Abstract:
A canvas framing system and method for attaching canvas to an extruded aluminum frame to achieve a taut mount painting surface, including forming the frame of aluminum material, rounding selected corners and edges of the frame, temporarily securing a first portion of the canvas to the frame and attaching the canvas to the frame, preferably with staples using a modified staple gun, stretching the canvas on the frame and temporarily securing an opposing portion of the canvas to an opposing side of the frame, which is then stapled thereto, and stretching and attaching remaining portions of the canvas to the frame with the staple gun. Cross bracing can be installed on the frame to prevent bending when the canvas is stretched taut thereon.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of U.S. Provisional Patent Application No. 60/363,737 filed Mar. 12, 2002, where this provisional application is incorporated herein by reference in its entirety. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention is directed to a system and method for framing canvas, and more particularly, to an extruded aluminum frame with canvas mounting system that achieves a taut painting surface with a rigid, lightweight construction. 
   2. Description of the Related Art 
   It is desirable when painting on canvas to have the canvas stretched as tight and taut as possible. Typical frames, such as those made of wood, while suitable for their purpose, have difficulty retaining their shape and holding the canvas in a taut condition as the size of the frame increases. In order for such wood frames to properly function, they must be constructed of sufficiently thick and large pieces of wood that the weight becomes difficult to handle with ease. 
   Although lightweight composite and metal frames exist, these frames can be cumbersome to construct, require complicated steps to mount the canvas, and frequently do not retain their shape in larger sizes. Moreover, such frames can cause premature wear at points of contact with the canvas, leading to tearing of the canvas, loss of tension, and sagging of the canvas on the frame. 
   BRIEF SUMMARY OF THE INVENTION 
   The disclosed and claimed embodiments of the invention are directed to a system and method for framing canvas, and in particular to mounting canvas on an extruded aluminum frame that achieves a taut painting surface in combination with a rigid, lightweight frame suitable for wall mounting. 
   In accordance with one embodiment of the invention, a method of attaching canvas to a frame is provided that includes modifying a staple gun to shorten a ram component in the staple gun; forming an aluminum frame to include a plurality of sides welded together at corners; filing the corners and selected edges of the frame to present a smooth, rounded corner and edge; cutting canvas material to be sized and shaped for stretching over and attachment to the frame; temporarily attaching the canvas to one side of the frame and stapling the canvas to a staple track in the side of the frame; stretching and temporarily attaching an opposing portion of the canvas to an opposing side of the frame and stapling the canvas to the staple track in the frame on the opposing side; and stretching and attaching the remaining portions of the canvas to the frame by stapling the canvas to the staple track in the frame with the staple gun. Ideally, the canvas is stretched across the filed edges and corners of the frame. 
   In accordance with another embodiment of the invention, a method for attaching canvas to a frame to be suitable for painting and mounting on a wall is provided that includes forming a frame having at least four sides and a corner where adjacent sides join together to form a desired polygonal shape, the frame formed of metal material; rounding selected edges of the frame to present a smooth, round edge to prevent tearing of the canvas; cutting the canvas to the desired polygonal shape and to a size larger than the size of the frame to facilitate stretching of the canvas; stretching a first portion of the canvas over the frame and temporarily securing the first portion of the canvas to the frame; attaching the stretched portion of the canvas to the frame with fasteners positioned in a fastener track on the frame; stretching a second portion of the canvas opposing the first portion of the canvas over the frame and temporarily securing the second portion of the canvas to the frame; attaching the second portion of the canvas to the frame with fasteners positioned in the fastener track on the frame; and stretching and attaching remaining portions of the canvas to the frame with fasteners positioned in the fastener track on the frame. 
   In accordance with another aspect of the foregoing embodiments of the invention, a staple gun is used to attach the canvas to the frame, the staple gun ideally being modified to prevent the staple from cutting and punching through the canvas. Preferably, the staple gun is modified by reducing the length of the ram, such as filing the end of the ram. 
   In accordance with yet another aspect of the foregoing embodiments, the frame is preferably formed of aluminum material that is welded together. Ideally, after welding, the corners formed by welding are rounded, such as with a file, and one or more selected edges of the frame can also be rounded to present a smooth rounded surface against which the canvas is stretched to prevent tearing and premature failure of the canvas. 
   In accordance with yet a further aspect of the present invention, the frame is reinforced by cross bracing, ideally formed from interconnecting rods, to prevent the frame from bending when the canvas is stretched taut thereon. Preferably, the cross bracing is attached to the frame to not contact the canvas when the canvas is painted. 
