Flap opening with zipper for screened enclosures and methods of making

Zippered curved screen flap access panels, systems, arrangements, kits and methods for making a zippered curved screen flap panels in order to access space on another side of a screen enclosure. In a preferred embodiment, the novel curved screen flap can be formed in a screen panel, where the panel is installed in an upper location of a screen cage such as in a roof section or upper wall section below or adjacent to a roof gutter. The panel can be easily unzipped with the flap hanging down so that the gutter can be easily accessed and cleaned through the access opening. After the gutter is cleaned, the flap can easily be zippered back in place with the screen material being retensioned.

FIELD OF INVENTION

This invention relates to screen enclosures, and in particular to zippered curved screen flap access panels, systems, arrangements, kits and methods for making a zippered curved screen flap panels in order to access space on another side of a screen enclosure, such as gutters above a screened enclosure attached to a house.

BACKGROUND AND PRIOR ART

Paneled screen enclosures attached to a side of a home are popular to enclose patios, decks, pools and the like. A common assembly of the panels can use spline material to fasten edges of the panels into grooves of surrounding frame members. See for example, U.S. Pat. No. 2,837,153 to Brown et al. and U.S. Pat. No. 3,374,597 to Whitener. A problem occurs in areas that can be difficult to access such as upper screen panels that are below drainage gutters.

If a horizontal roof edge gutter above a screen cage becomes full of debris, it can be difficult to access the gutter without having to climb on the roof or on top of the screen cage, which can be both difficult and dangerous.

Attempts have been made over the years to allow for some screen panels to be removeable. See for example, U.S. Pat. No. 5,038,530 to Watkins and U.S. Published Patent Application 2007/0119553 to Guffey. However, both these types of arrangements require panels to have hook and loop fasteners on the edges of the panels to reattach the screen panels, which may appear easy but is problematic.

One problem is that screen enclosure panels must be tightly stretched in order to be strong enough to handle weather conditions when installed and also to be aesthetically uniform with other panels. Having to manually position all four sides of a screen panel with hook and loop fasteners above one's head on a ladder and the like, would still be difficult and potentially dangerous to the installer. Additionally, it would be difficult to achieve a tight uniform tension across the installed panel to achieve the aesthetic uniform appearance with other panels that are attached by splines on their edges.

SUMMARY OF THE INVENTION

A primary objective of the present invention is to provide zippered curved screen flap access panels, systems, arrangements, kits and methods for making a zippered curved screen flap panels in order to access space on another side of a screen enclosure, such as gutters above a screened enclosure attached to a house.

A secondary objective of the present invention is to provide reusable, durable and long lasting screen flap access panels, systems, arrangements, kits, and methods for making a zippered curved screen flap panels in order to access space on another side of a screen enclosure, such as gutters above a screened enclosure attached to a house.

A method for making a zippered access panel for a screen enclosure, comprising the steps of preparing a screen panel for a selected frame opening in a screen enclosure, sewing a curved zipper in a mid-portion of the screen panel, and installing the screen panel with the sewn curved zipper into the selected frame opening in the screen cage.

The screen panel can include a generally rectangular shape. Additionally, the screen panel can include other geometrical shapes, such as but not limited to square shapes, triangular shapes, combinations of rectangular and triangular shapes, and the like.

The step of preparing the screen panel can include the step of cutting the screen panel into a rectangular configuration from a screen roll.

The step of preparing the screen panel can include the step of drawing a curved line in the mid-portion of the screen panel, and the step of sewing includes the sewing of the curved zipper over the drawn curved line.

The step of preparing the screen panel can include the steps of drawing a curved line in the mid-portion of the screen panel, and adhering and/or holding the curved zipper over the drawn line, and the step of sewing includes the sewing of the adhered curved zipper onto the screen panel.

The adhering step can include the steps of applying double sided tape side strips of the zipper and adhering the side strips of zipper with the double sided tape over the drawn line on the panel. Alternatively, zipper can be physically held in place by ones hand(s) until it is sewn in place.

The step of preparing the screen panel can include the steps of drawing a curved line in the mid-portion of the screen panel, and adhering or holding the curved zipper over the drawn line, and the step of sewing includes the sewing of the adhered or held curved zipper onto the screen panel, and cutting a cut line into the screen against the drawn line from an opposite side of the screen.

