Abstract:
An improved system of virtually seamless connected awning sections with a consistent visual appearance between the sections. A recessed awning bead encased with the fabric covering material chosen for the awning is contoured to, and fit into, a novel channel in the awning frame members. The awning bead allows for uniform weathering and fading of all visible awning parts. Such an improved awning is more aesthetically pleasing because no part of the seam protrudes above the plane of the awning surface. A narrowed neck of the channel in the awning frame member maintains the awning bead within the channel and thus slightly below the exterior awning surface in order to maintain a consistent surface between panel sections.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     This application is entitled to the benefit of Non-Provisional patent application Ser. No. 11/091,112 titled “Perma-Stitch Awning Staple System” filed on Mar. 23, 2005 by inventor Kennon Kyle McKinney, the technical disclosure of which is incorporated herein by reference, and to the benefit of the Provisional Patent Application Ser. No. 60/555,228 filed on Mar. 23, 2004. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT  
       [0003]     Not Applicable  
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC  
       [0004]     Not Applicable  
       BACKGROUND OF THE INVENTION  
       [0005]     1. Field of the Invention  
         [0006]     The present invention relates generally to the manufacturing and installation of commercial and residential awnings and fabric framing structures. More specifically, the present invention allows awnings and other fabric framing structures such as canopies, boat coverings, displays, signs, and the like to be manufactured and installed as a series of individual sections while presenting the appearance of a single, continuous assembly without obvious seams.  
         [0007]     2. Description of Related Art  
         [0008]     Traditional awnings and fabric framing structures consist of forming a rigid frame to the desired, often arcuate, shape. Over the rigid frame are stretched panels of a fabric material. The fabric panels are typically held in place by staples that are driven into a channel present in the rigid framing members. To hide the staples and seal the channel from the elements, a PVC bead is often pressed into the channel to fill the exposed gap. The PVC bead protrudes from the channel and extends well beyond the plane of the fabric panel. This results in an inconsistent appearance between the panels of fabric material due to the high visibility of the PVC bead. Also, the inconsistent appearance is further accentuated as the fabric panels weather due to exposure to the elements. This is because the fabric panels weather at a different rate than the PVC bead. Attempts have been made to attach fabric to the top surface of the PVC bead, but all this has done is further exaggerate the seam and make it even more visible. Also, the typical framing members feature essentially square channels which make it somewhat difficult to retain fabric panel material that has been stored in rolls. Essentially, when the fabric material is unrolled and placed in the channel the square bottom edges result in relatively large void spaces beneath the curving fabric that increase the difficulty in applying the retaining staples.  
         [0009]     U.S. Pat. No. 4,926,605 (&#39;605 patent) discloses a construction assembly for fabric closures such as awnings.  FIG. 1  illustrates an embodiment of this invention. This patent provides for framing members of different outer shapes, with an essentially square inner channel wherein staples are driven so as to secure the outer fabric panels to the framing member. Once stapled, an elongated trim pad (“bead”) is pressed into the channel to cover the staples and provide a tight seal over the channel. The disclosed elongated trim pad has coplanar longitudinal slots that engage in the opening of the channel for retention of the pad while the remainder protrudes above the surface of the fabric covering material. This patent is distinguished because the trim pad protrudes above the surface of the fabric covering material. Also, the trim pad is of a material different than that of the fabric covering material. This will cause the trim pad to weather at a rate different than that of the fabric covering material which will only serve to increase the visibility of the seams. In addition, this patent is distinguishable because it discloses an essentially square channel in the framing member which makes it more difficult to apply the staples necessary to retain the fabric covering material.  
         [0010]     U.S. Pat. No. D309,351 (&#39;351 patent) is a design patent that discloses an ornamental design for a combined frame extrusion and spline for framing awnings.  FIG. 2  illustrates an embodiment of this invention. The disclosed extrusion features a framing member with a square channel, within which the fabric awning material is retained by a spline (“bead”) that is pressed into the channel and is retained by the two coplanar longitudinal slots in the spline. This patent is distinguished by the spline because it protrudes above the surface of the fabric surface. Also, this patent is distinguished by the square shaped channel present in the framing member.  
         [0011]     U.S. Pat. No. 5,044,131 (&#39;131 patent) discloses a fabric awning assembly, method of assembling a fabric awning assembly, and a novel divider bead for spanning the joints between awning frame sections.  FIG. 3  illustrates an embodiment of this invention. The disclosed divider bead fits between two framing members whose channels have been rotated such that they face each other when the framing sections are joined. This patent is distinguished because the novel divider bead protrudes above the surface of the fabric covering material and is of a different material such that it will weather at a rate different than that of the fabric covering material.  
