Patent Abstract:
A hinged sign face assembly is provided for use on a standard sign box. The assembly may be retrofitted on an existing sign box to facilitate access to fluorescent light tubes and other components inside the sign box. The assembly pivots the face of a sign box to an open position to allow interior components to be accessed without the need for disassembling the sign box frame. The assembly includes a hinge adapter that mounts to a standard sign box. The hinge adapter is operable with commercially available components to convert a rigid standard sign box to a hinged sign box. The assembly may also include a hinge connector secured with the sign face that may be connected to the adapter in a hinged manner without fasteners. The hinge connector supports the sign face and cooperates with the adapter to allow the sign face to pivot on the sign box.

Full Description:
RELATED APPLICATIONS 
   This application claims priority from U.S. Provisional Application No. 60/369,747, filed Apr. 4, 2002, the entire disclosure of which is incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention relates generally to extrusion members used in the construction of sign and display assemblies and, more particularly, to an assembly for adding a hinged face to a sign or display cabinet. 
   BACKGROUND 
   In the present state of the art, illuminated signs are commonly constructed using rectangular sign boxes or cabinets. A sign box typically encloses a light source, such as a row of flourescent light tubes, that is mounted within the sign box. The sign box has one or more faces formed of translucent sheets that are mounted over the light source. Each face may be painted or marked with text or a design that is illuminated by the light source inside the sign box. 
   Sign boxes provide a weatherproof housing for the fluorescent light tubes, ballasts, wiring and other components in the sign. In many cases, the sign box is constructed using a framework of aluminum extrusions which form frame members and mounting components. The frame members and sign faces must be rigidly connected with one another to support the weight of the sign and withstand external forces, such as gale winds. At the same time, the frame members must allow access to the internal components of the sign so that the internal components can be serviced. 
   In many standard sign boxes, sign faces are bolted to the sign box frame. To service internal components in the sign box, the sign faces are disassembled from the frame to enable access to the sign box interior. Disassembly of a sign face requires effort and increases the overall time required to perform routine service on a sign installation. Accordingly, it is beneficial to provide an assembly for sign boxes to permit access to the interior of the sign box without requiring disassembly of the frame structure for the sign. One approach to solving this problem has been the use of sign boxes that have sign faces mounted to the frame on a piano hinge. Piano hinges allow a sign face to be pivoted to an open position without disassembling the frame. However, the piano hinge has been conventionally attached to both the frame and the sign face making complete removal of the sign face from the frame difficult. While it is nice to have a sign face that swings open, in certain applications, it would be even more desirable to have a sign face that has both the capability to be swung open and the capability to be easily detached from the frame. In still other applications, replacing the piano hinge for a more simplified hinge assembly creates a more cost effective design. 
   SUMMARY OF THE INVENTION 
   In light of the foregoing, the present invention provides a hinge assembly for enabling a sign face to be hinged to a sign box frame. The hinge assembly may be retrofitted to an existing sign box installation. Alternatively, the hinge assembly may be manufactured and sold as part of a new sign box installation. The hinge assembly allows a standard sign box to be opened and closed, permitting easy access to internal components in the sign box. In one embodiment of the invention, the components of the assembly may be mounted over the front face of a sign box to permit the front face to be pivoted open and closed. 
   The hinge assembly may include one or more components for mounting on a new or existing sign box. For example, an adapter may be provided to enable a sign face or a sign face assembly to be mounted on a sign box frame in a hinged manner. The hinged sign face may be mounted onto the adapter without the need for special tools or additional fasteners. The adapter may be formed from various materials and have different shapes for attachment to a sign box frame. For example, the adapter may be formed of an aluminum extrusion and include a main body portion configured for attachment to a sign box frame. A fulcrum may be provided on the adapter for supporting the sign face. Alternatively, a receptacle may extend from the main body portion of the adapter over a side of the sign box to allow for the hinged connection of a sign face assembly on the sign box. The receptacle may be configured in the form of a slotted box having a receptacle slot to serve as a hinge receptacle. The hinge assembly may also include a hinge connector on a sign face or a sign face assembly that is mountable on the adapter in a hinged manner without the need for tools or fasteners. The hinge connector may include a hinge tongue that is configured to be supported on the fulcrum or inserted within the receptacle slot of the adapter to form a hinge. The hinge connector may be attached to various types of sign faces or sign face assemblies for hinged mounting on the adapter. For example, the hinge connector may be attached to a rigid sign face material, a flexible sign face material, or a support assembly for such face materials for attachment to the sign box. 

