Patent Publication Number: US-2018050381-A1

Title: Preparing holes on rules or profiles used for channel letters

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) of co-pending U.S. Provisional Patent Application No. 62/352,942, filed Jun. 21, 2016, entitled “Preparing Holes on Rules or Profiles Used for Channel Letters.” The disclosure of the above-referenced application is incorporated herein by reference. 
    
    
     BACKGROUND 
     Technological Field 
     The present disclosure relates to channel letters, and more specifically, to preparing holes on rules or profiles used for the channel letters. 
     Background 
     Once a rule or profile is folded into a channel letter, the channel letter is attached to the bottom plate, light fixtures are placed on top of the bottom plate, and the top plate is attached to or placed on top of the channel letter to form a box of letter or shape (hereinafter referred to as “letter box”). 
     However, under certain weather conditions and with the light fixtures operating inside the letter box, moisture may build up in the letter box. The buildup of the moisture or water may cause the light fixtures to fail. 
     SUMMARY 
     This disclosure describes apparatus and methods related to preparing holes on rules or profiles used for channel letters. A rule, for the purposes of this application, is a strip of material used to form a channel letter or shape (hereinafter referred to as “channel letter”). A profile may refer to a rule with rib(s) attached to it. In general, the rule or profile may be interchangeably used. In general, the rule or profile may be interchangeably used. 
     In one embodiment, a method for preparing holes on rules or profiles used for a channel letter is disclosed. The method includes: determining a type of the holes to be prepared on the rules or profiles, wherein the type of holes determines a placement of the holes along at least a vertical direction of the rules or profiles; determining and measuring positions along a longitudinal direction for the holes to be prepared on the rules or profiles; making the holes at the positions along the longitudinal direction; and bending the rules or profiles into the channel letter. 
     In another embodiment, an apparatus for preparing holes on rules or profiles used for a channel letter is disclosed. The apparatus includes: means for determining a type of the holes to be prepared on the rules or profiles along at least a vertical direction of the rules or profiles; means for determining positions along a longitudinal direction for the holes to be prepared on the rules or profiles; means for making the holes at the positions along the longitudinal direction; and means for bending the rules or profiles into the channel letter 
     In another embodiment, a device configured to prepare holes on rules or profiles used for a channel letter is disclosed. The device includes: a processor configured to determine a type of the holes to be prepared on the rules or profiles, wherein the type of holes determines a placement of the holes along at least a vertical direction of the rules or profiles, the processor also configured to determine and measure positions along a longitudinal direction for the holes to be prepared on the rules or profiles; and a boring unit configured to make the holes at the positions along the longitudinal direction. 
     Other features and advantages of the present disclosure should be apparent from the following description which illustrates, by way of example, aspects of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The details of the present disclosure, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings. 
         FIG. 1A  shows the rule bent into a channel letter shape. 
         FIG. 1B  shows the completed channel letter (e.g., letter “K”). 
         FIG. 2A  shows a strip of rule. 
         FIG. 2B  shows a flange formed on the rule. 
         FIG. 2C  shows one side surface of a strip of profile. 
         FIG. 2D  shows the other side surface of the strip of profile. 
         FIG. 3A  shows several examples of the letter box shaped as letters S, T, and M. 
         FIG. 3B  shows drainage holes measured and punched and/or drilled on the rule. 
         FIG. 3C  shows the process of measuring the drainage hole placement in accordance with one embodiment of the present disclosure. 
         FIG. 4  shows one example of the drainage hole on a profile. 
         FIG. 5A  shows one example of the screw on a profile. 
         FIG. 5B  shows one example of the screw hole made to accept the screw and engage the clip, which is used to couple the channel letter to the base plate. 
         FIGS. 6A and 6B  show examples of decoration holes disposed on a channel letter in accordance with one embodiment of the present disclosure. 
         FIG. 7  is a block diagram of a device for preparing holes on a rule or profile used for a channel letter in accordance with one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. In some instances, well-known structures and components are shown in simplified form for brevity of description. As used herein, like reference numerals refer to like features throughout the written description. 
     Apparatus and methods for preparing holes on rules or profiles used for channel letters are described. A rule, for the purposes of this application, is a strip of material used to form a channel letter or shape (hereinafter referred to as “channel letter”). A profile may refer to a rule with rib(s) attached to it. In general, the rule or profile may be interchangeably used. 
     Rules (or profiles) may be used to form channel letters. For example,  FIGS. 1A and 1B  show a channel letter box  100  made with a profile in accordance with one embodiment of the present disclosure.  FIG. 1A  shows the rule bent into a channel letter shape.  FIG. 1B  shows the completed channel letter (e.g., letter “K”). As can be seen in  FIG. 1B , for example, the channel letter box  100  includes a top rib  110  for retaining the top plate and a bottom rib  112  for fitting into a bottom plate. In one embodiment, the channel letter can be shaped into any shape, not just a letter of the alphabet or writing (e.g., Chinese letters). For example, the channel letter can be in a shape such as a heart shape. 