         [0012]     U.S. Pat. No. 5,076,033 (&#39;033 patent) discloses a method of joining fabric framing structures.  FIG. 4  illustrates an embodiment of this invention. Because this patent is from the same inventor, it features the same frame extrusion and spline as the &#39;351 patent. This patent is distinguished because it claims a method of joining the framing structures. Also, the spline featured extends above the surface of the fabric covering material. The framing member also features a square shaped channel.  
         [0013]     U.S. Pat. No. 5,555,695 (&#39;695 patent) discloses a channeled extrusion for framing and holding flexible coverings, such as awnings and other fabric framing structures.  FIG. 5  illustrates an embodiment of this invention. This patent is distinguished because it merely discloses various channeled extrusions, each with an essentially square fabric attachment cavity. No means, other than staples, for retaining the fabric covering material is mentioned.  
         [0014]     U.S. Pat. No. 5,794,400 (&#39;400 patent) discloses a composite framing member and the method of producing it.  FIG. 6  illustrates an embodiment of this invention. The disclosed framing member features a square shaped channel for accepting the fabric covering material and the requisite fabric retention staples. This patent is distinguished because it applies to the manufacture of a framing member with a square shaped channel. Also, the bead featured in the drawing protrudes above the surface of the fabric covering material, making the seam highly visible.  
         [0015]     The Fabric ZipStrip® manufactured by Steel Stitch Corporation is a commercially available PVC bead used to fill the channel void space of a framing member after the fabric covering material has been stapled to the channel.  FIG. 7  illustrates an embodiment of this product. The PVC bead utilized to make the ZipStrip® is similar to the beads disclosed in the previously mentioned prior art in that it features two coplanar longitudinal slots that serve to positively engage within the opening of the channel in the framing member. The outer surface of the ZipStrip® is covered with a strip of fabric covering material, which is sewn directly to the outer surface. This product is distinguished because the ZipStrip® bead, once installed, protrudes well above the surface of the fabric covering material, making the seam highly visible. Also, the stitching used to retain the fabric greatly increases the bead&#39;s visibility.  
         [0016]     Nothing in the prior art addresses the problems associated with providing an awning and fabric framing structure with consistent, inconspicuous seams that, when combined with additional fabric framing structures, presents the appearance of being one, continuous, consistent unit. Therefore, a need exists for a method of conjoining separate fabric framing structure sections such that they appear to be one continuous unit with consistent, inconspicuous seams. Further, a need exists for a framing member channel that is shaped to provide for easier application of retention staples and increased gripping and retention of the fabric covering material. Further, a need exists for a retention bead that sits completely within the void space within the framing member&#39;s fabric covering material retention channel and does not protrude above the surface of the fabric covering material. And further, a need exists for a retention bead that weathers and wears at the same rate as the fabric covering material so as to make the seam between the two inconspicuous. The present invention fills these needs and other needs as detailed more fully in the remainder of the specification.  
       BRIEF SUMMARY OF THE INVENTION  
       [0017]     The present invention overcomes many of the disadvantages of the prior art by providing a method of conjoining discreet sections of awnings and other fabric framing structures in such a manner so as to give the sections the appearance of a single, continuous unit with inconspicuous seams. Prior art designs typically feature a flexible bead that is pressed into the channel space in the framing members to fill the gap between stapled sections of the fabric covering material. This prior art bead is highly visible because it protrudes above the surface of the fabric covering material and is of a different material than the fabric panels. This difference of materials creates an uneven appearance due to the different weathering characteristics.  
         [0018]     The disclosed method of assembling discreet sections of awnings or other fabric framing structures creates a seam between the discreet sections that is consistent in appearance to the other fabric panel seams in each section. The method includes a novel recessed bead apparatus that is encased with the same material as that chosen for the fabric covering material which allows it to weather consistently with the rest of the fabric. Also, the recessed bead fits completely and securely within the fabric retention channel within the framing members and does not protrude above the surface of the fabric covering material. This affords seams that are inconspicuous and consistent in appearance.  