   As will be appreciated from the foregoing, the use of aluminum provides a high strength-to-weight ratio, and the welding of the joints provides a much stronger structure than wood. This avoids the use of bracing in much larger sizes than traditionally have been accomplished with wood. Having the staple track or channel enables hiding of the staples from view and prevents a more finished appearance. In addition, using the clamps enables stretching the canvas with greater tension than manually. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     The disclosed embodiments of the invention will be more readily appreciated as the same become better understood from the following detailed description when taken in conjunction with the following drawings, wherein: 
       FIG. 1  is a cross-sectional view of a frame member formed in accordance with the present invention; 
       FIG. 2  is an illustration of the disassembled components of an embodiment of the framing system formed in accordance with the present invention; 
       FIG. 3  is an isometric view in partial cross-section of a corner construction of a frame in accordance with the present invention; 
       FIG. 4  is an illustration of a partially constructed frame of the present invention; 
       FIG. 5  is an illustration of one step of the method of the present invention for forming round corners; 
       FIG. 6  is a subsequent step of  FIG. 5  showing the rounding of a corner on the frame in accordance with the present invention; 
       FIG. 7  illustrates the completed frame placed on a sheet of canvas material; 
       FIG. 8  shows the frame of  FIG. 7  clamped to the sheet of canvas along one side; 
       FIG. 9  illustrates a staplegun modified in accordance with the present invention; 
       FIG. 10  illustrates the staplegun of  FIG. 9  positioned to attach the canvas to the frame of  FIG. 7 ; 
       FIG. 11  shows the attachment of staples to the canvas and the frame; 
       FIG. 12  illustrates trimming and cutting of the canvas after attachment to the frame; 
       FIG. 13  shows the partially assembled canvas on the frame; 
       FIGS. 14-19  show the finishing steps of attaching the canvas to the frame in accordance with the method of the present invention; and 
       FIG. 20  shows another embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The canvas framing system  21  of the present invention is illustrated in its completed form in FIG.  19 . The method for forming the canvas framing system will now be described in conjunction with  FIGS. 1-18 . 
   Referring initially to  FIG. 1 , shown therein is a cross-sectional view of an extruded aluminum frame member  20  having a top face  23 , front face  25 , bottom face  27 , and back face  29 . Projecting upward from the intersection of the top face  23  and back face  29  is a flange  22 . The frame member  20  is a commercially available component that can be purchased from American Sun Control, Alpharetta, Ga., and is identified as a Fabri-Frame 6063 aluminum extrusion. This particular frame is also shown and described in U.S. Pat. No. 5,555,695, which is incorporated in its entirety herein by reference. The frame member  20  has a staple track opening  24  formed in the bottom face  27 . Extending across an interior of the frame member  20  is a staple wall  30  that adjoins the front face  25  and the rear face  29 . In a preferred embodiment, the frame member  20  has a width of 1-inch and a height of 2-inches. 
   Referring next to  FIG. 2 , shown therein are the lengths and cuts of four aluminum pieces used to construct a frame, although it is to be understood that a frame could have different number of pieces, depending on its shape and application. In order to construct the pieces, a single extrusion of aluminum  32  is placed on a miter saw base with the bottom face  27  facing down and the rear face  29  placed against a saw guide or backing plate. The aluminum piece  32  is then cut at a mitered angle  34 , using a clockwise rotation of the saw&#39;s rotating base as viewed from the top. The length being cut is to the left of the blade. After putting this piece  32  on the other side of the blade and positioning it at the required length, shown with reference number  36 , the other end is cut at an opposite mitered angle  38  from the first cut, using a counterclockwise rotation of the saw&#39;s rotating base. A second piece is also cut using this same technique. 
   Two additional pieces  40  of the required dimension are also cut having a length  44  and mitered cuts  42  and  46 . 
   Cleaning of the pieces is ideally accomplished by holding the pieces  32  and  40  vertically and shaking aluminum shavings out of the end thereof. The pieces  32  and  40  are then cleaned, preferably with solvent. In one embodiment, rags soaked with acetone are used to wipe the entire surface of the pieces  32  and  40  to remove dirt and residue. 
   The pieces are then welded together, as shown in  FIG. 3. A  piece  32  and a piece  40  are welded at the miter joints  34  and  46  and at  38  and  42 , as shown in FIG.  4 . To accomplish the welding step, the two adjacent pieces  32  and  40  are clamped together flange-up on a flat table. Preferably, a TIG welder is used to weld the inside joint  48 . The process is repeated for the other joints. 
