Flexible face sign
CROSS REFERENCE TO RELATED APPLICATION 
     This is a continuation-in-part of Ser. No. 07/699,342, filed May 13, 1991, and now pending. 
    
    
     FIELD AND BACKGROUND OF THE INVENTION 
     The present invention relates in general to sign constructions, and in particular to a new and useful single or multiple face sign which utilizes flexible sign face material. 
     A wide variety of tensioning system for flexible sign face is known. See for example U.S. Pat. No. 3,885,335 to Egermayer which shows a double face sign having flexible face material and edge systems for tensioning the material. A back lighted sign using flexible material is also disclosed in U.S. Pat. No. 4,185,408 to Tracy. A sign having a flexible sheet material stretched on a heavy duty frame which is hinged to a sign box is disclosed in U.S. Pat. No. 4,516,343 to Stilling. 
     Flexible double face signs on the order of eight feet square and smaller are not economically feasible when compared to double face rigid acrylic signs common in the industry today. 
     Flexible double face signs with lighted graphics or displays on opposite sides require a stronger frame than rigid acrylic double face signs. Tensioning of the flexible vinyl creates a stress load of 30 lbs per square foot (pfs) that must be resisted by the frame. The flexible vinyl also transmits wind loads to the frame in a different manner than rigid acrylic, again requiring additional frame strength. Adding strength to the frame creates an exponential increase in cost and weight. The cost vs. strength equation has created an economic barrier in the sign industry which no one has been able to overcome. 
     In addition, one or both sign faces in a double face sign must be hinged to open and provide access to the interior of the sign for lamp and ballast maintenance. A rigid frame around the perimeter of the flexible sign face must be strong enough to resist tensioning and wind loads. 
     SUMMARY OF THE INVENTION 
     The present invention provides a sign with a low strength, light weight cover frame in combination with a stronger main sign frame which is comparably priced and stronger than rigid acrylic signs. 
     The frame of the invention is required only to hold the flexible sign face. Tension is completed only when the hinged or removable cover frame of the sign is closed and secured to the main sign frame. The main sign frame is inherently strong enough to resist all loads involved. 
     By combining a low strength, light weight cover frame with a rigid and strong main side frame, and an appropriate apparatus to tension the flexible sign face when the two frames are fixed to each other, the invention provides a relatively large flexible sign face with no seams. In addition, the sign face may be selected to match the color scheme, designs and texture of other flexible face signs used at a particular installation, for example, a gas station or convenience store. Accordingly, an object of the present invention is to provide a sign comprising, a rigid main frame having at least one face plane, a tension edge member connected to the rigid frame and having a tensioning edge extending parallel to the plane, a removable cover frame detachably connected to said main frame at said plane, at a location outwardly spaced from said tensioning edge, a flexible sign face for carrying a sign display and having a plurality of outer edges, preliminary tensioning means connected between the sign face edges and the cover frame for pretensioning the sign face on the cover frame, and final tensioning means connected between the cover frame and the main frame for urging the cover frame toward the plane of the main frame to press the flexible sign face against the tensioning edge to complete tensioning of the flexible sign face. 
     Another object of the present invention is to provide a sign which utilizes flexible face material and which is simple in design, rugged in construction and economical to manufacture. 
     The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which the preferred embodiments of the invention are illustrated. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
     FIG. 1 is a side elevational view of a double face sign incorporating the present invention; 
     FIG. 2 is a front elevational view of the sign shown in FIG. 1; 
     FIG. 3 is a side sectional view of the apparatus for pretensioning and final tensioning of the flexible sign face according to the present invention, in an open position; 
     FIG. 4 is a view similar to FIG. 3 of the invention in a closed position; and 
     FIGS. 5 and 6 are views similar to respective FIGS. 3 and 4 showing a second embodiment of the present invention; 
     FIGS. 7 and 8 are respective views similar to FIGS. 3 and 4 showing a third embodiment of the present invention; 
     FIGS. 9 and 10 are respective views similar to FIGS. 3 and 4 showing a fourth embodiment of the present invention; 
     FIGS. 11 is a view similar to FIG. 3 showing a fifth embodiment of the invention; 
     FIG. 12 is a schematic front elevational view of a double face sign showing the resilient deflection required in the frame for fully tensioning the flexible sign face; 
     FIG. 13 is a view similar to FIG. 3 of a sixth embodiment of the invention; 
     FIGS. 14 and 15 are views similar to respective FIGS. 3 and 4 showing a seventh embodiment of the invention; 
     FIGS. 16 and 17 are views similar to respective FIGS. 3 and 4 showing an eighth embodiment of the invention; 
     FIGS. 18 and 19 are views similar to respective FIGS. 3 and 4 showing a ninth embodiment of the invention; and 
     FIGS. 20 and 21 are views similar to respective FIGS. 3 and 4 showing a tenth embodiment of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings in particular, the invention embodied in FIGS. 1 and 2 is a double face sign generally designated 1 having a strong rigid main frame or sign box 10 which contains all appropriate ballasts, lighting tubes and structures for illuminating the opposite faces of the sign. The flexible sign face 20 carries all graphics, displays and indicia, and is illuminated from behind by the light fixtures in main frame 10. Although advantageously, two flexible sign faces are provided on opposite sides of the main frame 10, for the purposes of the present disclosure, only one of these sign faces will be discussed. The other may be identical or similar. 
     Flexible sign face 20 is carried on a relatively light weight cover frame 18 which is shown in its closed solid line position in FIG. 1, and an open phantom line position. Cover frame 18 is advantageously hinged at a hinge 19, to the top of main frame 10. Alternatively, the cover frame may be removably mounted to the main frame 10. 
