Patent Publication Number: US-2021183279-A1

Title: Signage mounting system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to co-pending U.S. Provisional Patent Application No. 62/948,554 filed on Dec. 16, 2019, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to a mounting system for signage. More specifically, the disclosure relates to a mounting system for illuminated signage. 
     BACKGROUND 
     Conventional mounting systems for signage include raceways that are complex to manufacture and cannot be easily interchanged with different signs. For example, conventional raceways define a complete enclosure that is formed by sheet metal fabrication, including cutting, bending, and punching. The process is labor intensive, requires specialized metal fabrication equipment (e.g., turret punches/presses, press brakes, laser cutting machines, etc.), and necessitates skilled sheet metal operators to operate the specialized metal fabrication equipment. As such, to produce complex raceway shapes is time intensive and cost prohibitive. Furthermore, once a sign has been attached to a conventional raceway, it is difficult and inconvenient for a user to change, adjust, or service the sign. 
     SUMMARY 
     Described herein is a mounting system for illuminated signage that provides a uniform mounting surface for signage, encloses electrical wiring and associate components, and simplifies fabrication and mounting. 
     In one aspect, this disclosure provides a sign assembly including a raceway, a plate removably coupled to the raceway, and a sign coupled to the plate such that the sign and the plate are removable together from the raceway. An electrical connection extends through the plate to the sign. 
     In another aspect, this disclosure provides a sign assembly including a body defining a channel and an opening, and a plate removably coupled to the body. The plate at least partially blocks the opening when the plate is coupled to the body. The sign assembly further includes a sign coupled to the plate such that the sign and the plate are removable together from the body. 
     In another aspect, this disclosure provides a raceway configured to mount to a surface. The raceway includes a rear portion, a top portion extending from the rear portion, a bottom portion extending from the rear portion, a first front portion extending from the top portion, and a second front portion extending from the bottom portion. The raceway further includes an opening positioned between the first front portion and second front portion, a ledge extending from the bottom portion, and a groove coupled to the top portion. The groove is positioned opposite the ledge and the opening is positioned between the groove and the ledge. 
     Other aspects of this disclosure will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illuminated sign assembly. 
         FIG. 2  is a rear perspective view of the illuminated sign assembly of  FIG. 1 . 
         FIG. 3  is a front perspective view of the illuminated sign assembly of  FIG. 1 , with illuminated letters removed. 
         FIG. 4  is a cross-sectional view of the illuminated sign assembly of  FIG. 1 , taken along lines  4 - 4  shown in  FIG. 2 . 
         FIG. 5  is a partial exploded view of the illuminated sign assembly of  FIG. 1 . 
         FIG. 6  is a perspective view of a raceway of the illuminated sign assembly of  FIG. 1 . 
         FIG. 7  is a cross-sectional view of the raceway of  FIG. 6 , taken along lines  7 - 7  shown in  FIG. 6 . 
     
    
    
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
     DETAILED DESCRIPTION 
     With reference to  FIG. 1 , a sign assembly  10  is illustrated attached and mounted to a surface  14 . More specifically, the sign assembly  10  is shown mounted to a vertical wall. In other embodiments, the sign assembly  10  is mounted to any suitable desired location (e.g., a building, interior wall, exterior wall, a post, a pole, or other suitable location for displaying a sign). The sign assembly  10  includes a raceway  18  (i.e., a main body), a face plate  22  removably coupled to the raceway  18 , and a sign  26  coupled to the face plate  22 . For purposes of this disclosure, the sign  26  is illustrated as including individual letters  30  (i.e., channel letters). It should be appreciated that the individual letters shown (“DNMEAN”) is for purposes of illustration and is in no way limiting. Alternatively or additionally, the sign  26  can include any indicia including a logo, a trademark, branding, messaging, or any other suitable information to provide visual identification of an associated product or service, or to communicate a message. In some embodiments, the sign  26  is electrically powered. In some embodiments, the sign  26  is illuminated. 