     In one embodiment, the rules can be made into strips or rolls.  FIG. 2A  shows a strip of rule  200 .  FIG. 2B  shows a flange  202  formed on the rule  200 .  FIG. 2C  shows one side surface  220  of a strip of profile  210 .  FIG. 2D  shows the other side surface  230  of the strip of profile  210 . The other side surface  230  may include ribs  232 ,  234  to support the top and bottom covers of a channel letter. Thus, in one embodiment, a profile can be formed using a rule with at least one strip of rib attached to one surface of the rule. 
     In some embodiments, the profile  210  can have a first surface  230  shown in  FIG. 2D . The first surface  230  may also be referred to herein as the “inside surface,” indicating that the first surface  230  may generally become the inside of a resulting channel letter once the profile  210  has been cut and folded. The profile  210  (or the rule  200 ) can generally have a profile height  236  on the order of a few centimeters (cm), for example, one or two cm to in excess of 20 cm. The profile height  236  can also describe the height of the first surface  230 . The profile  210  may also be many meters long (in the direction of the profile axis  238 ). In some embodiments, the profile  210  (and the rule  200 ) can be stored in large rolls from which certain portions or lengths can be cut, for example, to produce the portion of the profile  210  shown. Lengths or sections of the profile  210 , can be cut from the roll and then fed into a profile cutting and bending machine (not shown) to make a variety of channel letters or shapes from the profile  210 . 
     In some embodiments, the rule  210  can be formed of a suitable metallic material, such as aluminum, steel, stainless steel, or various other alloys that provide a malleable, yet sturdy construction. The rule  210  may further have a protective coating to prevent corrosion or oxidation and to provide a suitable mounting surface for the ribs  232 ,  234 . Such a protective coating can be applied at least to the first surface  230 , but can also be applied to an outside surface  220 . The outside surface  220  is opposite the first surface  230  and may generally become the outside of the resulting channel letter once the profile  210  is cut and folded. 
     In certain embodiments, such a protective coating may be an enamel coating. In some other embodiments, the profile  210  can be coated with certain types of powder coating, lacquer, or paint applied to the entire rule  200 . In some embodiments, coating the rule  200  in enamel can have certain chemical advantages for adhering or bonding of the ribs  232 ,  234 . The coating can further have desirable artistic or design characteristics provided by different colored coatings having various reflective or textured properties. For example, a white first surface  230  may have desirable reflective properties for light emitted from within a completed channel letter. The colors and coatings of the first surface  230  can be different from the colors and coatings of the outside surface. 
     As described above, the profile  210  can further have the ribs  232 ,  234 . In some embodiments, the ribs  232 ,  234  can be attached, bonded, or otherwise adhered to the first surface  230  of the profile  210 . In some embodiments, the ribs  232 ,  234  can be formed of a polymer, elastomer, plastic, fiber-reinforced plastic (FRP), or other suitable synthetic materials. In some other embodiments, the rib  232 ,  234  can be attached using a machine that applies or adheres the ribs  232 ,  234  in place on a blank surface  230  of the profile  210 . 
     As described above, once the rule or profile is folded into a channel letter, the channel letter is attached to the bottom plate, light fixtures are placed on top of the bottom plate, and the top plate is attached to or placed on top of the channel letter to form a box of letter or shape. However, under certain weather conditions and with the light fixtures operating inside the letter box, moisture may build up in the letter box. The buildup of the moisture or water may cause the light fixtures to fail. 
     Embodiments of the present disclosure also include preparing holes on rules or profiles used for channel letters. In one embodiment, the holes are configured as drainage holes. In another embodiment, the holes are configured as screw holes. In yet another embodiment, the holes are configured as decoration holes to enhance the appearance of the channel letter when the light inside the channel letter is turned on. 
       FIG. 3A  shows several examples of the letter box  310  shaped as letters S, T, and M. In accordance with embodiments of the present disclosure, drainage holes  312 ,  314 ,  316 ,  318  may be formed or prepared at the bottom of the letter box. In the example of letter M, more than one drainage holes  316 ,  318  may be formed. 
     In the illustrated embodiment of  FIG. 3A , the drainage holes  312 ,  314 ,  316 ,  318  are determined, measured, marked, and/or drilled using a punch apparatus including a processor, for example, prior to, during, or subsequent to the bending and cutting process. In one example, bending and/or cutting is done using a bending/cutting apparatus. At least one of the processes of measuring, marking, and drilling can be done in the same apparatus which does the bending and cutting of the rule or profile to make the channel letter. In one embodiment, the punch apparatus and the bending/cutting apparatus are configured into a single device such that measuring, marking, drilling, and bending/cutting operations are all done in the single device. In another embodiment, measuring, marking, and bending/cutting operations are done in the bending/cutting apparatus, and drilling is done in the punching apparatus. In another embodiment, different combinations of operations are done in the punch apparatus and the bending/cutting apparatus. 
