Abstract:
A screen wall system that provides the ability to form a screen wall using just a few, particular channel members and corresponding adapter members. One of the few, particular channel members is a “U” channel member that can be used to form other types of channel members. Each adapter member can be removably attached to one or two channel members to form “F” channel members, “H” channel members and corner members that are collectively used to assembly a screen wall.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/881,618, filed Jan. 20, 2007. Application No. 60/881,618 is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    (1) Field of the Invention 
         [0003]    The present invention relates to a system for supporting screen walls. 
         [0004]    (2) Description of the Prior Art 
         [0005]    “U” channel members, “F” channel members, “H” channel members and corner channel members are known in the art and have been and are currently used to support screen panels or screen walls. These prior art channel and corner members are shown in  FIGS. 1-14 . Specifically, in  FIGS. 1 and 2 , there is a prior art “F” channel member  10  that can be used as a top and/or base and/or a side expander for screen walls or panels. Channel member  10  has side walls  11  and  12  and a base  13 . Side walls  11  and  12  and base  13  define channel  14  which is sized to receive a portion of a screen frame or porch panel. Channel member  10  also has a flange portion  15  that is generally coplanar with base  13 . Referring to  FIGS. 3 and 4 , there is shown prior art “H” channel  20  that can be used as a top and/or base for screen walls or panels, as well as top and/or base expanders for screen walls or panels. Channel member  20  has side walls  21  and  22  and a base  23 . Side walls  21  and  22  and base  23  define channel  24  which is sized to receive a portion of a screen frame or porch panel. Channel member  20  also has a flange portion  25  that is generally coplanar with side wall  22 . Referring to  FIGS. 5 and 6 , there is shown a prior art “U” channel member  30  that can also be used as a top and/or base for screen walls or panels as well as a side expander for screen walls or panels. Channel member  30  has side walls  31  and  32  and a base  33 . Side walls  31  and  32  and base  33  define channel  34  which is sized to receive a portion of a screen frame or porch panel. Referring to  FIGS. 7 and 8 , there is shown a prior art corner channel member  40  that is used to form a 90° corner between two adjoining screen walls. Channels  41  and  42  receive portions of screen frames or porch panels. Referring to  FIGS. 9 and 10 , there is shown another prior art corner member  50  that can also be used to form a 90° corner between two adjoining screen walls or panels. Channels  51  and  52  are sized to receive portions of screen frames or porch panels. Referring to  FIGS. 11 and 12 , there is shown another prior art “H” channel member  60  that can be used with screen walls or screen panels. “H” channel member  60  has channels  61  and  62  that are sized to receive sections  70  of screen frames. Referring to  FIG. 13A , there is shown a structure  80  that utilizes prior art “F” channel members  10 , the “H” channel member  60  and corner member  50 . Structure  80  also uses square tubing  75 . Referring to  FIG. 13B , there is shown prior art “T” cover member  90  which is comprised of two sections  90 A and  90 B.  FIG. 13C  illustrates how “T” cover member  90  is joined to a pair of screen frame members  96 A and  96 B with fastening devices  97 . Referring to  FIG. 14 , there is shown a structure  100  that utilizes prior art “F” channel members  10  and prior art corner channel member  40 . Structure  100  also uses a prior art “T” channel member  90 . 
         [0006]    A need still exists for improved channel components for use with screens and screen walls that allow a user to quickly assemble sturdy screen walls. 
       SUMMARY OF THE INVENTION 
       [0007]    It is therefore a primary object and general purpose of the present invention to provide a screen wall system that provides the ability to form a variety of channel members using only a few, particular channel members and corresponding adapter members. 
         [0008]    It is a further object of the present invention to provide a cost savings in the manufacture of the components of the screen wall system of the present invention as well as a time savings in the assembly of screen walls using the screen wall system of the present invention. 
         [0009]    Specifically, the present invention is directed to a screen wall system that provides the ability to form a screen wall using just a few, particular channel members and corresponding adapter members. One of the few, particular channel members is a “U” channel member that can be used to form other types of channel members. Each adapter member can be removably attached to one or two channel members to form “F” channel members, “H” channel members and corner members that are collectively used to assembly a screen wall. 
