Abstract:
A channel letter has a rear surface for mounting against a raceway, wall, or a structure for supporting the signage, and sheet metal sides defining the figuration of the letter or shape to be depicted. A lighting element is positioned against the rear surface of the enclosure, and a lens is retained to the open front of the enclosure. The lens is secured with a retainer cap and a plurality of retainer clips. Each of the retainer clips comprises as least one side including an outwardly extending leg for retention with the retainer cap.

Description:
This application claims priority to U.S. Provisional Patent Application No. 62/152,129, filed Apr. 24, 2015, by Boyer et al. and entitled “CHANNEL LETTER AND TRIM CAP RETAINING CLIP THEREFOR” and U.S. Provisional Patent Application No. 62/269,319, filed Dec. 18, 2015, by Boyer and entitled “CHANNEL LETTER SIGN ASSEMBLY”; and are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     The present invention relates to channel letters of the type used to create signage and, in particular, to an improved retainer clip for retaining the trim cap and lens to the enclosure of a channel letter. 
     Channel letters are used to provide signage for buildings, shopping malls, and the like where it is desirable that the signage comprise illuminated letters or any other shapes that are easily seen, even at great distances, day or night. Each channel letter consists of an enclosure, usually a metal box, having a rear surface which is positioned against a raceway, or the wall of a building, on which the signage is mounted and a plurality of sides which define the figuration of a letter or number (or other shape) which make up a portion of the sign. A light source, such as a neon tube, LEDs, or other lighting mechanisms, can be positioned within the walls of the enclosure and attached to the rear (and/or side) surface to provide illumination for the letter or shape. 
     The light sources used in many existing channel letters are neon bulbs requiring high voltage power with transformers built into the metal enclosures. To prevent injury to those servicing such channels letters many municipalities require that such letters be inspected to ensure that they are adequately sealed using standards set by Underwriters Laboratories. 
     It is expected that relatively new technology in lighting sources will soon become the most prevalent for the manufacturers of channel letters. Specifically, low voltage LED type light sources have been developed which provide a very long lasting bright light without requiring the high voltage and transformers needed for neon lighting. It is expected that channel letters employing the new technology will not be required to meet the same standards set by Underwriters Laboratories for neon tubes. 
     In addition to the lighting, a channel letter also includes a planar transparent lens, the outer shape of which corresponds to the figuration of the letter or any other shape defined by the sides of the enclosure. The manufacture of the lens requires that the planar panel of transparent plastic be cut to the shape of the enclosure. The lens of existing channel letters have a trim cap glued or welded to the outer edges thereof which form a border to the lens. The trim cap also has a lip which, when assembled to the enclosure, is shaped to fit snugly around the forward ends of the walls thereof for retaining the lens to the enclosure and to maintain the water tight seal required by Underwriters Laboratories. Heretofore, typically screws are threaded through the lips of the trim cap and into the enclosure walls to retain the lens across the forward opening of the enclosure. 
     It would be desirable to provide a channel letter assembly having a lens and trim cap which could be installed without incurring the labor intensive, and aesthetically displeasing, step of attaching the trim cap with screws. It would also be desirable to provide a less cumbersome method of disassembling the trim cap and lens to gain access to the interior of the enclosure of a channel letter and the subsequent reassembling. 
     BRIEF DESCRIPTION 
     Briefly, the present invention is embodied in a channel letter. For the purposes of this description, a channel letter is defined as an illuminated contoured fixture in the shape of a letter of the alphabet, a numeral, an element of punctuation such as a comma, an exclamation point, or any other shape or form intended to constitute a portion of a sign advertisement or display. 
     The channel letter of the present invention has a rear surface for mounting against a raceway, a wall, or any other structure suitable for supporting the signage. The walls defining the figuration of the letter or shape to be depicted are made of sheet metal, or plastic, having a given thickness. A lighting element, such as a strip of LEDs according to the newly available technology or any other light source, is positioned against, or proximal to, the rear surface of the enclosure to provide illumination therefore. 
     A channel sign assembly can include a channel letter comprising an enclosure having at least two opposing walls. The at least two opposing walls can define the shape of the letter and include an open front. The at least two opposing walls can have an inner surface and a forward end. A lens can have a forward surface and an outer edge in the shape of the letter. A plurality of selectively positioned and oriented retention clips adjacent the forward end can frictionally and/or adhesively engage the enclosure walls. Each clip can include at least one outwardly extending leg relative to the walls. A retainer cap can be secured against the forward surface of the lens for retaining the lens adjacent the enclosure and the walls. The retainer cap can comprise an extrusion readily formable into a variety of shapes. The retainer cap can include an interior face having a first edge and an opposing second edge. The first edge having an overhang engaged to the forward surface of the lens. The second edge can have a channel, wherein the channel is adapted to securely engage a plurality of the legs along an outer surface of the enclosure walls. 