   
     DESCRIPTION OF THE DRAWINGS 
     The foregoing summary as well as the following description will be better understood when read in conjunction with the figures in which: 
       FIG. 1  is a fragmented cross-sectional elevation view of a hinge adapter mounted on a sign box in accordance with the present invention. 
       FIG. 2  is a fragmented cross-sectional elevation view of a hinged sign face assembly in accordance with the present invention, showing the hinge adapter and a sign face assembly hinged to the adapter and pivoted to an open position on a sign box. 
       FIG. 3  is a fragmented cross-sectional elevation view of the hinged sign face assembly of  FIG. 2 , showing the hinge adapter and the sign face assembly pivoted to a closed position on the sign box. 
       FIG. 4  is a fragmented cross-sectional elevation view of the hinge adapter of  FIG. 1  mounted with a pivot stop mechanism that engages the hinge connector of the sign face assembly. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring to  FIGS. 1–4  in general, and to  FIGS. 1–2  specifically, a hinge adapter, generally designated  10 , for use in a hinged sign face assembly is shown. The adapter  10  is configured to be mounted on the top surface  6  of a standard sign box  5 . The adapter  10  is mountable along a top edge  6  of the sign box  5  to support a sign face assembly  9  having a sign face  7  in a hinged manner on the sign box  5 . The sign face assembly  9  is supported by and hinged to the adapter  10  and is pivotal on the adapter between an open position, as shown in  FIG. 2 , and a closed position, as shown in  FIG. 3 . In the open position, the sign face assembly  9  is pivoted on the adapter away from the sign box so that the internal components in the sign box are accessible for servicing. In the closed position, the sign face assembly  9  is pivoted on the adapter so as to enclose and protect the internal components within the sign box. 
   The hinge adapter  10  has a configuration that is simple to manufacture by conventional techniques, such as by extrusion or molding. The adapter  10  can be incorporated onto existing sign boxes as well as new sign box installations. The adapter  10  comprises a generally rectangular body section  12 , which as shown in  FIG. 1  may be hollow. The main body section  12  is configured for attachment along the top edge  6  of the sign box  5 . The hinge adapter  10  has a fulcrum that extends from the body section  12  for supporting a number of commercially available components so as to form a hinge-like connection for a sign face assembly  9 . 
   In the embodiment of  FIG. 1 , the fulcrum comprises an extension arm  32  that extends from the body section  12  and connects with a side wall  37  that in turn supports an upper pivot arm or wall  38  having a face end  42  spaced away from the body section  12  to form a slotted receptacle  17  which serves as a hinge receptacle. The pivot arm  38  has a rounded terminal end  42  disposed at the mouth of a receptacle structure  39  that is configured to slidably engage and support a number of commercially available components so as to form a hinge-like connection for a sign face assembly  9 . 
   Referring now to  FIGS. 1–3 , the hinge adapter  10  will be described in more detail. The adapter  10  is an elongated member that may be formed, for example, by extrusion, out of aluminum or other suitable material. Alternatively, the adapter  10  may be formed from molded plastics. The body section  12  of the adapter  10  forms a generally rectangular shaped tube that is mountable on the top face of a standard sign box  5 . The body  12  has a substantially flat top wall  14  having a first end  16  and a second end  18 . The body  12  also has a substantially flat bottom wall  20  generally parallel to the top wall  14 . The bottom wall  20  has a first end  22  and a second end  24 . A first side wall  28  is connected to the first end  16  of the top wall  14  and extends toward the bottom wall  20  where it connects with the first end  22  of the bottom wall. A second side wall  30  is connected to the second end  18  of the top wall  14  and extends toward the bottom wall  20  where it connects with the second end  24  of the bottom wall. The top wall  14 , bottom wall  20 , first side wall  28  and second side wall  30  combine to generally form a hollow rectangular shaped body section  12 . 
   The body section  12  may be connected to the sign box  5  using any appropriate mounting method. In  FIG. 1 , the body section  12  is shown mounted to a sign box  5  using a screw  44 . A pair of aligned bores  46  are formed in the body section  12  for enabling the adapter  10  to be mounted on the sign box  5 . More specifically, the top wall  14  and bottom wall  20  have bores  46  that are centrally located between the first and second sidewalls  28 ,  30  and are axially aligned relative to one another. The bores  46  are configured to align axially with a threaded bore on the sign box  5  to allow the screw  44  to attach the body section  12  to the sign box. Preferably, the bores  46  have diameters that are slightly larger than the maximum outside diameter of the threading on the screw  44 . In this way, the bores  46  allow adequate clearance of the screw  44  while limiting the potential for movement of the adapter  10  on the sign box  5  if the screw becomes loose. 
