Abstract:
An enclosure for a room, patio, or the like is made of modular parts that hide from view all fasteners and other functional parts. The parts include upstanding regular posts, corner posts, open back posts, horizontal beams and chair rails, as well as door frames, door jambs, door sweeps, and other parts required for an enclosure construction. Aesthetic cover members are snap-fittingly engaged to the modular parts and confronting pairs of the cover members, in a first embodiment, are very closely spaced to one another to accommodate a screen between them. In second and third embodiments, the confronting cover members have larger spaces between them to accommodate opaque, translucent, or transparent panels of about one-half inch and three-quarter inches, respectively.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates, generally, to apparatus and methods for making enclosed structures of various types that include screens and/or panels of opaque, translucent, or transparent construction. More particularly, it relates to a construction technique that hides all of the unattractive parts of a screen, panel, or glass enclosure. 
     2. Description of the Prior Art 
     Screen, panel, and/or glass enclosures such as rooms, patios, porches, and the like are built by erecting frames that may include headers for attachment to an existing structure, posts, beams, door jambs, door sweeps, chair rails, and the like. Screens, opaque or translucent panels, and/or glass panels complete the structure. In a screen enclosure, various parts of the frame include channels formed therein that receive elongate rubber liners that are inserted, with a well-known hand tool that includes a roller, into the channels in overlying relation to the screen edges to secure the screens into position. Conventional construction techniques result in the liners being exposed to view, along with flanges, nuts, bolts, and other utilitarian but unsightly parts. In panel enclosures, whether of opaque, translucent, or glass panels, conventional construction techniques also leave bolts and the like in view. 
     What is needed, then, is a construction technique that hides from view not only the rubber liners that hold screens into place, but also the bolts and other such parts as well in screen and panel/glass enclosures. 
     However, in view of the art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in this art how such a construction method could be provided. 
     SUMMARY OF THE INVENTION 
     The long-standing but heretofore unfulfilled need for an apparatus that overcomes the limitations of the prior art is now met by a new, useful, and nonobvious invention. The present invention includes a method for building a screen or a panel/glass enclosure. 
     An elongate frame member having a predetermined extent and having a predetermined number of sides is provided. A first pair of cover-engaging members are formed along the extent of the frame member on a preselected first side thereof. A second pair of cover-engaging members is formed along the extent of the frame member on the first side thereof in transversely spaced apart relation to the first pair of cover-engaging members. An elongate first cover is attached to the first pair of cover-engaging members, and in a screen enclosure embodiment, a preselected screen edge is attached to the first cover by inserting a screen retaining means into a screen retaining means-receiving groove formed in the first cover. The screen retaining means overlies the preselected screen edge. 
     An elongate second cover is attached to the second pair of cover-engaging members. In the screen enclosure embodiment, the first and second covers are sized and configured so that they confront and substantially abut one another along their respective extents when attached to their respective cover-engaging members and so that they collectively cover the preselected side of the frame member. In the screen enclosure embodiment, the screen retaining means-receiving groove is positioned in the first cover so that it cannot be seen when the first and second elongate covers are respectively attached to the first and second cover-engaging members in confronting relation to one another. 
     In this way, a screen edge secured to the first cover is sandwiched between the first and second covers, the screen retaining means that secures the screen edge to the first cover is hidden from view, the first and second pairs of cover-engaging members are hidden from view, and the first side of the frame member is hidden from view. 
     There is no screen or screen-retaining groove formed in the cover members in the panel/glass enclosure embodiment. 
     In all embodiments, a pair of depending legs are integrally formed with each cover member, and the legs snap-fittingly engage the cover-engaging members formed on the various frame members. 
     In the screen enclosure embodiment, the depending leg nearest the screen is transversely offset in a direction away from the screen so that when two cover members are snapped into their respective cover-engaging members, the cover members abut one another and sandwich a screen therebetween. 
     In a first panel/glass enclosure embodiment, the depending leg nearest the opaque, translucent, or transparent panel is in co-planar alignment with the edge of the cover nearest the panel. Thus, there is a panel-accommodating space between confronting cover members. 
     It should be appreciated that as used hereinafter, the term &#34;panel&#34; or &#34;panel/glass&#34; includes opaque, translucent, and transparent panels such as glass or acrylic panels. It should also be understood that a single enclosure when fully constructed may include any number and mixture of screens, opaque panels, translucent panels, and transparent panels. 
     In a second panel/glass enclosure embodiment, the depending leg nearest the panel is transversely offset toward the panel, thereby creating a panel-accommodating space that is greater than the panel-accommodating space of the first embodiment. 
