Patent Publication Number: US-2009235562-A1

Title: Display board with integrated card holder and related method of manufacture

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This patent application claims priority to a provisional patent application Ser. No. 61/038,498, filed Mar. 21, 2008, pursuant to 35 U.S.C. §§111 and 119, the entire contents of said application being incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The application relates to the field of display systems and in particular to a display board having at least one integrated card holder, as well as a related method of manufacturing a display board that integrates at least one card holder therein. 
     BACKGROUND OF THE INVENTION 
     Presently, there are known card holders that are used in manufacturing, industrial, and other related fields for various purposes, such as tracking attendance or location of employees. For example, time cards are collected for a group of related individuals, such as employees in a factory, industrial plant, laboratory or other facility and retained in a card holder disposed in relation to a time punch. A portion of each card extends outwardly for reasons of identifying the card for example for purposes of displaying specific information (e.g., employee names). In one previously known version, card holders have been developed within a dedicated metallized frame structure wherein the structure further includes a plurality of spaced longitudinal slots. Cards are retained within each of the slots wherein a portion of an inserted card extends therefrom and is visible for display or card filing purposes, such as for time cards, job stations, tool control, calendaring and other functions as may be appropriate. 
     There are other situations and potential applications in which it would be preferred to provide other display aspects, apart from those that are provided by the cards themselves, in a common form. 
     SUMMARY OF THE INVENTION 
     Therefore and according to one aspect, there is provided a display board including a front panel, a rear panel and at least one card-holding portion directly integrated into the front panel of said display board. In one version, substrate material is disposed between the front panel and the rear panel of the display board, wherein the substrate material includes a plurality of cavities or recesses that correspond in number and dimension to the number of card-holding portions provided on the front panel. The at least one card-holding portion includes a plurality of spaced slots provided in a louvered or other convenient configuration, each slot being sized to receive a portion of a card. Each of the slots/cavities are appropriately sized for retaining at least a portion of a card. 
     Each card-holding portion of the display board is manufactured with a plurality of spaced slots that are sized to accommodate a card disposed within the card-holding portion. A plurality of slotted portions of varying size and width can be created for placement and provide considerable versatility of varying types of display board, such as, for example, a magnetic dry-erase board. 
     According to another aspect, there is described a method of manufacturing a display board, said method comprising the steps of: providing a front panel and a backing substrate, forming at least one cavity in said backing substrate and forming at least one card holding portion in said front panel wherein said card holding portion includes at least one column of louvered slots, said at least one card holding portion being indexed with said at least one cavity of said substrate and assembling said front panel to said substrate, said front panel including a display portion along with said at least one carding portion thereby creating an display board with an integrated card holder. 
     One advantage provided herein is that the herein described method of manufacture permits considerable variety in the forms of display board that can be provided wherein the manufacture is not significantly time, labor or cost intensive. 
     Another advantage realized is that variability in the number of card holding portions is also integrally permitted in display systems. 
     Yet another advantage is that a manufacturing process is provided that permits a display board to be fabricated and easily assembled with any convenient number of card-holding portions, allowing the remainder of the board to be used for other purposes, such as display, calendaring, etc. 
     These and other features and advantages will become readily apparent from the following Detailed Description, which should be read in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front facing view of a card holding apparatus in accordance with the prior art; 
         FIG. 2  is an exploded front perspective view of a display board that is manufactured in accordance with one embodiment; 
         FIG. 3  is a side elevational view, taken in section, of the display board of  FIG. 2 ; 
         FIG. 4  is a front facing view of a card holding apparatus that is manufactured in accordance with a second embodiment; and 
         FIG. 5  is a partially exploded view of a display board that is manufactured in accordance with a third embodiment, including a schematic representation as to the formation of certain elements of the display board. 
     