   The receptacle  39  is attached to one side of the main body  12  to provide the hinge receptacle. The receptacle  39  may be integrally formed with the main body  12 , for example, as a single extrusion, or may be separately attached or secured to the main body  12 . The receptacle  39  includes an extension arm or wall  32  which is a generally flat wall having a first end  34  and second end  36 . The second end  36  of the extension arm  32  is connected to the first end  22  of the bottom wall  20 . As such, the extension arm  32  forms a generally continuous surface with the bottom wall  20 . The pivot arm  38  is also generally flat and extends generally parallel to the extension arm  32 . The pivot arm  38  has a first end  40  and a rounded second end  42  that extends toward the body section  12 , as shown in  FIG. 1 . A gap  43  is formed between the rounded end  42  of the pivot arm  38  and the first side wall  28  on the body section  12  to provide an access slot to the slotted receptacle  17 . A third side wall  37  is connected to the first end  40  of the pivot arm  38  and extends toward the extension arm  32  where it connects with the first end  34  of the extension arm to form an elongated slotted box-like structure which serves as the slotted receptacle  17 . The third side wall  37  may be shorter than side walls  28  and  30  to account for the thickness of a mating hinge connector  51  of the sign face assembly  9 . 
   As stated earlier, the hinge adapter  10  is configured to attach a sign face assembly  9  to a sign box  5 . The rounded second end  42  of the pivot arm  38  is configured to pivotally support a sign face assembly  9  to permit the face to be opened and closed on the sign box  5 . More specifically, the rounded second end  42  is configured to slidably engage a curved hinge connector element  51  on a separate mounting assembly for the sign face  7  to permit the connector element  51  to pivot about the rounded second end  42  of the adapter. The hinge adapter  10  is compatible with a variety of mounting components having different geometries. Therefore, the hinge adaptor  10  is intended as a universal adapter for use in a variety of hinged sign face assemblies. 
   Referring to  FIGS. 2–3 , the adapter  10  is shown as part of a hinge assembly generally designated as  8 . The adapter  10  pivotally engages with the hinge connector  51  of a sign support component  50  of the sign face assembly  9  in a hinge-like manner. The sign support component  50  serves as a mounting bracket for holding the sign face  7  in a hinged interrelationship with the sign box  5 . The sign face assembly  9  may be used to support either a flexible sign face material or a rigid sign face material. In  FIGS. 2–3 , the sign face assembly  9  is shown pivotally supporting a flexible sign face  7 . The hinge connector  51  may, as shown in  FIG. 2 , be provided as an integral part of the sign support  50 . The sign support  50  includes a first channel  66  in which the flexible sign face  7  is anchored using a staple  70  and a flexible insert  72  pressed into the channel over the sign face material. The sign support  50  also includes a second channel  74  configured to connect with a backset brace  76  to provide strength and rigidity in the sign box  5 . Details regarding the construction of the flexible sign face  7  and backset brace  76  may be found in U.S. Pat. No. 6,112,444, the contents of which are incorporated herein by reference. 
   The sign support bracket  50  has a generally flat top wall  52  having a first end  54 , a second end  56  and a middle section  58 . A first sidewall  60  extends from the middle section  58  on the top wall  52  in a direction generally perpendicular to the orientation of the top wall. A short second sidewall or tongue  62  extends from the second end  56  of the top wall in a direction generally parallel to the first side wall  60  so as to form an “L” shaped projection which serves as the hinge connector element  51 . The top wall  52  connects with the second side wall  62  to form an interface hook  64  that engages the second end of the pivot arm  38 . The interface hook  64  may be rounded, as shown in  FIG. 2 , to generally conform to the radius of curvature of the second end  42  of the pivot arm  38 . The inner curvature of the “L” shaped projection slidably pivots on the second end  42  of the pivot arm  38 . As such, the support bracket  50  is configured to pivot relative to the second end of the pivot arm. 
   The hinge connector  51  is configured for pivoting between a closed position and an open position. In the closed position, the top wall  52  of the support bracket  50  rests on top of the pivot arm  38  such that the top wall  52  is generally parallel to and supported by the pivot arm and such that the first side wall  60  of the support bracket  50  rests against and is supported by wall  37  of the adapter, as shown on  FIG. 3 . In the open position, the top wall  52  of the support bracket  50  is rotated such that the top wall  52  is pivotally spaced away from and disposed at an acute angle relative to pivot arm  38 , as shown in  FIG. 2 . The hinge connector  51  is operable to pivot the flexible sign face  7  and backset brace  76  such that the interior components of the sign box can be accessed. More specifically, the hinge connector  51  is operable to move the sign face  7  and backset brace  76  so that the fluorescent light bulbs and other interior components in the sign box are accessible for servicing. The flexible sign face  7  is pivoted about its top edge on the sign box. The bottom edge of the sign face  7  may be releasably connected to the sign box using a hasp or other latching device that releases to allow the sign face to be opened and then pivoted open about its top edge. 