     In both panel enclosure embodiments, a panel is supported along its edge by a flat wall formed in the frame member that divides the first and second pair of cover-engaging members from one another. 
     It is a primary object of this invention to advance the art of screen and panel/glass enclosure construction by providing parts and methods that hide bolts, nuts, rubber liners, and the like from view so that the screen or panel/glass enclosure has a very high level of aesthetic appeal. 
     Another object is to provide screen and panel enclosure construction methods having minimal reliance on tools and having, instead, many parts that are snapped together in the absence of tools. 
     Yet another object is to provide novel frames for panel enclosures made from panels of varying thicknesses. 
     These and other important objects, features, and advantages of the invention will become apparent as this description proceeds. 
     The invention accordingly comprises the features of construction, combination of elements and arrangement of parts that will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which: 
     FIG. 1 is an exploded, perspective view of a screen enclosure made in accordance with the teachings and suggestions of this invention; 
     FIG. 1A is a sectional view of a corner post; 
     FIG. 1B is a sectional view of an open-back post; 
     FIG. 1C is a sectional view of a variable degree corner post; 
     FIG. 1D is an end view of a flat slope adapter; 
     FIG. 1E is an end view of a pitched slope adapter; 
     FIG. 1F depicts a pitched slope adapter engaged to a beam; 
     FIG. 2 is a transverse sectional view taken along line 2--2 in FIG. 1; 
     FIG. 2A is a transverse sectional view taken along line 2A--2A in FIG. 1. 
     FIG. 3 is an end view of a cover member used in the screen enclosure embodiment; 
     FIG. 3A is an end view depicting two of the FIG. 3 cover members when disposed in confronting relation to one another; 
     FIG. 4 is an end view of a cover member used in a first panel enclosure embodiment; 
     FIG. 4A is an end view depicting two of the FIG. 4 cover members when disposed in confronting relation to one another; 
     FIG. 5 is an end view of a cover member used in a second panel enclosure embodiment; 
     FIG. 5A is an end view depicting two of the FIG. 5 cover members when disposed in confronting relation to one another; 
     FIG. 6A is an end view of a connecting bracket; 
     FIG. 6B is a sectional view taken along line 6B--6B in FIG. 1. 
     FIG. 7 is a front elevational view of a screen door assembly including the novel parts; 
     FIG. 8 is a sectional view taken along lines 8--8 in FIG. 7; 
     FIG. 8A is an end view of a novel frame cover that serves as a door jamb; 
     FIG. 9 is a sectional view taken along line 9--9 in FIG. 7; and 
     FIG. 9A is an end view of a novel frame cover that serves as a bottom door sweep. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIG. 1, it will there be seen that an exemplary embodiment of the invention is denoted as a whole by the reference numeral 10. 
     Enclosure 10 is attached to an existing structure 12. A wall header 14, which may be in the form of a channel member as depicted, is secured by suitable means to existing structure 12. A plurality of roof panels 16 have their respective inboard ends snugly received within channel-shaped wall header 14. Their respective outboard ends are supported by at least one transversely disposed beam 18 that is in turn supported by at least one vertically disposed regular post 20 and corner posts 20a (see FIG. 1A). 
     Beams 18 and posts 20 have the same structural configuration but are given separate reference numerals in view of their different functions. Chair rails 19 also have the same configuration, but may have less vertical extent than a post or a beam. The cross-sectional view provided in FIG. 2 is thus the same for a post or a beam. In the claims that follow, beams 18, chair rails 19, and posts 20 are generically referred to as frame members. 
     The respective longitudinal sides 16a of the panels 16 are interlocked to one another in well known ways and the longitudinally disposed sides of the completed roof are supported by at least one longitudinally disposed beam 18. 
     The slope of the roof formed by roof panels 16 varies between applications. Accordingly, a slope adapter such as slope adapter 17a or 17b is snap-fittingly attached to transverse beam 18 to support roof panels 16 of varying pitches; see also FIGS. 1D and 1E. Slope adapter 17a is used for a relatively steep roof and slope adapter 17b, which is essentially unsloped, is employed in roofs having nominal slope. For example, a 1/2/12 pitch adapter 17c is depicted in FIG. 1E. Slope adapters 17a, 17b are provided in any slope desired. Note that each adapter has a pair of depending legs and that each depending leg has a detent formed in its free end. These detents releasably engage beam 18 in the manner depicted in FIG. 1F. 