     A channel sign assembly comprising an enclosure having at least two opposing walls. The at least two opposing walls defining the shape of the sign assembly and having an open front. The at least two opposing walls having an inner surface and a forward end. The walls can include a plurality of intermittent retention clips mounted adjacent to the forward end. Each clip can include at least one outwardly extending leg relative to the walls. The legs are aligned with and offset from the forward end. A planar lens having a forward surface, and an outer edge in the defined shape of the sign, is sized to fit within the at least two opposing walls of the enclosure. A retainer cap mounted against the forward surface of the lens is used for retaining the lens within the enclosure and against the walls. The retainer cap comprises an extrusion readily formable into a variety of shapes. The retainer cap includes an interior face having a first edge and an opposing second edge. The first edge includes an overhang engaged with the forward surface of the lens. The second edge forms a retention channel, wherein the channel is adapted to securely engage a plurality of the legs along an outer surface of the enclosure walls. 
     The disclosure provides for a channel sign assembly comprising an enclosure having at least two opposing walls. The at least two opposing walls define the shape of the sign assembly and include an open front. The at least two opposing walls form a forward end. The walls include a plurality of intermittent retention clips mounted adjacent to the forward end. Each clip can be mounted in a first orientation having a first outwardly extending leg relative to the walls. The legs are aligned with and offset from the forward end. A planar lens is provided having a forward surface and an outer edge in the defined shape of the sign. A retainer cap can be mounted against the forward surface of the lens for retaining the lens within the enclosure and against the walls. The retainer cap comprises an extrusion readily formable into a variety of shapes. The retainer cap includes an interior face having a first edge and an opposing second edge. The first edge includes an overhang engaged with the forward surface of the lens. The second edge forms a retention channel, wherein the channel is adapted to securely engage a plurality of the legs along an outer surface of the enclosure walls. 
     The disclosure further provides for a channel sign assembly comprising an enclosure having at least two opposing walls. The at least two opposing walls define the shape of the sign assembly and include an open front. The at least two opposing walls form a forward end. The walls include a plurality of intermittent retention clips mounted adjacent to the forward end. Each clip can include a unitary structure comprising a top edge, a planar body, and an outwardly extending leg relative to the body. The plurality of clips and associated legs are aligned with and offset from the forward end. The sign assembly further includes a planar lens having a forward surface and an outer edge in the defined shape of the sign. A retainer cap can be mounted against the forward surface of the lens for retaining the lens within the enclosure and against the walls. The clips further comprise double faced adhesive tape including a first face of the tape secured to a mounting side of the body of the clip; a second face of the tape secured to an outer surface of the walls; and, the top edge of the clip including a first portion generally at about 90 degrees to the body for resting on the forward end and stopping the clip at the proper mounting position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an edge view of a retainer clip according to a first embodiment; 
         FIG. 2  is a front view of the retainer clip of  FIG. 1 ; 
         FIG. 3  is a rear view of the retainer clip of  FIG. 1 ; 
         FIG. 4  is a cross sectional view of the channel letter assembly employing the retainer clip of  FIG. 1  in accordance with the present invention; 
         FIG. 5  is a front view of a retention or retainer clip according to a second embodiment; 
         FIG. 6  is an edge view of the retainer clip of  FIG. 5 ; 
         FIG. 7  is a rear view of the retainer clip according to the second embodiment; 
         FIG. 8  is a top view of the retainer clip of  FIG. 7 ; 
         FIG. 9  is a cross sectional view of the channel letter assembly employing the retainer clip of  FIG. 5 ; 
         FIG. 10  represents a continuous extrusion of retaining clip material prior to cutting or punching into individual clips; and, 
         FIG. 11  provides a view of a plurality of clips mounted to a channel letter wall. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1-4 , and in accordance with the present disclosure, a channel letter assembly  10  having a retaining clip  132  is therein displayed. The clip  132  provides a means for securing a trim cap or retainer cap  34  to the walls  38  of an enclosure  44 . To facilitate retention of a lens  42  against the front edge  58  of the walls  38  of the enclosure  44 , a plurality of the retainer clips  132  can be spaced along the front edges or terminal ends  58  of the walls  38  of the enclosure  44 . Each of the retainer clips  132  can comprise a unitary structure comprising a top edge  134 , a planar body  136 , and an outwardly extending leg  138  relative to the body  136 . The clip  132  can be made from plastic (i.e. extruded). The extruded (or metal formed) clips can be cut, bent, and/or punched to a variety of shapes including the exemplary clip shape  132 . It is to be appreciated that any number of similarly shaped and/or similarly dimensioned clips can be extruded, cut, and/or formed to meet the objectives described herein. The clip  132  comprises a left arm  140  and a right arm  142  extending in a co-planar arrangement from the body  136 . The distance L between the terminal ends of the left arm  140  and the right arm  142  can be greater than twice the height H of the body  136 . It is to be appreciated that the greater length L, relative to the height H, provides an increased surface area A for supporting the clip  132  to the walls  38  of the enclosure. The increased surface area A also provides for an increased adhesive area for securing the clip  132  to the walls  38  of the enclosure. A double faced adhesive tape can be applied to area A to further secure clip  132  to the walls  38  of the enclosure. In one exemplary embodiment the clip  132  is made from a rigid PVC material. A plurality of such retainer clips  132  can be positioned around the outer edge of the walls  38  thereby providing an attachment means for the trim cap  34  and lens  42  to the walls  38  of the enclosure  44 . Retaining the trim cap  34  to the walls  38  of the enclosure in turn provides the means for securing the lens  42  to the enclosure walls  38  thereby providing a water resistant cover to the interior of the enclosure  44 . 