   Thus far, the hinge assembly  8  has been described with reference to a single hinge adapter  10  mounted on a sign box. However, the hinge assembly  8  may utilize one or more hinge adapters  10  to attach a sign face assembly to a sign box. A single hinge adapter  10  may span the entire width of a sign box or span a portion of the sign box width. Alternatively, the hinge assembly  8  may utilize a plurality of short adapters that are mounted in series along the width of a sign box  5 . Where a plurality of adapters  10  are used, the adapters are mounted such that the rounded ends  42  of each pivot arm  38  are substantially aligned with one another. 
   As stated earlier, the hinge connector  51  is pivoted on the rounded second end of the pivot arm  38  to move the sign face assembly  9  to the open position. When the hinge connector  51  is pivoted beyond a certain threshold angle relative to the pivot arm  38 , the sign face assembly  9  may succumb to gravitational forces and disengage from the pivot arm. That is, the inner curvature of the “L” shaped projection of hinge connector  51  may slide out of engagement with the second end  42  of the pivot arm  38  under the weight of the sign face assembly  9 . At such time, the top wall  52  of the hinge connector  51  may slip through the gap  43 , rendering the hinge connection inoperable until the hinge connector is reset on the pivot arm. Such disengagement may be desirable in certain applications in order to permit the removal of the sign face assembly  9  from the adapter  10 . However, in applications where the sign face assembly  9  is not intended to be removed, it may be desirable to limit the angular rotation of the hinge connector  51  so that it cannot be pivoted beyond the threshold angle. 
   Referring now to  FIG. 4 , the hinged sign face assembly is shown with a pivot stop  80  attached to the hinge adapter  10 . The pivot stop  80  is configured to limit the angular rotation of the hinge connector  51  relative to the adapter  10  and maintain the hinge connector  51  in pivotal engagement with the pivot arm  38 . The pivot stop  80  comprises a substantially flat base  82  and a cantilever arm  84  extending from the base. The base  82  is configured for mounting on top of the body  12  of the hinge adapter  10 . The cantilever arm  84  extends from the base and over the pivot arm  38 . More specifically, the cantilever arm  84  projects from the base  82  outwardly and upwardly relative to the base, extending at an acute angle relative to the pivot arm  38 . The cantilever arm  84  has a bottom surface  85  that is configured and positioned to contact the top wall  52  of the hinge connector  51  when the hinge connector is pivoted to the open position. When the top wall  52  of the hinge connector  51  bears against the bottom surface  85  of the cantilever arm  84 , further rotation of the hinge connector is substantially prevented. As such, the angle of orientation of the cantilever arm may be selected to limit the angular displacement of the hinge connector  51 . The selected angle of orientation of the cantilever arm may be a function of several variables and conditions, including but not limited to, the weight of the sign face assembly and the clearance space required when the sign face assembly is pivoted to the open position. 
   A pivot space  86  is formed between the pivot arm  38  and the cantilever arm  84  and is configured to permit limited angular rotation of the hinge connector  51 . Preferably, the hinge connector  51  is shaped such that the top wall  52  and second side wall  62  have the same thickness. In addition, the pivot space  86  preferably has a width generally equal to the width of the top wall  52 . In this way, the hinge connector  51  can pivot smoothly on the pivot arm  38  between the open and closed positions with minimal potential for sliding or disengagement from the pivot arm. The pivot stop  80  may be connected to the adapter  10  using any appropriate mounting method. In  FIG. 5 , the pivot stop  80  is shown mounted with the same screw  44  used to secure the adapter  10  to the sign box  5 . The pivot stop  80  has a bore  88  that is configured to receive the screw  44  and align coaxially with the bores  46  in the adapter  10 . 
   The terms and expressions which have been employed are used as terms of description and not of limitation. There is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or any portions thereof. It is recognized, therefore, that various modifications are possible within the scope and spirit of the invention. For example, it may be desirable to have a sign face that is easily removable from the hinge adapter  10 . In such case, the pivot stop  80  may be omitted, and/or the gap  43  may be widened to facilitate lifting and removal of the sign face assembly out of the hinge adapter. Accordingly, the invention incorporates variations that fall within the scope of the following claims.

Technology Classification (CPC): 6