     An upstanding half-post member 20b (see also FIG. 1B), preferably known as an open-back post, is secured to a vertical wall of existing structure 12 by any suitable means; it performs substantially the same function as regular posts 20 and corner posts 20a, but since it is mounted to existing structure 12, it may be longitudinally bisected to save materials, i.e., a single regular beam 18 is bisected to provide two open-back posts 20b, thereby saving materials. In a simple screen enclosure, only two half posts are needed because each abuts an existing structural wall as depicted; FIG. 1 depicts only one open-back post to simplify the drawing. 
     Regular posts 20, corner posts 20a, and open-back posts 20b are all supported at their respective lowermost ends by a suitable support surface such as a concrete slab 24. 
     Open-back posts 20b are also positioned horizontally in overlying relation to concrete slab 24, along the peripheral edges thereof as depicted. At their respective opposite ends, they abut regular posts 20, corner posts 20a, and upstanding cover-posts 20a. Since they are horizontally disposed, the open-back posts that overlie support surface 24 are termed open-back beams 18a. 
     Chair rails 19 are also provided in the form of regular posts 20 but are beam-like in view of their horizontal orientation. 
     FIG. 1C depicts a variable degree corner post 20c that includes a post 21 pivotally mounted in a channel 23. Arcuate exterior surfaces 25, 25 are slideable with respect to one another as post 21 rotates within channel 23. Accordingly, corner post 20c may be employed in constructions where screens or panels forming different walls are set at an angle other than ninety degrees with respect to one another. 
     FIG. 2 depicts a beam 18 and FIG. 2A depicts a post 20 in transverse cross section. Flat side walls 30, 32 are aesthetically pleasing and therefore need not be covered. Sides 31, 33, however, are functional and not particularly aesthetic; they are completely covered with aesthetic cover members when the novel enclosure is in its fully constructed form. 
     Each functional side 31, 33 includes a pair of cover-engaging members, generally denoted as 34a, 34b. More particularly, each cover-engaging member 34a, 34b includes a bottom wall 35a, 35b that is slightly inset from the respective ends of flat side walls 30, 32, and a pair of overhang members 36a, 36b and 37a, 37b that are parallel to said bottom walls. Each overhang member defines a small undercut or recessed area that is not numbered to avoid cluttering the drawings. 
     Significantly, each pair of cover-engaging members 34a, 34b engages a separate cover member. Each functional side of members 18, 20 is covered for aesthetic reasons by a pair of preferably arcuate cover members disposed in confronting relation to one another, thereby collectively forming an elongate hemispherical profile. In the screen enclosure embodiment, the cover members are sized and complementally configured with respect to one another to substantially abut one another and provide the appearance of a whole cover when attached to their respective cover-engaging members 34a, 34b. In the panel enclosure embodiments, the confronting cover members are transversely spaced apart from one another by an amount sufficient to accommodate a panel therebetween. 
     Both cover members in a pair of cover members, however, are not provided for aesthetic reasons only. In a first embodiment of the cover members, one of them is specifically configured to engage the peripheral edge of a screen. In a second embodiment, both cover members in a pair of confronting cover members are configured to receive therebetween a panel/glass member having a first predetermined thickness, and in a third embodiment, both cover members in a pair of confronting panel members are configured to receive therebetween a panel/glass member having a preselected thickness greater than the thickness of the panel engaged by the confronting panel members of the second embodiment. 
     The first embodiment of cover members is depicted in FIG. 3. Cover member 40 has an arcuate surface 41 that is the only part of the cover member that is exposed to view when construction of the screen or panel enclosure is completed; see FIG. 3A. A first depending leg 42 of generally straight construction has a detent 42a formed in its free end; said detent snap-fittingly engages overhang 36a by snapping into the undercut recess defined thereby when cover member 40 is attached to cover-engaging member 34a. 
     A second depending leg 44 is of irregular form but also terminates as at 44a in a free end that snap-fittingly engages overhang 36b of cover-engaging member 34a, in much the same way as detent 42a of leg 42 is engaged, when cover member 40 is installed. Lips 45 and 46 cooperate with leg 44 to collectively define a recessed area 47 that receives rubber liner 49 when a screen is installed. Liner 49 overlies screen 51 and holds it in recessed area 47, it being understood that said liner is installed with a well-known roller tool. Accordingly, when the confronting counterpart of cover member 40 has its respective detents engaged in the undercuts defined by overhangs 37a, 37b, lip 45 substantially abuts the lip of its confronting counterpart and screen 51 is sandwiched therebetween as depicted in FIGS. 1 and 3A. This conceals from view liner 49, depending legs 42, 44 and cover-engaging members 34a, 34b. Thus, only flat side walls 30, 32 and arcuate cover member walls 41, 41 are visible. 