         [0010]    Other objects, features and advantages of the present invention will be apparent from the ensuing description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The invention itself, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
           [0012]      FIG. 1  is a side view, in elevation, of a prior art “F” channel member; 
           [0013]      FIG. 2  is a perspective view of the prior art “F” channel member of  FIG. 1 ; 
           [0014]      FIG. 3  is a side view, in elevation, of a prior art “H” channel member; 
           [0015]      FIG. 4  is a perspective view of the “H” channel member of  FIG. 3 ; 
           [0016]      FIG. 5  is a side view, in elevation, of a prior art “U” channel member; 
           [0017]      FIG. 6  is a perspective view of the “U” channel member of  FIG. 5 ; 
           [0018]      FIG. 7  is a side view, in elevation, of a prior art corner channel member; 
           [0019]      FIG. 8  is a perspective view of the prior art corner channel member of  FIG. 7 ; 
           [0020]      FIG. 9  is a side view, in elevation, of another prior art corner channel member; 
           [0021]      FIG. 10  is a perspective view of the prior art corner channel member of  FIG. 9 ; 
           [0022]      FIG. 11  is a perspective view of a prior art “H” channel corner member; 
           [0023]      FIG. 12  is a side view, in elevation, of the prior art “H” channel corner member of  FIG. 11  having screen frames positioned within the channels of the prior art “H” channel corner member; 
           [0024]      FIG. 13A  is a diagram of a structure that is assembled utilizing the prior art channel members of  FIGS. 1 ,  9  and  12 ; 
           [0025]      FIG. 13B  is a perspective view of a prior art “T” cover member; 
           [0026]      FIG. 13C  is a side view, in elevation, of the prior art “T” cover of  FIG. 13B  connected to screen frames; 
           [0027]      FIG. 14  is a diagram of another structure utilizing the prior art channel members of  FIGS. 1 ,  7  and  13 B. 
           [0028]      FIG. 15A  is a side view, in elevation, of a large “U” channel member in accordance with one embodiment of the present invention; 
           [0029]      FIG. 15B  is a perspective view of the “U” channel member in of  FIG. 15A ; 
           [0030]      FIG. 15C  is a side view, in elevation, of a small “U” channel member in accordance with another embodiment of the present invention; 
           [0031]      FIG. 16  is a perspective view of an adapter that is configured to be used with either of the “U” channel members shown in  FIG. 15B  and  FIG. 15C  in order to form other types of channel members; 
           [0032]      FIG. 17A  is a side view, in elevation, of an “H” channel member formed by connecting the adapter member of  FIG. 16  to the “U” channel member shown in  FIG. 15A ; 
           [0033]      FIG. 17B  is a perspective view of the “H” channel member of  FIG. 17A ; 
           [0034]      FIG. 17C  is a perspective view of an “H” channel member in accordance with another embodiment of the present invention, this “H” channel member being formed by connecting the adapter member of  FIG. 16  to the small “U” channel member shown in  FIG. 15C ; 
           [0035]      FIG. 18A  is a side view, in elevation, of an adapter in accordance with another embodiment of the present invention; 
           [0036]      FIG. 18B  is an exploded view illustrating the interconnection of the adapter of  FIG. 18A  with the large “U” channel member of  FIG. 15A  so as to form a large “F” channel member; 
           [0037]      FIG. 18C  is a perspective view of the “F” channel member formed by connecting the adapter of  FIG. 18A  to the large “U” channel member of  FIG. 15A ; 
           [0038]      FIG. 18D  is a perspective view of a small “F” channel member formed by connecting the adapter of  FIG. 18A  to the small “U” channel member of  FIG. 15C ; 
           [0039]      FIG. 18E  is a perspective view of the adapter of  FIG. 18A ; 
           [0040]      FIG. 19A  is a side view, in elevation, of an adapter in accordance with a further embodiment of the present invention; 
           [0041]      FIG. 19B  is an exploded view illustrating the interconnection of the adapter member of  FIG. 19A  to the large “U” channel member of  FIG. 15A  and the small “U” channel member of  FIG. 15C  so as to form a corner channel member; 
           [0042]      FIG. 19C  is a perspective view of a corner channel member formed by connecting the adapter member of  FIG. 19A  to the large “U” channel member of  FIG. 15A  and the small “U” channel member of  FIG. 15C ; 
           [0043]      FIG. 19D  is a perspective view of the adapter of  FIG. 19A ; 
           [0044]      FIG. 20  is an exploded view showing a channel member and adapter in accordance with another embodiment of the present invention; 
           [0045]      FIG. 21  is an exploded view showing a channel member and adapter in accordance with a further embodiment of the present invention; 