    
    
     DETAILED DESCRIPTION 
     The following description relates to various embodiments of a display board with an integrated card holder and more particularly in conjunction with a magnetic dry-erase display board. It will be readily apparent, however, that other variations and modifications are possible within the inventive aspects that are described in greater detail herein. In addition, a number of terms are used throughout for purposes of providing a suitable frame of reference with regard to the accompanying drawings. It is not intended that these terms shall in any way be limiting, however, except where so specifically indicated. 
     Referring to  FIG. 1  and for reasons of providing a suitable background, there is shown a known card holding apparatus  20 . The card holding apparatus  20  is constructed of a sheet-metal section  24  that is defined by a facing surface  28  and a plurality of inwardly bent side tab-like surfaces (not shown) forming lateral sides of the apparatus. This version is shown wherein the bent side tab-like surfaces are inserted into a frame  35 , forming a border for the apparatus  20 . A plurality of very closely spaced slots  32  are stamped or punched into the facing surface  28  of the facing surface  28  by means of a turret press or other forming apparatus (not shown) wherein the spaced slots  32  are disposed in a louvered pattern that is formed in a plurality of vertically defined slot columns  37  that are disposed in parallel spaced relation with each other. According to this embodiment, five (5) vertical columns  37 , each column containing a plurality of closely spaced slots  32  are provided, although it will be readily apparent that this parameter can be suitably varied based on the size of the sheet metal section  24 . Each of the columns  37  of slots  32  shown in this structure are spaced equally from one another between respective top and bottom sides  36 ,  40  of the facing surface  28  of the sheet metal section  24 . 
     Each slot  32  is sized to permit a corresponding card  44  to be vertically placed within the slot and into a cavity (not shown) that is defined in the rear of the frame  24 , enabling each card to be stored without folding or tearing. The cards  44 , referred to hereinafter as “T-cards”, are each defined by a major rectangular portion  48  and a smaller extending top portion  52 . The extending top portion  52  of each T-card  44  has a width dimension that is larger than the major portion  48  of the card, this dimension also being larger than that of the spaced slots  32 . This particular sizing enables the major portion  48  of a T-card  44  to be fitted into a selected one of the slots  32  with the extending top portion  52  being visible upon insertion above the slot. As such, various information can be included on each of the major and extending portions  48 ,  52  of the T-card  44 , for example, wherein identifying information can be included on the extending top portion  52  and more detailed information on the major portion  48 . In the present example, the number of columns  37  can be varied to provide some versatility, but the card holder apparatus  20  themselves are used more or less as dedicated apparatus. 
     With the preceding background and turning to  FIGS. 2 and 3 , there is depicted a display board  100  made in accordance with a first embodiment. The display board  100  according to this embodiment is defined by a multi-layered assemblage including a front panel  108  and a backing or rear panel  110 . According to this specific embodiment, a substrate material  112 , such as a plastic or rubber structural foam, is sandwiched between the front and rear panels  108 ,  110 . According to this design, the front panel  108  of the display board  100  is defined by a thin sheet-steel and the rear panel  110  is similarly made from a somewhat thinner metal sheet material, although other materials, such as corrugated cardboard or other suitable material can be utilized. Optionally, a layer of corrugated cardboard or other backing material can also be provided between the sandwiched substrate material  112  and the rear panel  110 . In certain other alternative versions, having a rear panel  110  is optional wherein substrate material  112  itself may be able to provide the necessary backing structure for the display board  100 . As noted, the front panel  108  according to this embodiment is made from a sheet-steel material that permits magnetic attachment. In addition, the front facing surface of the front panel  108  is coated with a material, enabling use of the surface for display purposes. In a preferred version, the front facing surface is coated with Magnalux® manufactured by W. A. Krapf, Inc., or similar coatings, that enables use of this surface as a dry-erase surface for write-on and printing purposes. Applications for the latter feature will be further discussed in a later embodiment. 