     As shown in  FIG. 3B , drainage holes  320 ,  322  are measured and punched and/or drilled on the rule  330 , for example, prior to bending/cutting using an apparatus (which may be the same apparatus as the bending/cutting apparatus). In other embodiments, the holes  320 ,  322  are measured and marked so that the holes can be punched or drilled later, subsequent to the bending and cutting of the rule  330  into the channel letter. 
       FIG. 3C  shows a process  350  of measuring the hole placement in accordance with one embodiment of the present disclosure. In the illustrated embodiment of  FIG. 3C , once the channel letter to be formed is determined (e.g., letter S in  FIG. 3C ), the processor determines the length of the rule to be folded into the channel letter and the hole placement data. The hole is then marked and/or drilled (or punched). 
     For example, in  FIG. 3C , a drainage hole is to be punched or drilled at the bottom of letter S. The processor first determines the length of letter S to be 10 units long and that the bottom where the moisture is to be drained is 1 unit of distance from the left side. The processor instructs the apparatus to move the rule or profile  1  unit to the left and then instructs the drill/punch to make a hole for drainage. 
       FIG. 4  shows one example of a drainage hole  410  on a profile  400  in accordance with one embodiment of the present disclosure. In the illustrated embodiment of  FIG. 4 , the profile  400  includes a pair of ribs  420 ,  422  coupled to one surface of the profile. Generally, the drainage holes (e.g., drainage hole  410 ) are placed near the middle of the profile along the perpendicular direction  430  (“vertical direction”) to the profile feeding direction  440  (“longitudinal direction”) so that the water can drain evenly. The exact placement of the holes are programmed and/or determined by the processor. The profile feeding direction  440  is the direction which the profile is fed into the apparatus to be hole punched and/or folded. 
     In addition to the drainage holes, the channel letter formed with profiles (or even with the channel letter formed with rules) may need screw holes to hold the clips in place. In one embodiment, the clips are used to insert the channel letter into the base plate. 
       FIG. 5A  shows one example of screw holes  510 ,  512  disposed on a profile  500  in accordance with one embodiment of the present disclosure. Generally, the screw holes (e.g., screw holes  510 ,  512 ) are placed near the bottom of the profile along the perpendicular direction  530  to the profile feeding direction  540  so that the screw can fit through a screw hole and a clip positioned above the bottom rib. The exact placement of the holes are programmed and/or determined by the processor. In the description above, the top of the profile generally refers to the side of the channel letter that is facing the outside, while the bottom of the profile generally refers to the side of the channel letter that is facing the surface (e.g., a wall) onto which the channel letter is attached. 
       FIG. 5B  shows one example of the screw hole  510  made to accept the screw  520  and engage the clip  522 , which is used to couple the channel letter  550  to the base plate  560 . Typically, the base plate  560  is attached to a surface on which the channel letter will be displayed. 
       FIGS. 6A and 6B  show examples of decoration holes  610  disposed on a channel letter  600  in accordance with one embodiment of the present disclosure. In the illustrated embodiment of  FIGS. 6A and 6B , the holes  610  are configured as decoration holes to enhance the appearance of the channel letter  600  when the light inside the channel letter is turned on. 
       FIG. 7  is a block diagram of a device  700  for preparing holes on a rule or profile used for a channel letter in accordance with one embodiment of the present disclosure. In the illustrated embodiment of  FIG. 7 , the device  700  includes a processor  710 , a boring unit  720 , and a bending unit  730 . 
     The processor  710  is configured to determine a type of the holes to be prepared on the rule or profile  722 , wherein the type of holes determines a placement of the holes along at least a vertical direction of the rule or profile. The processor  710  is also configured to determine and measure positions along a longitudinal direction for the holes to be prepared on the rule or profile. The boring unit  720  is configured to receive the rule or profile  722  and make the holes at the positions along the longitudinal direction of the rule or profile  722 . The type of holes includes a drainage hole, a screw hole, and a decoration hole. In general, the drainage hole is placed near the middle of the rule or profile  722  along the vertical direction, while the screw hole is placed near the bottom of the rule or profile  722  along the vertical direction. In one embodiment, the boring unit includes at least one of a punching unit and a drill unit. The bending unit  730  is configured to bend the rules or profiles into the channel letter  732 . 
     The above descriptions of the disclosed embodiments are provided to enable any person skilled in the art to make or use the disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the disclosure. For example, although the examples describe only include three types of holes (i.e., drainage, screw, and decoration), other types of holes (e.g., access holes for maintenance) can be made using the apparatus and methods as described in the description section of the present disclosure. Thus, it will be understood that the description and drawings presented herein represent embodiments of the disclosure and are therefore representative of the subject matter which is broadly contemplated by the present disclosure. It will be further understood that the scope of the present disclosure fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present disclosure is accordingly limited by nothing other than the appended claims. 
     Accordingly, the foregoing embodiments are merely presented as examples and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatus and/or devices. The description of the present disclosure is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.