           [0046]      FIG. 22  is a perspective view of an “R” channel member in accordance with one embodiment of the present invention; 
           [0047]      FIG. 23  is a end view, in elevation, of a pair of “R” channel members, one of which being shown in  FIG. 22 , that are connected to screen frames; and 
           [0048]      FIGS. 24 ,  25  and  26  illustrate various ways the “R” channel member of  FIG. 22  can be used as a mounting flange. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0049]    Referring now to  FIGS. 15A and 15B , there is a shown large “U” channel member  150  in accordance with one embodiment of the present invention. “U” channel member  150  comprises walls  152  and  154  and base  155  which between walls  152  and  154 . Base  155  is attached to walls  152  and  154 . In a preferred embodiment, walls  152  and  154  are substantially parallel to each other. Walls  152  and  154  and base  155  define channel  156 . Channel  156  is sized to receive a frame of a screen wall or panel. Base  155  has a top side  157  and a bottom side  158 . Bottom side  158  is configured to have a plurality of longitudinally extending dovetail grooves  160 . In a preferred embodiment, dovetail grooves  160  are equidistantly spaced. The purpose of dovetail grooves  160  is explained in the ensuing description.  FIG. 15C  shows a “U” channel member  162  that is relatively smaller in size than the large “U” channel member  150 . “U” channel member  162  comprises walls  163  and  164  and base  165  which between walls  163  and  164 . Base  165  is attached to walls  163  and  164 . In a preferred embodiment, walls  163  and  164  are substantially parallel to each other. In accordance with this embodiment, walls  163  and  164  are relatively smaller than walls  152  and  154 , respectively, of large “U” channel member  150 . Walls  163  and  164  and base  165  define channel  166 . Channel  166  is sized to receive a frame of a screen wall or panel. Base  165  has a top side  167  and a bottom side  168 . Bottom side  168  is configured to have a plurality of longitudinally extending dovetail grooves  169 . In a preferred embodiment, dovetail grooves  169  are equidistantly spaced. The purpose of dovetail grooves  169  is explained in the ensuing description. The “U” channel members  150  and  162  replace prior art “U” channel member  30  shown in  FIG. 5 . 
         [0050]    Referring to  FIG. 16 , there is shown adapter  170  in accordance with one embodiment of the present invention. Adapter  170  is used in combination with either large “U” channel member  150  shown in  FIG. 15A  or small “U” channel member  162  shown in  FIG. 15C . Adapter  170  comprises sections  172  and  174  that are, in a preferred embodiment, arranged orthogonally. Section  172  has an inner side  176  and outer side  178 . Adapter  170  further includes a plurality of longitudinally dovetail-shaped ribs  180  that are complementary to dovetail-shaped grooves  160  and  169  of channel members  150  and  162 , respectively. In a preferred embodiment, ribs  180  are equidistantly spaced. Each rib  180  is sized to slide into a corresponding longitudinally extending dovetail groove  160 , of large “U” channel member  150 , or a corresponding longitudinally extending dovetail groove  169 , of small “U” channel member  162 , in order to form an “H” channel member.  FIGS. 17A and 17B  show large “H” channel member  190  formed by attaching adapter  170  to large “U” channel member  150 .  FIG. 17C  shows small “H” channel member  192  formed by attaching adapter  170  to small “U” channel member  162 . The size of adapter  170  can also varied depending upon the desired size of the “H” channel member. The “H” channel member shown in  FIGS. 17A ,  17 B and  17 C replace prior art “H” channel member  20  shown in  FIG. 2 . 
         [0051]    Referring to  FIGS. 18A and 18E , there is shown adapter  200  in accordance with a further embodiment of the present invention. Adapter  200  comprises base  202  which has top side  204  and bottom side  206 . Adapter  200  includes a plurality of longitudinally dovetail-shaped ribs  208  that are complementary to dovetail-shaped grooves  160  and  169  of channel members  150  and  162 , respectively. In a preferred embodiment, ribs  208  are equidistantly spaced. Referring to  FIG. 18B , each rib  208  is sized to slide into a corresponding longitudinally extending dovetail groove  160  of large “U” channel member  150 , or a corresponding longitudinally extending dovetail groove  169  of small “U” channel member  162  in order to form an “F” channel member.  FIG. 18C  shows large “F” channel member  220  formed by attaching adapter  200  to large “U” channel member  150 .  FIG. 18D  shows small “F” channel member  230  formed by attaching adapter  200  to small “U” channel member  162 . The size of adapter  200  can also be varied depending upon the desired size of the “F” channel member. The “F” channel members  220  and  230  replace prior art “F” channel member  10  shown in  FIG. 1 . 