The zipper can include one zipper pull. The zipper can include two zipper pulls.

The installing step can include the step of applying spline against perimeter edges of the panel and into grooves along the frame in the screen enclosure.

The selected frame opening in the screen enclosure can be located adjacent to a roof gutter.

A method of installing an access door into a screen panel for a screen enclosure, can include the steps of sizing a selected screen panel, drawing a curved line having an upward extending convex curved edge in the selected screen panel, sewing a curved zipper over a front surface of the screen panel over the drawn curved line, cutting a curved opening matching the curved line through a rear surface of the screen panel, installing the selected screen panel with the sewn curved zipper into a framed opening of the screen enclosure adjacent to a gutter located outside of the screen enclosure, unzipping the zipper to cause the upward extending convex curved edge to turn into a flap where the upward extending convex curved edge falls downward creating an opening, and accessing the gutter through the opening in the screen panel caused by the flap falling downward.

The method can include the step of adhering or holding the curved zipper on the curved drawn line with an adhesive before the step of sewing the curved zipper against the drawn line.

The step of adhering can include the step of applying double sided tape between side strips of the curved zipper and the drawn line on the selected screen panel.

The installing step can include the step of attaching perimeter edges of the selected screen panel by placing spline against the perimeter edges and into grooves along side edges of the framed opening.

A zippered screen flap opening in a screen panel attached to a frame, can comprise a generally rectangular screen panel in the frame, a flap formed from a screen portion in a mid-portion of the screen panel, the flap having a bottom edge as part of the screen panel and an upward convex curved cut-out of the screen portion in the mid-portion of the screen panel, and a zipper sewn along the upward convex curved cut-out of the screen portion, wherein the zipper allows for the flap to fold downward forming an opening through the screen panel when the zipper is unzipped, and the zipper when zipped closed causes the flap to close the opening through the screen panel.

The zippered screen flap opening in the screen panel attached to the frame, can include a spline pushing perimeter edges of the screen panel into corresponding grooves along perimeter side portions of the frame, for attaching the screen panel to the frame.

The zipper can include one zipper pull. The zipper can include two zipper pulls.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description.

A list of components will now be described.1screen roll with portion being rolled out10Sized rectangular screen panel15drawn curved line (tracing a flap)17convex curved edge20zipper22top zipper material strip23top row of teeth24bottom zipper material strip25bottom row of teeth30double sided tap roll32strip of double sided tape40sew lines on top and bottom zipper material strips50cut line on rear side of panel62first zipper pull (slide)64cap end on first zipper66second zipper pull (slide)68cap end on second zipper90gutter on roof edge100screen enclosure110upper frame section115spline120screen flap/door

FIG. 1is a perspective view of a screen roll1with a screen portion being rolled out. The screen roll can be the type of plastic, fiberglass, plastic coated, resin coated and/or metallized screening used screen enclosures for structures such as those around pools, covering patios, decks, and against backs of homes, and the like

FIG. 2is a front view of a pre-cut screen panel10taken from the screen roll1shown inFIG. 1with a drawn curved line15. Screen enclosures are known to use rectangular shaped screen panels attached to frames in the screen enclosures, such as those shown and described in U.S. Pat. No. 2,837,153 to Brown et al. and U.S. Pat. No. 3,374,597 to Whitener which are both incorporated by reference in their entirety. These systems generally have frame sections where generally rectangular shaped screen panels are locked in place by pushing spline against perimeter edges of the screen panel into grooves along the perimeter edges of the frame.

For the invention a frame of a screened enclosure can be picked for the location of the novel screen flap. The installer can cut a rectangular screen panel10that would fit the picked frame of the screen enclosure. Such a selected frame can be an upper side frame or top frame of a screen enclosure with a gutter on the outside of the selected frame.

After the frame is selected and screen panel10is sized and cut from the roll1, the installer can mark a curved line15, by drawing the curved line15on a mid portion of a front face of the screen panel10. The drawn line15can have an upwardly extending convex curved edge or convex curved edges17.

FIG. 3shows a zipper section20with two material strips22,24attached to one another by two rows of teeth23,25with double sided tape32being applied to one of the material strips22. The double sided tape32can come from a double sided tape roll30. The double sided tape32can have peel and stick layers that cover adhesive surfaces.

