     Referring now to the example of  FIG. 5 , the planar connector  550  includes at least one opening  570 . The opening  570  has an opening width that surrounds the fastener  160  at the fastener body  162  to permit the individual fan blade  507  to be swivelably held within the fan deck  100 . For example, the opening  570  can be between about 0.20 inch and about 0.50 inch wide. By one approach, the planar connector  550  of the individual fan blade  507  defines a channel  572  extending from a channel end  574  to the at least one opening  570  to permit removal and/or addition of the fan blade  507  from/to the fastener  160 . This channel  572  can effect a changing of the fan deck  100  without the fastener  160  being opened or removed from the fan deck  100 . 
     At least a portion of the channel  572  has a width less than the body width of the fastener  160 . In the example of  FIG. 5 , the channel  572  defines a shoulder  576  or narrowing next to the opening  570 . The narrowing or shoulder  576  pinches around the fastener  160  so that the fan blade  507  stays secured on the fastener  160 . The channel  572  may define further or other narrowings such as that at narrowing portion  577  to further secure the fan blade  507  to the fastener  160 . The planar connector  550  has flexibility and resiliency to flex efficiently to permit opening the channel  572  effective to allow removal and/or addition of the fan blade  507  from/to the fastener  160  and a deformation strength sufficient to hold the fan deck  100 &#39;s weight without deformation. This prevents separation of the fan deck  100  from the fastener  160  when the fan deck  100  is held by one blade  507  having the opening  570  and the channel  572 . 
     In the example of  FIG. 5 , the planar connector  550  is integral with the body of the fan blade  507 . In other words, the opening  570  and channel  572  are cut from the body of the fan blade  507 . In this embodiment, the portion  580  of the fan blade  507  comprises a tongue that wraps around the fastener  160  and together with a further cut portion  582  of the fan blade  507  define the channel  572  through which the fastener  160  passes when adding the fan blade  507  to the fan deck  100 , or removing it from the fan deck  100 . In this way, the fastener  160  can pass through the edge  552  of the fan blade  507  via the channel  572  and sit within the opening  570 . In various embodiments, the planar connector  550  has a thickness of from about 0.5 mils to about 100 mils (about 0.0005 inch to about 0.10 inch) wherein the thickness corresponds to the thickness of the fan blade  507 . The thickness and materials of the fan blade  507  provide the deformation strength such that the planar connector  550  will hold a fan deck  100  when the fan deck  100  is held by the individual blade having the opening  570  and the channel  572 . A typical fan deck  100  that will include such a fan blade has a weight from about 1.5 to about 30 ounces excluding weight of the individual blade by which the fan deck  100  is held. 
     Referring to  FIGS. 3, 6, and 7 , in one aspect, a polymeric film  602  is disposed on one or both sides of the planar connector  550  such that the polymeric film  602  surrounds the opening  570  and the channel  572 . In this example, the polymeric film  602  strengthens the planar connector  550  to provide additional strength such that the fan blade  507  is better able to support the weight of the fan deck  100  without accidently coming loose during regular use by a user. For example, the polymeric film  602  can have a thickness from about five point to about seven point depending on the fan blade  507  to which the polymeric  602  is applied. Inherently stronger fan blades  507  can use polymeric films  602  having a smaller thickness or no polymeric film at all. The polymeric film  602  in different embodiments may be selected from the group consisting of polyethylene, polypropylene, and polyethylene terephthalate. 
     Referring to  FIG. 3 , the polymeric film  602  can be disposed on merely one side of the planar base  115 . The polymeric film  602  may be adhered to the planar base  115  using an adhesive  603 . In other approaches, the polymeric film  602  may be laminated to the fan blade  507  to effect bonding between the polymeric film and fan blade  507 , in which case a layer of one to four mil (0.001 to 0.004 inch) thick paper  603  is disposed between the film  602  and the fan blade  507  to facilitate adhesion. The thickness of the polymeric film can be between about 0.5 mils to about 100 mils (about 0.0005 inch to about 0.1 inch). By another approach, a second polymeric film  604  may be applied to the back or bottom of the fan blade  507  separately from or in addition to the polymeric film  602  applied to the top or front portion of the fan blade  507 . In still a further approach, the polymeric film may be wrapped around the edge of the fan blade resulting in a portion of polymeric film  606  wrapping around the edge of the fan blade  507 . The dimensions for one example polymeric film that can be applied to a fan blade are illustrated in  FIG. 7 . In this case, the opening and channel formed by the polymeric film  602  match that of the fan blade  507 . In one approach that can simplify the manufacturing process, the polymeric film  602  without a pre-cut opening or channel can be applied to the fan blade  507 , which combined polymeric film and fan blade are die-cut once at the same time to provide the opening  570  and channel  572  used for the planar connector  550 . In this case, the planar connector  550  will include a portion of at least the fan blade  507  and the polymeric film  602  having therefore a combined thickness from about 1 mil to about 200 mils (about 0.001 inch to about 0.20 inch). The planar connector  550  having this combination of elements will hold the fan deck  100  when the fan deck  100  is held by the one individual blade  507  having the opening  570  and channel  572  through both the polymeric film  602  and the fan blade  507 . The fan deck has a weight from about 1.5 to about 30 ounces excluding weight of the individual fan blade by which the fan deck  100  is held. 