   The welded sections are then fitted together to make a desired shape. The remaining joints are welded in the same manner.  FIG. 4  shows the front view of a welded frame  50 . 
   To smooth the corners and prevent the canvas from tearing on the burred edges, the frame  50  is now filed at the corners  52 . The filing process begins as shown in  FIG. 5  on the frame  50 . While supported on supports, such as two sawhorses, the frame  50  is placed face-down. At a first corner  52  a bi-metal file  54  is used to smooth the corner edge  56 . The 2-inch edge  56  is rounded off to a ⅛-inch radius. The back corner  58  is also rounded to the same radius. All other back corners and corner edges are rounded in the same manner. 
   The frame  50  is then turned over to the face-up position, as shown in  FIG. 6 , for filing of the front side. The front corner  60  is filed and rounded in the manner described above, as are the other three front corners. With all corners and edges filed as described above, the frame  50  is now ready to have the canvas mounted thereon. 
   In most embodiments, the canvas material that is used is a # 10  cotton duck canvas. Referring next to  FIG. 7 , the canvas is rolled off the canvas roll and cut along line  62  a foot longer than the length of the frame  50 , which means approximately 6-inches longer on each end of the frame  50 , to provide sufficient extra material to grasp for stretching. The cut at  64  is also made approximately 1 foot longer. The canvas  66 , after it is cut, is laid flat on a work surface, as shown in FIG.  7 . The frame  50  is placed on top of the canvas  66 , either in a face-up or face-down position. One side  32  of the frame  50  is placed approximately 2-inches from the cut edge  64  of the canvas  62 . The frame  50  should be centered along its length on the canvas  66 . A line  70  is drawn on the canvas  66  along the outside edge  26  of the side  32  of the frame  50 . The canvas piece  66  is now ready for stretching. 
   The canvas  66  is stretched onto the aluminum frame  50 , as seen in FIG.  8 . The frame  50  is set against a wall or other supporting surface face-in and having the long dimension in a horizontal orientation. The canvas  66  is placed over the top of the frame  50  and behind it, as shown in FIG.  8 . The drawn line  70  on the canvas should be showing at the top back edge  26  of the frame  50 . The side  64  of the canvas  66  will be along the top edge of the frame  50 . Using two spring clamps  74  (Pong model no. 3202), one at each end, the canvas  66  is secured to the top face  29  of the frame  50  and centered lengthwise. 
   The canvas  66  is then stapled onto the frame  50  using an air-powered staplegun  76 . In a preferred embodiment, a Senco model no. SLS20 with Senco L06BAB staples  78  is used. As shown in  FIG. 9 , the staplegun  76  must be modified so that the movable ram  80  (the component that shoots the staple out of the staple gun  76  when the trigger is pulled) is filed back approximately 1/16-inch. This prevents the entire staple from punching through the canvas  66  and cutting the canvas  66 . The pressure in the air compressor used with the staplegun  76  should be at approximately 60 psi. 
   Referring next to  FIG. 10 , the staplegun  76  is held at one end of the staple track  24 . The spring clamp  74  is removed from that end of the frame and (with the canvas  66  and the staplegun  76  positioned in the staple track  24 ) adjust the position of the canvas  66  so that the drawn line  70  is positioned at the bottom center of the staple wall  30 . When the canvas  66  is correctly positioned, two staples  78 , positioned approximately 2-inches from the end of the side track  24 , are installed. 
   Referring next to  FIG. 11 , while keeping the drawn line  70  at the center of the staple wall  30 , the canvas  66  is pulled tight horizontally and stapled at 3-inch intervals, as shown by the staples  78 . The other spring clamp  74  is removed when half of the side of the canvas  66  is stapled. Stapling is continued until 2-inches from the end of the frame  50 . All vacant spaces are then stapled, except the ends, at 1-inch intervals. 
     FIG. 12  shows the next step. At one end, the canvas  66  is pulled tight. With the use of scissors  80 , a cut  82  is made along an outside edge of the canvas adjacent the staple track  24 , and ¼-inch past the drawn line  70 , as shown in FIG.  12 . While still pulling the canvas horizontally  66 , two staples  78  are installed in each end section. This procedure is repeated at the other end. 