     It should be noted that depending leg 44, i.e., the inboard leg or the leg nearest the screen, has a transversely offset part 48 that extends away from the screen. This positions the respective inboard edges of the confronting cover members into abutting relation to one another when they are attached to a frame member as perhaps best understood in connection with FIG. 3A. 
     The second embodiment of the novel cover member is depicted in FIG. 4 and is denoted 50 as a whole; the arcuate part thereof that is exposed to view when an enclosure assembly is complete is denoted 53. This embodiment holds an opaque panel, such as a sheet of drywall, also known as sheetrock, or a translucent or transparent panel, between a pair of confronting cover members when they are snap-fittingly engaged to a frame member such as depicted in FIG. 4A. Accordingly, there is no rubber liner-receiving recess as in the first embodiment. Depending legs 52 and 54 end in detents 52a, 54a, respectively, which snap-fittingly engage overhangs 34a, 34b as in the first embodiment. A space of about a quarter of an inch wide, sufficient to receive a quarter inch thick panel/glass, is defined between the inboard surfaces of the confronting cover members. The edge of a panel sandwiched between confronting cover members 50 abuts and is supported by support wall 35c (see FIG. 2) that forms a part of sides 31, 33 of a beam 18 or post 20. The respective free ends of arms 55 and 56 abut said panel and hold it in a vertical position, in sandwiched relation to the respective counterpart free ends of a confronting cover 50. 
     Note that said free ends of arms 55, 56 are co-planar with one another and with the detent 54a formed in the free end of depending leg 54, said leg being nearest the panel. This co-planar alignment, as distinguished from the transverse offset formed in the depending leg nearest the screen in the first embodiment, positions the confronting cover members in a transversely spaced apart relation to one another sufficient to receive a panel/glass of predetermined thickness therebetween. 
     The third embodiment of the novel cover is denoted 60 as a whole in FIG. 5. It includes arcuate visible surface 61 and depending legs 62, 64 which end in detents 62a, 64a, respectively. The respective free ends of arms 65, 66 abut and help support a panel (or sheet of glass or acrylic or the like) having a thickness of about 13/16&#34;, it being understood that said panel is sandwiched between arms 65, 66 and similar arms of a confronting panel 60 (FIG. 5A) and that the innermost edge of said panel abuts support wall 35c (FIG. 2). 
     Transverse offset 68 formed in leg 64, the leg nearest the panel, serves to position the free ends of arms 65, 66 further away from one another than in the second embodiment. 
     FIGS. 6A and 6B depict a connecting bracket 70 that interconnects an upstanding post 20 to a beam 18. Bracket 70 also interconnects beams 18 to corner posts 20a and open back posts 20b. It includes &#34;L&#34;-shaped legs 70a, 70b, 71a, 71b that snap-fittingly fit into the undercut recesses defined by overhang members 36a, 36b and 37a, 37b, respectively, as depicted in FIG. 6B. 
     A screen door and its associated parts are depicted in FIG. 7. As best understood in connection with FIGS. 8 and 8A, the door frame and jamb are both made by attaching a cover member 80 (FIG. 8A) to the confronting inboard surfaces of posts 20, 20 (FIG. 8). Note that the respective outboard sides of said posts are covered by cover members 40 (FIGS. 3 and 3A). Note also that cover member 80 has a pair of depending legs 82, 84 and that a detent 82a, 84a is formed in the free end of each of said legs for snap-fitting engagement with the undercut areas defined by overhangs 36a, 37a of posts 20. A suitable wiper or weather-strip is retained within part 85 of said cover member 80. 
     A similar part 90, depicted in FIGS. 9 and 9A, is used to cover the bottom wall of a horizontal beam 18 in a door sweep construction. Post 90 has depending legs 92, 94 that terminate in detents 92a, 94a, respectively, and which snap-fittingly engage overhangs 36a, 37a. 
     This invention is highly versatile and is not limited to the particular application shown and described herein. It revolutionizes the art of screen and panel room construction because it provides the first such construction where all of the bolts, flanges, and other utilitarian features of the construction are aesthetically hidden from view. Moreover, the cover members that cover the various utilitarian features are snap-fit into place, thereby providing an easy-to-assemble structure. Significantly, the cover members cooperate with the frame members they cover to hold a screen or panel into position, i.e., the cover members perform a utilitarian function as well. 
     It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the foregoing construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing construction or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. 
     Now that the invention has been described,