     It is to be appreciated that the channel enclosure can be made from non-metal materials (i.e. rigid or semi-rigid plastics). Non-metal materials can be used in conjunction with clips  132  discussed herein. 
     Referring to  FIG. 4 , the channel sign assembly  10  in accordance with the present disclosure is therein displayed. The assembly can include a metal enclosure  44  having a plurality of sheet metal side walls  38 . The retainer cap, snap cap, or trim cap  34  can be attached, i.e. firmly glued to the lens  42 . The lens  42  and retainer cap  34  provide lateral support to the walls  38 . The lens  42  and the retainer cap  34  prevent the walls  38  from moving towards each other and from bowing outward away from each other. 
     Referring to  FIG. 4 , the retainer clip  132  can be fitted on the forward end  58  of a wall  38  with the leg  138  extending outward away from the wall  38 . The retaining clip  132  can be easily installed with a double faced adhesive tape  150 , or cyanoacrylate glue, or similar, secured to the inside of the body  136 . When all the retainer clips  132  have been installed along the walls  38  of the enclosure  44 , the lens  42  can be positioned to rest on the outer surface of the top edge  134  of the clips  132 . Referring to the figures, it is to be appreciated that after a retainer clip  132  has been installed, the top edge  134  will ‘rest’ against the front edge  58  of the wall  38  and, along with the double faced adhesive tape  150 , will resist removal of the retainer clip  132  (i.e provide retaining anchor for trim cap  34 ). 
     In accordance with the present invention, to retain the lens  42  against the terminal ends of the shoulder, a plurality of retainer clips  132  are spaced and mounted along the outer end of the walls of the enclosure. Each of the retainer clips  132  can comprise a unitary generally rigid body  136  having a first interior side and a second exterior side. The top edge  134 , body  136 , leg  138 , and arms  140 ,  142  of the clip  132  can be made from rigid metal (i.e. stainless steel) or plastic (i.e. rigid PVC). The top edge  134  can be at a generally 90 degree angle relative to the body  136 . The top edge  134  resting on the front edge  58  of the wall  38 , coupled with the double faced adhesive  150  secured between the body  136 , arms  140 ,  142 , and wall  38 , resists removal of the clip  132 . A plurality of such retainer clips  132  can be positioned around the front edge of the walls thereby providing an attachment means for the trim cap  34  to the walls  38  of the enclosure  44 . Retaining the trim cap  34  (in place) in turn provides the means for securing the lens  42  to the enclosure walls. 
     The clips  132 , once installed, provide a tab or leg  138  that extends outward away from the walls  38  of the channel and can engage a foot  36  of the retainer cap  34  (i.e. in a ‘snap cap’ or friction engagement arrangement). The foot  36  can extend in a length from about ¼ inch to about 1¼ inches. The foot  36  of the retainer cap  34  can be in the form of a receiver or retention channel having a face  37  angled upward from about 3 degrees to about 9 degrees from horizontal. In one arrangement, the receiver can be angled upward from about 5 degrees to about 7 degrees from horizontal. 
     The clips  132  can be placed onto the channel walls  38  at random positions around the letter or shape at the discretion of an installer. The number and intermittent spacing of the clips  132  will be dependent upon the size and design of the channel sign. The interlocking effect of the foot  36  of the retainer cap  34  to the tabs  138  will enable secure attachment of the plastic lens  42  and retainer cap  34  to the metallic channel  38 . 
     The tabs  138  of the clips  132  can be positioned such that they are aligned with and proximal to the front edge  58  of the side walls  38 . The adhesive  150  securing the clips  132  to the wall  38  enables a positive engagement of the inside faces of the clips  132  to the forward edge and forward side portions of the metallic channel  38 . 