         [0052]    Referring to  FIGS. 19A and 19D , there is shown adapter member  300  in accordance with a further embodiment of the present invention. Adapter  300  comprises section  302  and section  304  which, in a preferred embodiment, are arranged orthogonally. Section  304  has an exterior side  306  and an interior side  308 . Similarly, section  304  has an exterior side  310  and interior side  311 . Adapter  300  includes longitudinally extending dovetail-shaped ribs  312  attached to exterior side  306  of section  302 . Ribs  312  are complementary to dovetail-shaped grooves  160  and  169  of channel members  150  and  162 , respectively. Ribs  312  are equidistantly spaced. Each rib  312  is sized to slide into a corresponding longitudinally extending dovetail groove  160  of large “U” channel member  150 , or into a corresponding longitudinally extending dovetail groove  169  of small “U” channel member  162 . Adapter  300  further comprises a plurality of longitudinally extending dovetail-shaped ribs  314  attached to interior side  311  of section  304 . Ribs  314  are complementary to dovetail-shaped grooves  160  and  169  of channel members  150  and  162 , respectively. Thus, each rib  314  is sized to slide into a corresponding longitudinally extending dovetail groove  160  of large “U” channel member  150 , or into a corresponding longitudinally extending dovetail groove  169  of small “U” channel member  162 . Referring to  FIGS. 19B and 19C , in one embodiment, adapter  300  is connected to large “U” channel member  150  and small “U” channel member  162  to form corner channel member  400 . The size of corner channel member  400  can be varied by connecting adapter  300  to two large “U” channel members  150 , or to two small “U” channel members  162 , or to one large “U” channel member  150  and a small “U” channel member  162  (as shown in  FIG. 19C ). Thus, corner channel member  400  replaces prior art corner channel member  50  ( FIG. 7 ) and prior art corner channel member  60  ( FIG. 9 ). 
         [0053]    Although channel members  150 ,  162  and adapters  170 ,  200  and  300  have been described in the foregoing description as having either dovetail-shaped grooves or complementary dovetail-shaped ribs, it is to be understood other configurations can be used to attach adapters  170 ,  200  and  300  to the channel members  150  and  162 . One example of a different configuration is shown in  FIG. 20 . Channel member  400  is a “U” channel member that comprises sidewalls  402  and  404  and base section  406  which is connected to sidewalls  402  and  404 . Sidewalls  402  and  404  and base section  406  define channel  407  that receives a portion of a screen frame (not shown). Base section  406  has a bottom side  408  which is configured to have a plurality of generally circular shaped, longitudinally extending grooves  410 . Channel member  400  is configured to be used with adapter  420 . Adapter  420  has plate section  422  and a plurality of longitudinally extending ribs  424  that are shaped so as to conform to the shape of grooves  410 . Thus, each rib  424  is shaped to be slid into a corresponding one of grooves  410 . The ribs  424  and grooves  410  are sized so that there is slight degree of friction between each rib  424  and the inner walls of each corresponding groove  410  so as to prevent adapter  420  from becoming disengaged from channel member  400 .  FIG. 21  shows another example of a different configuration used to attach an adapter to a channel member. Channel member  450  is another “U” channel member that comprises sidewalls  452  and  454  which are joined to base section  456 . Sidewalls  452  and  454  and base section  456  define channel  457  which receives a portion of a screen frame (not shown). Base section  456  has a bottom side  458  that is configured to have a plurality of longitudinally extending, generally “T” shaped grooves  460 . Channel member  450  is configured to be used with adapter  470 . Adapter  470  has a plate section  472  and a plurality of longitudinally extending, generally “T” shaped ribs  474  that are shaped so as to conform to the shapes of grooves  460 . Each rib  474  is shaped so as to be slid into a corresponding one of grooves  460 . The ribs  474  and grooves  460  are sized so that there is slight degree of friction between each rib  474  and the inner walls of each corresponding groove  460  so as to prevent adapter  470  from becoming disengaged from channel member  450 . 