         [0019]     Also, the disclosed method includes a novel framing member channel that is shaped to allow easier application of retention staples and improved retention of the fabric covering material. The channel is shaped so that the fabric covering material, which is typically stored in rolls, will contact the walls of the channel and prevent the formation of void spaces. Also, the channel features longitudinal grooves to assist in the trimming of excess fabric covering material. Once the material has been attached within the channel and before the bead is inserted, the excess material is trimmed from the channel. The grooves afford a clean, strait cut by providing a guide for the tip of the trimming knife to follow.  
         [0020]     Accordingly, it is one general object of the invention to provide a retention bead that weathers at the same rate and appears visibly consistent with the fabric covering material. It is another general object of the invention to provide a retention bead that sits completely within the channel of the framing member and does not protrude above the surface of the fabric covering material. It is another general object of the invention to provide an improved means of inserting and retaining the fabric covering material within the framing member channel. It is yet another general object of the invention to provide an improved means for trimming the excess fabric covering material from within the framing member channel. The invention accordingly comprises the features described more fully in the remainder of the specification, and the scope of the invention will be indicated in the claims. Further objects of the present invention will become apparent in the following detailed description read in light of the drawings.  
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)  
       [0021]     J The present invention will be more fully understood by reference to the following detailed description of the preferred embodiments of the present invention when read in conjunction with the accompanying drawings, in which like reference numbers refer to like parts throughout the views, wherein:  
         [0022]      FIG. 1  is a cross-sectional view of a prior art construction assembly for closures and awnings that utilizes a traditional square shaped channel and retention bead that protrudes above the surface of the fabric covering material;  
         [0023]      FIG. 2  is a perspective view of a prior art ornamental design for a combined frame extrusion and spline for framing awnings;  
         [0024]      FIG. 3  is a cross-sectional view of a prior art fabric awning assembly and protruding divider bead used in conjoining two discreet sections of an awning assembly;  
         [0025]      FIG. 4  is perspective view of a prior art apparatus for conjoining parallel structural members of two discreet sections of an awning assembly, with the framing members shown in conjunction with the protruding bead;  
         [0026]      FIG. 5  is a perspective view of a prior art channeled extrusion illustrating the essentially squared inner channel surface for attaching and retaining the fabric covering material;  
         [0027]      FIG. 6  is a cross-sectional view of a prior art composite frame member illustrating the essentially squared inner channel surface for attaching and retaining the fabric covering material by using staples and a protruding bead;  
         [0028]      FIG. 7  is a perspective view of a prior art commercial product known as a “Fabric ZipStrip®” which utilizes fabric material sewn to the outer surface of a conventional bead;  
         [0029]      FIG. 8  is a perspective view of an embodiment of the present invention illustrating a single sheet of fabric covering material attached to the inner channel of the framing member and being positively retained by the use of a flexible bead encased in the same material as the fabric covering;  
         [0030]      FIG. 9  is a cross-sectional view of an embodiment of the present invention illustrating the attachment and retention of two sheets of fabric covering material within the frame member channel using staples and an recessed bead;  
         [0031]      FIG. 10  is a cross-sectional view of an embodiment of the present invention illustrating only the channel of the frame member;  
         [0032]      FIG. 11  is a perspective view of an embodiment of the present invention illustrating only the recessed bead;  
         [0033]      FIG. 12  is a cross-sectional view of an embodiment of the present invention illustrating the recessed bead in the shape of an octagon;  
         [0034]      FIG. 13  is a cross-sectional view of an embodiment of the present invention illustrating the recessed bead in the shape of a trapezoid;  
         [0035]      FIG. 14  is a cross-sectional view of an embodiment of the present invention illustrating the recessed bead in the shape of a pentagon;  
         [0036]      FIG. 15  is a perspective view of the cross-section of the seam between two discreet sections of a fabric structure, conjoined so as to present a seam appearance similar to that created by the novel recessed bead; and  
         [0037]      FIG. 16  is a perspective view of two discreet sections of an awning structure utilizing an embodiment of the present invention to present a consistent seam appearance, conjoined using the methods disclosed. 
     
    
       [0038]     Where used in the various figures of the drawing, the same reference numbers designate the same or similar parts. Furthermore, when the terms “top,” “bottom,” “first,” “second,” “upper,” “lower,” “height,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,”and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the invention.  
         [0039]     All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following teachings of the present invention have been read and understood.  