     With reference to  FIG. 2 , the sign assembly  10  is illustrated removed from the mount surface  14 . The raceway  18  includes a rear wall portion  34  that is configured to be attached to the mount surface  14 . In the illustrated embodiment, an electrical inlet  38  is positioned on the rear wall portion  34 . An electrical power source (e.g., a conventional 120V or 240V AC power source) is coupled to the sign assembly  10 , with electrical power entering the sign assembly  10  through the electrical inlet  38  in the rear wall portion  34 . 
     The sign  26  is coupled to the face plate  22  by fasteners or the like. In the illustrated embodiment, the individual letters  30  are secured to the face plate  22  by fasteners  42  ( FIG. 4 ). As explained in greater detail herein, the face plate  22  and the corresponding sign  26  are easily attached or removed from the raceway  18  without removing the raceway  18  from the mount surface  14 . In this way, the sign  26  can be easily interchanged for a different sign coupled to the raceway  18 . This improves the overall flexibility and serviceability of the sign assembly  10 . For example, if the sign needs to be changed to a different sign, the entire sign assembly  10  does not need to be replace or removed from the mount surface  14 . In particular, the raceway  18  remains secured to the mount surface  14  while only the face plate  22  and corresponding sign  26  are replaced. 
     With reference to  FIG. 3 , the sign assembly  10  is illustrated with the letters  30  removed for clarity. The face plate  22  includes an aperture  46  that extends through the face plate  22 . In the illustrated embodiment, the face plate  22  includes a plurality of apertures  46 . The apertures  46  permits an electrical connection  50  (e.g., a wire harness, an electrical cable, etc.) to extend through the face plate  22  to reach the letters  30  ( FIG. 4 ). In other words, the electrical connection  50  extends through one of the apertures  46  to provide electrical power to a corresponding sign letter  30 . 
     With reference to  FIG. 4 , a cross-section through the sign assembly  10  is illustrated. The letters  30  include light emitting diodes  54  positioned within a cavity  58  of the letter  30 . In the illustrated embodiment, the light emitting diodes  54  are mounted to an interior wall  62  of the letter  30  and powered by the electrical connection  50 . The raceway  18  forms a channel with an interior chamber  66  and an opening  70  (i.e., an elongated gap). In the illustrate embodiment, the opening  70  in the raceway  18  is forward-facing, opposite the rear wall portion  34 . As illustrated in  FIG. 4 , the electrical connection  50  is at least partially positioned within the chamber  66  and passes through the opening  70  in the raceway  18 . Therefore, the raceway  18  does not require any additional apertures to be drilled or otherwise formed in order to electrically connect the sign  26 . 
     With continued reference to  FIG. 4 , the face plate  22  is removably coupled to the raceway  18 . The face plate  22  includes a first end  74  and a second end  78  opposite the first end  74 . The first end  74  of the face plate  22  is received within a groove  82  on the raceway  18 . The second end  78  of the face plate  22  is seated on a ledge  86  on the raceway  18 . In the illustrated embodiment, the groove  82  is positioned opposite the ledge  86 , and the opening  70  is positioned between the groove  82  and the ledge  86 . A fastener  90  secures the face plate  22  to the raceway  18 . Specifically, the fastener  90  secures the second end  78  to a wall portion  94  on the raceway  18 . Without the fasteners  90  the face plate  22  is movable and slidable with respect to the raceway  18 . With the second end  78  secured to the raceway  18 , the first end  74  of the face plate  22  is trapped within the groove  82 . Therefore, fasteners are not necessary to secure the first end  74  to the raceway  18 . As such, the number of fasteners required to secure the face plate  22  to the raceway  18  is advantageously reduced; decreasing the time require to assemble the sign assembly  10 . When the face plate  22  is attached to the raceway  18 , the face plate  22  at least partially blocks the opening  70 . In other words, the face plate  22  covers at least a portion of the opening  70  on the front of the raceway  18 . 