     With reference to  FIGS. 6, 8, and 9 , another approach includes a foldable overlay flap  621  that is configured to be folded along a fold line  623 , which may be a perforated or scored portion of the film. In the illustrated example, the foldable overlay flap  621  is made of the same polymeric film  602  that is adhered to the fan blade  507 . The overlay flap  621  is removably adhered to cover at least a portion of the channel  572  to block removal of the at least one individual blade  507  from the fastener  160  by blocking movement of the planar connector  550  relative to the fastener  160 . In other words, by adhering the portions of the fan blade and polymeric film that define the channel  572  together, the channel  572  is unlikely to open during regular use such that the fan blade  507  inadvertently becomes removed from the fastener  160 .  FIG. 8  illustrates example dimensions for one such approach to having a polymeric film  602  including a foldable overlay flap  621  to secure the channel  572 .  FIG. 9  illustrates one such example with the overlay flap adhered to the channel  572 . In this example, the polymeric film  602  is adhered to the planar base  115  using adhesive  603 . The adhesive  603  is a long term and non-removable adhesive to secure the polymeric film  602  to the fan blade  507 . In contrast, a removable adhesive  613  is applied to either the polymeric film surface  602  or to the inside of the overlay flap  621  such that when the overlay flap  621  is folded along a fold line  623 , the removable adhesive  613  adheres the overlay flap  621  to the polymeric film  602  over at least a portion of the channel  572 . In this way, the overlay flap  621  may be readily peeled off of the polymeric film  602  and the channel  572  to allow the individual blade  507  to be removed from or added to a fan deck  100 . 
     Turning to  FIGS. 10 and 11 , the planar connector  1050  comprises a polymeric tongue  1002  connected to and extending from the edge  1012  of the fan blade  1007 . By one approach, the polymeric tongue  1002  is comprised of the polymeric film such as that described above. In this example, the at least one opening  1070  in the fan blade  1007  is defined not by the fan blade body itself but instead by the polymeric tongue  1002  which extends from the edge  1012  of the fan blade  1007 . Similarly, the channel  1072  is defined by the polymeric tongue  1002 . The channel  1072  may have any of the features described above with respect to the other approaches to the channel including, for example, having a narrowing or shoulder  1076  next to the opening  1070  to help secure the fastener  160  within the opening  1070 . The channel  1072  then will extend to the edge  1052  of the tongue  1002  where the fastener  160  can slide out of the channel end  1074  during removal of the fan blade  1007  from the fan deck  100 . 
     Referring to  FIG. 11 , the polymeric tongue  1002  can be adhered to the fan blade  1007  using a non-removable adhesive  1003 . As illustrated in  FIG. 11 , the polymeric tongue  1002  may be adhered to the back or bottom of the fan blade  1007 , or, as illustrated in  FIG. 10 , the polymeric tongue  1002  may be adhered to the top or front of the fan blade  1007 . By still another approach, the polymeric tongue  1002  may be laminated or adhered via legs to both or either of the top and bottom of the fan blade  1007  with the opening  1070  and channel  1072  being positioned above the edge  1012  of the fan blade  1007 . In this approach, the fan blade  1007  need not be die-cut during the manufacturing process; instead the opening  1070  and channel  1072  is only die-cut into the polymeric tongue  1002  either before or after being adhered to the fan blade  1007 .  FIG. 12  illustrates one example set of dimensions for the polymeric tongue  1002 , and other dimensions and shapes are possible for the polymeric tongue  1002 . Referring to  FIG. 13 , the polymeric tongue  1002  may further include an optional foldable overlay flap  1021  that folds along a line  1023 , which may be a perforated or scored portion of the film, to adhere to and cover at least a portion of the channel  1072 . Accordingly, the flap  1021  can be adhered to the channel  1072  to further strengthen the channel and prevent flexing of the planar connector  1050  to secure the fastener within the opening  1070 . As discussed above, the thickness of the polymeric tongue  1002  and the necessity of having the flap  1021  depends upon, in part, the weight of the fan deck that would be supported by the individual blade  1007  when a user holds the fan deck by the one individual blade  1007  during typical use. 