       REFERENCE NUMBERS  
       [0000]    
       
           800  awning bead and staple system  
           802  bead  
           804  core  
           806  encasement  
           808  channel  
           810  framing member  
           812  groove  
           814  staple  
           816  fabric covering material  
           1500  center seam  
           1600  awning system  
       
     
       DETAILED DESCRIPTION OF THE INVENTION  
       [0051]     Turning now to the drawings in which like reference numbers represent like parts throughout the several views of the drawings,  FIG. 8  illustrates a perspective view of one embodiment of the present invention.  FIG. 8  details one embodiment of the awning bead and staple system  800  in which only one sheet of fabric covering material  816  is attached using the novel bead  802  and channel  808  disclosed herein. In a typical awning installation, the framing members  810  are measured and bent to an arcuate shape prior to installation. Once bent, the chosen fabric covering material  816  is stretched across the framing members  810  and fixedly attached to the inner surface of the channel  808  using an attachment means such as nails, screws, tacks, glue, heat tacking (melting of the covering material to the inner channel surface), or staples  814 . The longitudinal groove  812  on the inner surface of the channel  808  serves as a guide for trimming excess fabric covering material  816  from the channel  808 . After the fabric covering material  816  has been attached and tensioned over the framing members  810 , the tip of a trimming knife is inserted into the groove  812  and slid the length of the fabric covering material  816 . This affords a clean, straight cut on the edge of the fabric covering material  816  prior to bead  802  insertion. Finally, a flexible bead  802  is inserted into the channel  808  such that it fills the remaining void space of the channel  808  and does not protrude above the top surface of the fabric covering material  816 .  
         [0052]      FIG. 9  illustrates a cross-sectional view of an embodiment of the present invention in which two sheets of fabric covering material  816  are attached using the novel bead  802  and channel  808  disclosed herein. The sheets of fabric covering material  816  are inserted, one at a time, such that the inserted edge of each sheet wraps almost completely around the inner surface of the channel  808  without extending beyond the opposite side of the channel  808  opening. Once inserted, the fabric covering material  816  is fixedly attached to the inner surface of the channel  808  using an attachment means such as previously mentioned. The longitudinal groove  812  on the inner surface of the channel  808  further serves to increase the gripping strength of the channel by allowing some of the fabric covering material  816  to extend into the groove  812 . Once attached, a flexible bead  802  is inserted into the channel  808  such that it fills the remaining void space of the channel  808  and does not protrude above the top surface of the fabric covering material  816 .  
         [0053]      FIG. 10  is a cross-sectional view of a framing member  810  of an embodiment of the present invention. The channel  808  illustrated is essentially circular, but can be any other shape as long as the channel opening is narrower than the overall width of the channel  808 . Formed in the inner surface of the channel  808  are grooves  812  that run longitudinally with respect to the channel  808  surface. With respect to  FIGS. 8 and 9 , each groove  812  is intended to act as a guide for the tip of a fabric trimming knife. This provides for a clean, straight cut on the edge of the attached fabric covering material  816  in order to remove the excess from the channel  808  prior to bead  802  insertion. Also, this grove  812  has the added benefit of providing increased gripping strength by allowing a portion of the fabric covering material  816  to extend into the groove  812 . For instance, if an adhesive is utilized as an attachment means between the fabric covering material  816  and the inner surface of the channel  808 , the adhesive will tend to gather in the groove  812  as well which will further increase the gripping strength. Thus, the groove  812  also increases the surface area of the inner surface of the channel  808  which consequently increases the friction between the inner channel  808  surface and the inserted fabric covering material  816 .  
         [0054]     With respect to  FIGS. 8, 9 , and  10 , a circular inner surface of the channel  808  allows for easier installation of the fabric covering material  816 . The typical awning fabric utilized as a covering material tends to be quite stiff. Because it is usually stored in rolls, this imparts a natural tendency for the material to want to curl when unrolled. To leverage this natural tendency for the covering material to curl, an essentially circular channel  808  is provided. Thus, the natural curl will tend to cause the fabric covering material  816  to lay flat against the inner surface of the channel for easier insertion of staples  812  or other attachment means.  
         [0055]     The framing member  810  is constructed from metal, preferably aluminum. Aluminum is chosen because it is lightweight, rigid, corrosion resistant, easily formable, and relatively inexpensive. Also, aluminum readily accepts metal staples  814  (such as steel or stainless steel) that are typically used to retain the covering material  816 . The framing member  810  can also be manufactured from other more rigid materials, such as galvanized steel, for use in areas with high wind loads. When galvanized steel is used, an aluminum insert is typically added to the inner surface of the channel  808  to allow for the ability to utilize staples to retain the fabric covering material  816 . It is further possible to substitute other materials for the framing member  810  depending upon the structural requirements of a particular awning or other fabric framing structure.  