The type of zipper20can be a marine grade zipper such as those used on boats and the like, that is both durable and waterproof, and can have a top zipper material22with an edge having a top row of teeth23, and a bottom row of teeth25along one edge of a bottom zipper material24. The zipper20must have at least one curved edge17so that the zipper can match and overlay against the drawn curved line15.

The double sided tape32is used to adhere the top and bottom material strips22,24about the drawn curved line15on a front side of the screen panel10.

FIG. 4shows a curved zipper attached over the drawn curved line on the front of the panel15inFIG. 2using the doubled sided tape32ofFIG. 3to stick the zipper over the drawn line15.

Next, the installer can sew the top and bottom material strips22,24on the zipper20in place on the front of the screen panel10.FIG. 5shows the attached zipper20after being sewn in the place on the front of the panel10shown inFIG. 4and the sew lines40on the top and bottom strips22,24of the zipper20.

Next, the installer can make a cut line50by a cutting tool, such as a knife, and the like, against the drawn line visible on the rear side of the panel10.FIG. 6shows a rear side of the panel10ofFIG. 5ready to have a cut line50cut between two rows of zipper teeth23,25.

FIG. 7Ais a first version of a front side of the panel10ofFIG. 6with two zipper pulls62,64(slides) installed, and the zipper20having capped ends64,68for a finished look.

FIG. 7Bshows a second version of a front side of the panel10ofFIG. 6with two zipper pulls (slides)62,64installed on a zipper20with no cap ends64,68.

FIG. 8shows a front side of the panel10ofFIG. 6with one zipper pull (slide)62installed.

FIG. 9shows the panel with two zipper pulls (slides)62,64ofFIG. 7Abeing installed with spline115in an upper screen frame110of a screen enclosure100adjacent to a roof gutter90.

WhileFIG. 9implies the spline115on the inside of the screen frame110, spline115can be installed into grooves about the frame110on the outside of the screen enclosure100.

FIG. 10shows the screen enclosure installed panel10ofFIG. 9with both zipper pulls (slides)62,64opened to allow the screen flap120to fold down inside of the screen enclosure100allowing access to the roof gutter90on the other side of the screen enclosure100. As discussed, in the background section, the gutter90can easily become clogged with debris. The invention allows for a reusable, durable zippered flap that can be easily opened with one or two zipper pulls (slides)62,64. The novel flap panel120can be easily zipped up when not used. Once the flap panel120is zipped, the resulting screen surface becomes under tension similar to the screens under tension in other frame sections of the screen enclosure100.

Although a preferred embodiment shows using double sided tape to pre-position the curved zipper in place before sewing the zipper to the screen, the invention can have a person physically hold the curved zipper while the zipper is being sewn without using tape, and the like.

While the preferred embodiment describes application of the invention to screen enclosures, the novel invention can be used to create a reusable zipper flap opening in other screen frames, such as in a screen door and/or screen over a window, and the like.

Although the preferred embodiment describes installing the screen panel with the flap opening adjacent a roof section of a screen enclosure, the flap opening can be placed in other locations of the screen enclosure, such as on a wall or adjacent to a floor of the screen enclosure to allow for access between the inside and outside of the screen enclosure.

The novel flap opening can be installed in lower frames of a screen enclosure to be used to allow for passing water lines, hose lines therethrough as well as passing power cords there through, so that the hose lines and power cords do not have to be run by opening doors in the screen enclosure.

While the preferred embodiment shows a flap having an upwardly protruding convex curved top or upwardly protruding convex curved top portions, the flap can be oriented in a substantial U shaped orientation, where the top of the flap is part of the screen (to function as a hinge) and the lower part of the U shape is formed from a zipper. In this configuration and orientation, the flap can be used as another pass through for animals, such as but not limited to dogs, cats, and the like, to be able to pass through when the flap is unzipped.

Although the flaps for the access opening are shown having upper left and upper right convex corners, the flap can have other shapes, such as having one upper convex edge. Other shapes can have the flap having a triangular shape with the apex end having a convex curve, and the like.

Additional variations of the invention can allow for pre-packaging an oversized screen panel with the sewn in curved zipper, as part of a kit, that can include spline, a spline tool, and knife. The kit can allow customers to size the oversized screen panel fit a screen frame so that the novel screen with sewn zipper flap is able to be installed where needed.

Although specific advantages have been enumerated above, various embodiments may include some, none, or all of the enumerated advantages.