     So configured, an individual fan blade displaying paint on one or both sides is particularly configured to be added to and removed from a color display fan deck without having to open the fastener of the color display fan deck. The configuration or dimensions of the opening and channel of a particular version of the planar connector for the individual fan blade can be tailored to a particular application such that the planar connector  1050  will not deform and the fan blade  1007  will not accidently be removed from the fan deck during typical use. Thus, each of the options described above can be combined in different ways to achieve a satisfactory deformation strength of the planar connector  1050  to support the fan deck. In this way, a color fan deck can be modified and fan blades can be replaced or added to a given fan deck by moving the fastener for a given fan deck through the individual blade&#39;s channel so that the opening surrounds the fastener to pivotably secure the individual blade within the fan deck. The planar connector of the individual blade holds the fan deck&#39;s weight without deformation to prevent separation of the individual blade from the fastener when the fan deck is held by one individual blade. 
     Example methods of making a fan blade for displaying paint color that is removable from a color fan deck having a plurality of fan blades without removing the fastener that pivotably holds the fan blades together will be described with reference to  FIG. 14 . One method includes receiving  410  the fan blade that may be made pursuant to any applicable fan blade construction method. The fan blade is die-cut  1420  to define within the fan blade an opening having an opening width configured to surround a fastener to permit the fan blade to be pivotably held with a plurality of other fan blades within a color display fan deck. The die-cutting also defines within the fan blade a planar connector of the fan blade defining a channel that extends from a first channel end at the opening to a second channel end at or near an edge of the fan blade. The channel permits removal and/or addition of the fan blade to/from the fastener to effect a changing of the color display fan deck without the fastener being opened or removed from the color display fan deck. The die-cutting will be adapted to provide cutting the fan blade such that the planar connector having a thickness from thickness of from about 0.5 mils to about 100 mils (about 0.0005 inch to about 0.10 inch) will have a deformation strength sufficient to hold the color display fan decks weight from the fastener without deformation to prevent opening the channel to a width larger than the fasteners width. The planar connector will further have flexibility and resiliency to flex sufficiently to permit opening the channel to a width larger than the fasteners width to allow removable and/or addition of the fan blade from/to the fastener when desired. 
     Where a polymeric film is used, the method may include adhering  1415  the polymeric film to one or both sides of the individual blade where the polymeric film surrounds the at least one opening and the channel. The polymeric film may have a width of about five point to about seven point depending on the deformation strength sufficient to hold the fan deck in which the fan blade is contemplated to be used. As discussed above, the polymeric film to be adhered to the fan blade may be one of polyethylene, polypropylene, and polyethylene terephthalate or other suitable material. When using the polymeric film, the step of die-cutting  1420 , the fan blade may further include die-cutting the fan blade together with the polymeric film after the polymeric film has been adhered  1415  to one or both sides of the fan blade. Such an approach would remove the need for precision in aligning the polymeric film having its own opening and channel with the opening and channel of the fan blade. 
     In the option where the polymeric film includes an overlay flap, the method may include applying releasable adhesive  1425  to releasably adhere a portion of the polymeric film over at least a portion of the channel. The flap may be folded  1430  where the flap is a portion of the polymeric film over itself to cover at least a portion of the channel. The releasable adhesive adheres the flap of the polymeric film to itself over the portion of the channel. 
     Whether the planar connector is made out of the fan blade itself, a combination of the fan blade and the polymeric film, or just out of the polymeric film in the form of a tongue extending from the fan blade, the fan blade is mounted  1435  to a fastener to help create a fan deck. So configured, the fan blades can be readily adapted for use in a fan deck to provide flexibility and provision of color pallets to users and customers without the difficulties in undoing a fastener or otherwise destroying a fan deck in the process of modifying the color pallet. The fan blade may be simply die-cut with a particular channel and opening sufficient to hold the weight of the fan deck, or a further in-line process may be applied to a fan blade manufacturing process to adhere or laminate a polymeric film to the fan blade to provide additional or supplemental strength for the planar connector used to connect the fan blade to the fan deck&#39;s fastener. 
     Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.