     As shown in  FIGS. 2 and 3 , the front panel  108  includes a plurality of spaced slots  122  that are arranged in vertical columns  126 , similar to that previously described in  FIG. 1 , for purposes of this discussion. Like the preceding, the slots  122  are stamped or pressed in a louvered pattern using a turret press or other forming machine, such as that shown schematically as  150  in  FIG. 5 . In this specific embodiment, five (5) columns of closely-spaced slots  122  are provided, although it will be readily apparent that this parameter can be suitably varied. Unlike the preceding, however, a front facing surface of the substrate material  112  is also provided with a corresponding number of vertically extending recesses  116  matching the number of slot columns  126  formed in the front panel  108 . The recesses  116  are preferably indexed with the locations of the columns  126  of the spaced slots  122  of the front panel  108  and are appropriately sized in terms of their height and width dimensions with that of each column  126 . Referring to  FIG. 5 , each of the recesses  116  are formed on an CNC router or other forming apparatus  160 , although other forming apparatus can be used. Each of the router  160  and the turret press  150  are linked to one another by means of a common controller  164  according to this embodiment. Alternatively separate controllers could be used, though preferably the files for each of the front panel  108  and the substrate material  112  are used in conjunction with one another for indexing purposes. As such, the introduction of a T-card  44 , as shown in  FIG. 3 , into a slot  122  allows the major extending portion  48  to be nested within the cavity  116  formed in the substrate material  112  without tearing, while the substrate material  112  provides structural support for the display board  100 . As noted, the rear panel  110  is optional as well as a truss or other appropriate frame (not shown) that can be added to each lateral edge of the display board  100 . 
     Referring to  FIG. 4 , it will be appreciated that considerable versatility is afforded by the concepts described herein wherein the herein described display board can include various uses and applications. For example, a display board  200  can be manufactured, the board including a front panel  204  having a pair of card-holding portions  208 ,  212  as well as a surface portion  214  that permits other display therebetween. In this version, the front panel  204  is made from a sheet-steel such as in the preceding in which the front facing side has also been coated with a dry-erase coating, such as Magnalux®, which permits write-on applications as well as preprinting of heat fused display lines or other indicia, as desired, depending on the application. As such, the front facing surface of the front panel  204  acts as a magnetic dry-erase display board for purposes of this embodiment. 
     Each of the card-holding portions  208 ,  212  according to this exemplary embodiment include a pair of vertically disposed columns  216 , each having a louvered pattern of closely spaced slots  219 . The two columns  216  of each card holding portion  208 ,  212  are provided on opposite sides of the front panel  208 . A substrate material (not shown) but similar to that of  112 ,  FIG. 2 , is disposed beneath the front panel  204  and includes four (4) recesses  116 ,  FIG. 2 , that are sized and indexed in accordance with the locations of the columns  216  of the card holding portions  208 ,  212 . In terms of manufacture, the substrate material and a rear panel (not shown) are then assembled with the edges of the front panel  204 , rear panel and substrate material within a frame  230  that retains the sandwiched components in an integrated assemblage. 
     Various applications are possible using the herein described display board  200 . For example, the front panel  204  can include various printed indicia or material (not shown) for the display portion  214  or for purposes of identifying the card-holding portions  208 ,  212 , such as heat fused identification lines for scheduling, planning and visual control of information relating to the cards (not shown in this view). Display boards as described herein can also be provided as part of larger assemblies, for example, rotating kiosks that can include a plurality of display boards in cubic and other configurations. Such kiosks typically have bases and rotating display members including a plurality of display boards, wherein the herein described version can be provided as at least one of said display boards. According to yet another example, the front surface  214  of the front panel  204  can be printed by means of a dye-sublimation process in which material is directly added into the steel material for example, geographic maps or other media. Numerous other variations can be appreciated wherein this design is intended only to be exemplary. 
     PARTS LIST FOR FIGS.  1 - 5   
     
         
           20  card holding apparatus 
           24  frame structure 
           28  facing surface 
           32  spaced slots 
           35  frame 
           36  top side 
           37  columns 
           40  bottom side 
           44  cards 
           48  major portion 
           52  top extending portion 
           100  display board 
           104  frame 
           108  front side or panel 
           110  rear side or panel 
           112  substrate material 
           116  recesses, plurality 
           122  slots 
           126  columns 
           150  forming machine, turret press 
           160  forming apparatus 
           164  controller 
           200  display board 
           204  front panel 
           208  card-holding portion 
           212  card-holding portion 
           214  display portion or surface 
           216  columns 
           219  slots 
           230  frame 
       
    
     It will be readily apparent that there are other variations and modifications that can be made, which include the concepts described and detailed herein. These and other modifications and variations will become readily apparent to those of sufficient skill in the field. For example and in lieu of a foam substrate material, other materials could be substituted in order to provide suitable backing for the front panel.