     With reference to  FIG. 5 , the sign assembly  10  is illustrated with the face plate  22 , the electrical inlet  38 , a first cover  98 , a second cover  102 , a divider  106 , a tray  110 , and an electrical driver  114  (i.e., a power supply) exploded off from and out of the raceway  18 . 
     With reference to  FIG. 4 , the tray  110  is supported within the interior chamber  66  of the raceway  18  by a rail  118  on the raceway  18 . In the illustrated embodiment, the rail  118  includes a first groove  120  and a second groove  124  opposite the first groove  120 . The tray  110  is slidable with respect to the rail  118  and the tray  110  is at least partially received within both the first groove  120  and the second groove  124 . The tray  110  supports the electrical driver  114  within the raceway  18 . Specifically, the electrical driver  114  is in physical contact with the tray  110  and the electrical driver  114  does not directly contact the raceway  18 . In other embodiments, the tray  110  may support any electrical component (e.g., a driver, a circuit board, a wire, etc.). In other embodiments, the sign assembly  10  may include a plurality of trays  110  that are similarly slidable relative to a plurality of rails  118  in the raceway  18 . For example, in some embodiments a tray is provide in the bottom of the raceway  18  to keep any electrical component from contacting the bottom surface of the raceway  18 . 
     When assembled, the first cover  98  and the second cover  102  are attached to an axial end  128  of the raceway  18 . The first cover  98  partially encloses the electrical driver  114  within the interior chamber  66  of the raceway  18 . As such, removal of the first cover  98  from the raceway  18  provides easy access to the electrical driver  114 . In some embodiments, the electrical driver  114  is a light emitting diode (LED) driver designed to provide current to the lights associated with the sign  26 . For example, the electrical driver  114  can rectify higher voltage, alternating current to low voltage, direct current suitable for the light emitting diodes  54 . The electrical driver  114  may be referred to more generally as a “power supply.” In other embodiments, the electrical driver  114  may be replaced with a ballast for a fluorescent light, for example, in which case the “power supply” would refer to the ballast. In other words, the term “power supply” encompasses the electrical driver  114 , a ballast, a transformer, or other suitable components that supply electrical power. 
     In the illustrated embodiment, the electrical connection  50  ( FIG. 4 ) is made between the electrical driver  114  and the light emitting diodes  54 . The electrical driver  114  also protects from voltage or current fluctuations. In other embodiments, the electrical driver  114  is any suitable driver for facilitating proper operation of the lights or other electronic components associated with the sign. A wire guide  130  at least partially supports the electrical connection  50 . In the illustrated embodiment, the wire guide  130  is coupled to the raceway  18  and extends into the chamber  66 . 
     Like the first cover  98 , the second cover  102  partially encloses a portion of the electrical inlet  38 . In the illustrated embodiment, the divider  106  is received within the raceway  18  and at least partially forms a high voltage chamber  132 . In the illustrated embodiment, the high voltage chamber  132  is enclosed by the raceway  18 , the divider  106 , the face plate  22 , the tray  110 , and the second cover  102 . The electrical inlet  38  is at least partially within the high voltage chamber  132 . An aperture  136  is provided in the tray  110  to permit electrical connections between the electric power source in the high voltage chamber  132  and the electrical driver  114 . The second cover  102  includes a user-activated switch  140  that is accessible from the exterior of the sign assembly  10 . In some embodiments, the switch  140  is a main power on/off switch that controls, for example, illumination of the sign  26 . As such, the high voltage input to the sign assembly  10  through the electrical inlet  38  is safely isolated within the high voltage chamber  132 . In some embodiments, the divider  106  is be omitted. 