         [0056]     As demonstrated by the prior art, a typical bead used in awning and framing structure manufacture has somewhat of a “T” shaped cross-section with coplanar longitudinal slots to provide positive retention in the opening of a framing member&#39;s channel.  FIG. 11  illustrates an embodiment of the present invention which is a novel bead  802  with a circular shaped cross-section. With respect to  FIGS. 8 and 9 , the bead  802  can have essentially any shaped cross-section providing that it can sit entirely within the channel  808  of the framing member  810  and not protrude beyond the top surface of the fabric covering material  816 . Ideally, the bead  802  will be the same cross-sectional shape as the channel  808 . However, that is not a necessity. For instance, it is possible to utilize an octagonal bead  802  (as illustrated in  FIG. 12 ) inside an essentially circular channel  808  as long as the diameter of the bead  802  is sufficient to positively engage the entire inner surface of the channel  808 . An octagonal bead  802  in a circular channel  808  can actually improve the sealing effect of the bead  802  due to the increased pressure points on the tips of the edges. In addition, the bead  802  should not protrude above the surface of the fabric covering material  816 .  
         [0057]     In the preferred embodiment, and with respect to  FIGS. 11 through 14 , the bead  802  consists of a flexible core  804  and an encasement  806 . The core  804  can be made from a semirigid yet flexible material such as PVC, foam cord, rope, or even a roll of the same fabric as that chosen for the fabric covering material  816 . This affords the bead  802  a certain amount of strength and compressibility to allow the bead  802  to pass, with force, through the channel  808  opening and for the channel  808  opening to still physically retain the bead  802 . Around the core  804  is an encasement  806  material. In the preferred embodiment, the encasement  806  material is the same as the fabric covering material  816  chosen for the outer face of the fabric framing structure. The encasement  806  is attached to the core  804  by any suitable means, such as adhesive or heat welding. If the same fabric covering material  816  is chosen for the encasement  806 , this will ensure that both the encased bead  802  and the fabric covering material  816  weather and wear at the same rate and present the same visible appearance. If the core  804  is made from the same material as that chosen for the fabric covering material  816 , then an encasement  806  is not necessary as long as the core  804  is the proper diameter to fit snuggly within the channel  808 .  
         [0058]      FIG. 16  is a perspective view of an awning system  1600  comprised of two independent sections of an arching awning constructed using the awning bead and staple system according to the present invention.  FIG. 15  illustrates a cutaway view of the center seam  1500  between the two awning sections. With reference to  FIG. 16 , a fabric covering material  816  is stretched over several framing members  810 . On side facing the fabric covering material  816 , the framing members  810  have channels  808  for receiving an awning bead  802 . The fabric covering material  816  may be any material known in the art to provide a covering over frame members  810 . Standard tubing without a channel can be used to create the frame in sections where there is no fabric covering material  816  seam which requires anchoring to the frame.  
         [0059]     In the center region of the awning system  1600  of  FIG. 16 , the fabric covering material  816  is drawn tightly together using an embodiment of the present invention shown in  FIG. 15 . With reference to  FIG. 8 , the outer two framing members  810  are assembled by placing and securing the edge of the fabric covering material  816  into the channel  808  of each framing member  810  and rotating each of said framing members  810  such that the respective channels  808  are facing and the fabric covering material  816  enters the seam from the top. In this manner, the two sections of fabric covering material  816  are abutted tightly against each other.  FIG. 15  shows that the awning bead  802  is not necessary when used in this configuration. However, the addition of an awning bead  802  would provide increased gripping strength for the fabric covering material  816 .  
         [0060]     It will now be evident to those skilled in the art that there has been described herein an improved computer-based learning system that through a combination of repetitive narrative solutions and multiple choice questions greatly facilitates trainee learning, improving significantly the retention of information over existing training methods.  
         [0061]     Although the invention hereof has been described by way of a preferred embodiment, it will be evident that other adaptations and modifications can be employed without departing from the spirit and scope thereof. For example, some of the steps in the system procedure could be conducted mechanically in addition to those conducted electrically. The terms and expressions employed herein have been used as terms of description and not of limitation; and thus, there is no intent of excluding equivalents, but on the contrary it is intended to cover any and all equivalents that may be employed without departing from the spirit and scope of the invention.