   Still referring to  FIG. 12 , and starting at an intersecting corner of the staple track  24 , a utility knife  84  is used to make a 3-inch cut  86  along the inside edge of the staple track  24  to release the excess canvas. A cut  88  is then made to the edge of the canvas  66  at approximately a 135° angle  90  to the previous cut  86 . The above process is repeated at the other end of the side  32 . The first side  64  of the canvas  66  is now stapled to the side  32  of the frame  50 , as seen in FIG.  13 . 
   Next, the frame  50  with the canvas  66  is inverted (turned 180°). Referring next to  FIG. 14 , the canvas  66  is pulled tight at the midpoint of the length  92  of the frame  50 . Using a Vice-Grip clamp  94  (preferably model no. 9R with two 90° bent fingers  96  as shown in FIG.  15 ), the canvas  66  is fastened to the frame  50  with the clamp fingers  96  in the staple track  24 . The clamp fingers  96  must also be filed at the end, as shown in  FIG. 15 , so they do not tear the canvas  66 . 
   Working on one-half of this side  92 , the canvas  66  is pulled tight and secured with clamps  94  at 5-inch intervals until the corner is reached. 
   Starting with the second clamp  94  from the center, the canvas  66  is retightened and reclamped with vice-grips  94  to the frame  50 . With several clamps  94  on the frame  50 , it allows the canvas  66  to be tightened gradually. This is repeated two or three times until the canvas  66  is extremely taut. 
   A cut  82  is made adjacent the staple track  24 , as shown in FIG.  12 . Three staples  78  are put between each clamp  94 , and one staple  78  is placed on the outside of the second and corner clamps  94 . All clamps  94  are removed except the center clamp, and three staples  78  are put in each vacant space, approximately 1-inch apart in this embodiment. Two cuts  86 ,  88  are made on the end as described above in conjunction with FIG.  12 . 
   The above procedure is repeated for the second half of this side  92 , but also stapled on each side of the center clamp and in the vacant space when the center clamp is removed. The second side  92  is now stretched on, as seen in FIG.  13 . 
   The frame is then turned a quarter turn (90°). As shown in  FIG. 16 , working at either corner, the canvas  66  is pulled tight around the 2-inch edge  56 . The canvas edge  82  is then pulled, after folding it under ½-inch at a mitered angle from the corner  58  of the frame  50  and down the staple track  24  miter. The resulting flap  100  is then stapled  78  into the staple track  24 . Using a utility knife  84 , the excess canvas is trimmed off the flap  100  along the inside edge of the staple track  24 , and it is cut along edge  102 . 
   As illustrated in  FIG. 17 , the remaining canvas  66  starting from the front corner  60  is folded, and this edge is pulled to the outside edge of the adjacent staple track  24 . This flap  104  is then stapled into the staple track  24  with two staples  78 . For the other corner on this side  106 , the above process is repeated, as shown in  FIGS. 16 and 17 . 
   For the remaining length of this side  106  of the canvas  66 , the process as described for the second side  92  is repeated, except for the corner-procedure because the corners are already completed. The third side  106  is now stretched on. 
   For the last side  108 , the procedure described for the third side  106  is repeated. The canvas  66  is now stretched onto the frame  50  as illustrated in FIG.  13 . 
   The canvas  66  is now ready to be trimmed along the back. The stretched canvas  110  is standing with the back face showing and the front face towards the wall. As seen in  FIG. 18 , a sharp knife  112 , such as an X-acto knife with a # 11  blade is used. Starting on either of the sides  64 ,  92 ,  106 , or  108 , the entire length of the canvas  66  along the inside edge of the staple track  24  is trimmed. This process is repeated on the other three remaining sides. The canvas  66  is now trimmed in the installed configuration. 
     FIG. 19  shows the front and back views of the framing system  114  that includes the frame  50  and the stretched canvas  66 , in this case a quadrilateral example. 
   It is to be understood that while a preferred embodiment of the invention has been illustrated and described, various changes may be made therein. For example, the frame may have any polygonal shape, or it may be circular or oval. 
   In situations where the frame is larger than 4 feet along any side, reinforcing members should be used. These reinforcing members are shown in  FIG. 20  as cross braces formed of solid round aluminum rods  120  that are attached at the back of the frame  50  and intersect each other across the center of the back. The intersection  122  of the rods  120  may be formed in any conventional manner. In frames larger than 8 feet, a meshwork of reinforcing rods may be used, in which case the center section should be left open in order to prevent interference with the canvas as it is pushed by the brush when being painted. In other words, it is undesirable to have the canvas contact the tubular reinforcing rods  120  when being painted. 
   From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims and the equivalents thereof.