     With reference to  FIGS. 6 and 7 , the raceway  18  is illustrated in more detail. The raceway  18  extends along a longitudinal axis  144  and defines a length  148  that extends between the axial ends  128 . The raceway  18  is a unitary body that is an extruded material. In the illustrated embodiment, the raceway  18  is extruded and formed of metal, and more specifically aluminum. The aluminum extrusion of the raceway  18  advantageously eliminates the need for forming or press brake operations required to manufacture conventional raceways. In other embodiments, the raceway may be formed of any suitable metal, plastic, metal alloy, or other suitable material (e.g., steel, polyvinyl chloride, polypropylene, low-density polyethylene, etc.). 
     With reference to  FIG. 7 , the body of the raceway  18  includes the rear wall portion  34 , a top wall portion  150  extending from the rear wall portion  34 , and a bottom wall portion  154  extending from the rear wall portion  34 . The rear wall portion  34  is the surface of the raceway  18  configured to be mounted to the desired location (e.g., a wall, a pole, a building, etc.). In the illustrated embodiment, the top wall portion  150  and the bottom wall portion  154  are parallel to each other. In addition, in the illustrated embodiment the top and bottom wall portions  150 ,  154  extend perpendicular from the rear wall portion  34 . The rear wall portion  34  extends beyond the top and bottom wall portions  150 ,  154 . Drain holes  156  are formed in the bottom wall portion  154  to allow any liquid (e.g., rain water) to drain out of the raceway  18 . 
     With continued reference to  FIG. 7 , the raceway  18  includes a first front wall portion  158  extending from the top wall portion  150  and a second front wall portion  162  extending from the bottom wall portion  154 . The opening  70  is positioned between the first front wall portion  158  and the second front wall portion  162 . In other words, the opening  70  to the interior chamber  66  of the raceway  18  is formed in the front of the raceway  18  (i.e., the side of the raceway  18  that supports the sign  26 ). In the illustrated embodiment, the first front wall portion  158  is parallel to the rear wall portion  34  and perpendicular to the top wall portion  150 . Likewise, the second front portion  162  is parallel to the rear wall portion  34  and perpendicular to the bottom wall portion  154 . 
     With continued reference to  FIG. 7 , the ledge  86  extends from the bottom wall portion  154  and the groove  82  is coupled to the top wall portion  150 , opposite the ledge  86 . In the illustrated embodiment, the ledge  86  is co-planar with the bottom wall portion  154 . The first groove  120  of the rail  118  is coupled to the rear wall portion  34  and the second groove  124  of the rail  118  is coupled to the first front wall portion  158 . In the illustrated embodiment, the wall portion  94  to which the fasteners  90  are secured is the same as the second front wall portion  162 . The rear wall portion  34 , the top wall portion  150 , the front wall portions  158 ,  162 , and the bottom wall portion  154  at least partially define the interior chamber  66  of the raceway  18 . 
     To assemble the sign assembly  10 , a length of extruded aluminum raceway  18  is formed and cut to a desired length. The sign  26  is mounted to the face plate  22  by the fasteners  42 . For example, the face plate  22  can be turret punched (or other suitable process) to form apertures (e.g., aperture  46 ) to facilitate coupling of the sign  26  to the face plate  22  and to allow the electrical connection  50  to connect between the electrical driver  114  and the sign  26 . The face plate  22  is attached to the raceway  18  but inserting the first end  74  into the groove  82  and then securing the second end  78  to wall portion  94  with fasteners  90 . Either before or after the face plate  22  is secured to the raceway  18 , the tray  110  is inserted into the rail  118 . The electrical driver  114  is electrically connected to the sign  26  and the electrical power source that is at least positioned at least partially within the high voltage chamber  132 . The covers  98 ,  102  are then fastened to the axial ends  128  of the raceway  18  by a plurality of fasteners. The assembled illuminated sign assembly  10  is then mounted to the desired location (e.g., mount surface  14 ). A plurality of fasteners or other suitable fastening assembly can be used to couple the raceway  18  to the desired location. In some embodiments, the raceway  18  is mounted to the desired location as an initial step (e.g., before the face plate  22  is secured to the raceway  18 ).