     According to another method, each individual retainer clip  232  can be cut along lines  233  from a continuous extrusion  332  ( FIG. 10 ). The clips  232  can comprise a unitary rigid body  236  having a first leg  238 , and an angled top side  234  ( FIGS. 5-8 ). A plurality of such retainer clips  232  can be cut along lines  233  from extrusion  332  and positioned around the outer edge of the walls  38  thereby providing an attachment means for the trim cap and lens to the walls  38  of the enclosure. Retaining the trim cap to the walls  38  of the enclosure in turn provides the means for securing the lens to the enclosure walls  38  thereby providing a water resistant cover to the interior of the enclosure. The retainer clip  232  is fitted on the forward end of a wall  38  with the leg  238  extending outward away from the wall  38 . It is to be appreciated that when all the retainer clips  232  have been installed along the walls  38  of the enclosure the lens  42  can be positioned to rest on the outer surface of the clips (partially illustrated in  FIG. 9 ). 
     The clips  232 , once installed, provide a tab or leg  238  that extends outward away from the walls  38  of the channel and can engage a foot of the retainer cap ( FIG. 9 ). The clips  232  can be placed onto the channel walls  38  at random positions around the letter or shape at the discretion of an installer to form a channel letter assembly  20 . The number and intermittent spacing of the clips  232  will be dependent upon the size and design of the channel sign. The interlocking effect of the foot  36  of the retainer cap  34  to the tabs  238  will enable secure attachment of the plastic lens  42  and retainer cap  34  to the metallic channel. The tabs  238  of the clips  232  can be positioned such that they are aligned with and proximal to the front edge of the side walls. 
     It should also be appreciated that the retainer clips  132 ,  232  may be manufactured and/or cut in more than one size and/or shape to provide desirable fitting between the sides and clips in order to accommodate a variety of wall thicknesses (and materials), and a variety of installation means. To further secure the clips  132 ,  232  to the enclosure walls  38 , an adhesive or double-faced tape  150 ,  250  can be used to secure the clips  132 ,  232  along the walls  38 . It is to be appreciated that the channel enclosure can be made from non-metal materials (i.e. rigid or semi-rigid plastics). Non-metal materials can be used in conjunction with retainer clips and trim cap discussed herein. 
     As described herein and illustrated in  FIGS. 4 and 9 , the retainer clips  132 ,  232  can be fitted on the forward end of a wall  38  with the leg  138 ,  238  extending outward away from the wall. The retaining clips can be easily installed, in one arrangement, with an adhesive glue or epoxy (i.e. cyanoacrylate) secured to the inside of the body  136 ,  236 . When all of the retainer clips  132 ,  232  have been installed along the walls of the enclosure, the lens  42  can be positioned to rest on the outer surface of the top edge  134 ,  234  of the clips. It is to be appreciated that after a retainer clip  132 ,  232  has been installed, the top edge  134 ,  234  will ‘rest’ against the front edge of the wall and along with the adhesive epoxy, or double faced tape, will resist removal of the retainer clip  132 ,  232 . 
     In accordance with the present invention, to retain the lens against the walls of the letter sign, a plurality of retainer clips  132 ,  232  are spaced along the outer end of the walls of the enclosure ( FIGS. 4, 9, and 11 ). Each of the retainer clips  132 ,  232  can comprise a unitary generally rigid body having a first interior side and a second exterior side. The top edge, body, and leg of the clip  232  can be cut from a cured rigid plastic extrusion  332 . Also, the top edge can be at a generally 90 degree angle relative to the body. The top edge resting on the front edge of the wall, coupled with the adhesive epoxy or, in another arrangement, double-faced adhesive tape secured between the body and wall, resists removal of the clip. A plurality of such retainer clips  132 ,  232  can be positioned around the front edge of the walls thereby providing an attachment means for the trim cap  34  to the walls of the enclosure. Retaining the trim cap  34  (in place) in turn provides the means for securing the lens  42  to the enclosure walls. 
     The adhesive epoxy securing the clips to the wall enables a positive engagement of the inside faces of the clips to the forward edge and forward side portions of the metallic channel. In another embodiment, the individual clips can be cut or punched from the extrusion to include extended ‘arms’ to provide increased surface area for mounting the clips to the wall. 
     It is to be appreciated that the different dimensioned lenses can include thicknesses of ⅛ inch and 3/16 inch. When a channel sign assembly is assembled using the clips  132 ,  232  as described, the finished product will present a more attractive appearance than one assembled using screws. In addition, when it is time to service the sign assembly to replace LEDs, or other devices, the trim or retainer cap can be pried off, which will allow the service technician to free the entire perimeter, or a desired portion thereof, of the retainer cap from the forward end of the channel sign enclosure without the use of a screwdriver and the cumbersome removal of screws. 
     The exemplary embodiments have been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.