         [0054]    The shapes of the grooves and ribs of the channel members and adapters, respectively, shown in  FIGS. 20 and 21 , are just examples and it is to be understood that grooves and ribs having other shapes can be used. Furthermore, instead of using a plurality of grooves and ribs, channel member  400  can be configured to have a single, large sized groove in bottom side  408  and adapter  420  can be configured to have a single, large size corresponding rib, or similar structure, that has a shape that conforms to the single, large size groove in bottom side  408 . Other configurations for attaching the adapters to the channel members are possible. 
         [0055]    Referring to  FIG. 22 , there is shown an “R” channel member  500  in accordance with another embodiment of the present invention. “R” channel member  500  can be used to replace prior art “H” channel member  60  ( FIG. 11 ) and “T” cover member  90  ( FIG. 13B ). “R” channel member  500  is configured for use in mounting a screen frame, or joining assembled screen frames. The “R” channel member  500  comprises a generally flat plate section  502  and section  504  which is configured to have a channel section  506 . Channel  506  has a generally trapezoidal shape. In a preferred embodiment, section  504  is rigidly attached to flat plate section  502 . 
         [0056]      FIG. 23  illustrates how “R” channel members  500  are connected to screen frame members  730 . In this particular example, screen frame sections  730  are each configured as screen frame members that are disclosed in commonly owned U.S. provisional application Nos. 60/827,312 and 60/827,304, both filed Sep. 28, 2006. Each channel section  506  is positioned within a corresponding channel  732  of a screen frame member  730 . Each “R” channel member  500  is secured to each screen frame member  730  with fastening devices  734  such as nails or screws. 
         [0057]      FIGS. 24 ,  25  and  26  illustrate various ways in which “R” channel member  500  can be used as a mounting flange. In  FIG. 24 , “R” channel member  500  is mounted to support member  1000 . Support member  1000  can be any type of column, post or support that is part of a screen wall, or part of a structure to which a screen wall is to be attached. Specifically, “R” channel member  500  is mounted to face  1002  of support member  1000 . Screw  1004  is used to attach “R” channel member  500  to support member  1000 . A screen frame  730  (shown in  FIG. 23 ) is mounted to section  504  of “R” channel member  500  with screw  1006 . It is to be understood that “R” channel member  500  can be used with types of screen frames as well. 
         [0058]    In  FIG. 25 , illustrates “R” channel member  500  mounted from the exterior to a support member  2000 . Support member  2000  can be any type of column, post or support that is part of a screen wall, or part of a structure to which a screen wall is to be attached. Specifically, support member  2000  has an interior face  2002 , an exterior face  2004  and side  2005 . Section  504  of “R” channel member  500  is mounted to screen frame  730  with screw or fastener  2006 . Section  502  of “R” channel member is attached to exterior face  2004  such that the head of screw or fastener  2006  faces side  2005  of support  2000 . Screw or fastener  2008  is used to attach section  502  to exterior face  2004 . Interior molding  2010  may be used for additional support for screen frame  730 . In this configuration, the screen frame  730  abuts the interior molding  2010 . 
         [0059]    In  FIG. 26 , illustrates “R” channel member  500  mounted from the interior to a support member  3000 . Support member  3000  can be any type of column, post or support that is part of a screen wall, or part of a structure to which a screen wall is to be attached. Specifically, support member  3000  has an interior face  3002 , an exterior face  3004  and side  3005 . Section  504  of “R” channel member  500  is mounted to screen frame  730  with screw or fastener  3006 . Section  502  of “R” channel member is attached to interior face  3002  such that the head of screw or fastener  3006  faces side  3005  of support  3000 . Screw or fastener  3008  is used to attach section  502  to interior face  3002 . 
         [0060]    The channel members of the present invention may be fabricated from any one of a variety of materials, e.g. plastics, resins, composites, and metals such as aluminum, steel, brass, etc. In the case of plastics, injection molding techniques may be used in forming the channel members. 
         [0061]    It is to be understood that the sizes and dimensions of any of the channel members and adapters of the present invention may be varied depending upon the particular application. 
         [0062]    The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is neither intended to be exhaustive nor to limit the invention to the precise form disclosed; and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.