     FIG. 3 is a sectional view of a front lower portion of the sign in its open condition. Main frame 10 has a face plane 12 which is parallel to the final display plane of the flexible sign face 20 when the frame is closed. A tension edge member 14 in the form of an aluminum angle iron or similar structure, is attached to the main frame 10 by a rivet or other means 15, at the face plane 12. A foam gasket 17 is provided between one leg of tension member 14 and the face plane 12 of the frame 10. The other leg of member 14 carries a tensioning edge 16 which extends parallel to the face plane 12. The tension edge member 14 may also be a continuation of the main frame 10, providing the tensioning edge 16 without gasket 17 or rivet 15. Frame 10 includes four sides which form the rectangular or square frame. A tension member 14 with edge 16 is advantageously provided on each side of the frame. Alternatively, however, two opposite tension members may be provided on opposite sides of the frame or even a single tension member may be utilized opposite the hinge to satisfactorily tension the flexible face. A preferred embodiment of the invention however, includes four tensioning edges 16 in a rectangular or square configuration. 
     In constructing the sign, outer edges of the flexible sign face 20 are first pretensioned to the cover frame 18 by preliminary tension means 22. This may be of the type disclosed in U.S. Pat. No. 4,955,928, entitled TENSIONING CONNECTOR FOR RETAINING SIGN MEMBRANES, assigned to the assignee of the present application. Other preliminary tensioning means may be provided, however. The only requirement is that the flexible face 20 be pretensioned across the cover frame 18 to avoid wrinkles and somewhat support the flexible face in a planar configuration. Pretensioning must not be particularly strong however, because of the light weight construction of cover frame 18. 
     The preliminary tensioning means 22 shown in FIGS. 3 and 4 comprises a click member 24 containing an open channel 26 extending along the side of cover frame 18. A plastic binder 28 is wedged into channel 26 by the outer edge area of flexible face 20 which is partly wrapped around the binder 28. 
     An outer surface of click member 24 carries teeth 30 which are inclined outwardly with respect to the sign face 20 and toward the main frame 10. These teeth mesh with teeth 32 defined on the inner surface of the cover frame 18. By moving the click member 24 outwardly on the cover frame 18, a meshing engagement between selected teeth on the two members is established to pretension the flexible face 20. To maintain the position of click member 24, a set screw 34 screwed into the outer edge of frame 18 is turned to press inwardly against the click member 24 and hold it in position. 
     Frame 18 is also provided with a plurality of bores 36 which are spaced at intervals around the frame. Each bore receives a bolt 38 which extends toward the main frame 10. A spacer in the form of a plastic or aluminum spool 40 is engaged around the bolt 38 to maintain a desired spacing between the frame 18 and frame 10 when the two frames are engaged with each other. 
     At spaced locations corresponding to the locations of bores 36, frame 10 includes its own set of bores 42 which each contain a threaded insert 44 having female threads which match the male threads of bolt 38. 
     An additional foam gasket 46 is engaged around frame 10 outwardly of the bores 42. The preliminary tensioning means 22 is also positioned on the cover frame 18 in a position that is outwardly of the tension member 14, when the cover frame is engaged to the main frame. 
     Cover frame 18 also includes a second tensioning edge 48 which extends inwardly of the frame but which is still positioned outwardly of the first tensioning edge 16 when the cover frame is engaged to the main frame. 
     To complete the tensioning of flexible face 20, the cover frame 18 is fully engaged to the main frame 10 and urged toward the face plane 12 in a manner shown in FIG. 4. 
     For this purpose, the detached or hinged cover frame 18 is pushed toward the face plane 12 and the bolts 38 are screwed into their respective inserts 44. In the final closed position as shown in FIG. 4, the inner surface of sign face 20 is urged against the first tensioning edge 16. This causes the material of sign face to be moved outwardly with respect to the frame 18, and thus, at a close outwardly positioned location with respect to edge 16, the material of sign face 20 is pressed against the second edge 48. This S-shaped configuration for the edge area of sign face 20 completes the tensioning which is transmitted to the stronger main frame 10 by the bolts 38. For this reason, cover frame 18 may be made of light and relatively weak construction. 
     For the same reason, the completely tensioned sign face 20 in the sign construction 1 is capable of withstanding 70 psf. This far exceeds the maximum required 55 psf for double face signs using flexible sign faces, and is far in excess of the 35 psf which is the maximum force rating on acrylic signs. 
     To exclude water from inside the main frame 10, gaskets 17 and 46 are provided, between the cover frame and the main frame 10. Spacer 40 maintains a correct spacing to avoid over crushing the gaskets. 
     Alternate embodiments of the invention position the second tensioning edge 48 inside the first tensioning edge 16 to achieve complete tensioning of the flexible sign face 20. Pretensioning means 22 may also be replaced by a simpler apparatus. For example, the cover frame 18 may be formed of angles and the edge of flexible sign face 20 trapped to one leg of the angle by a plate riveted or otherwise connected to the leg of the angle. Shims can be used between the cover frame and the main frame to adjust the amount of tensioning of the flexible sign face. In a still further embodiment of the invention, complete tensioning is achieved without the use of any tensioning edge but simply by connecting the cover frame to the main frame through an inclined, wedged, cammed or rocker arrangement which tends to spread the frame as the frame is brought to the face plane of the main frame. 
     In addition to the comparable cost of the flexible sign of the present invention and the acrylic signs of the prior art, the present invention is far safer since when the acrylic sign blows out, the sharp jagged pieces of acrylic material represent a serious safety hazard. 
     In FIGS. 5 through 21, the same reference numerals are utilized to designate the same or structurally similar parts wherever practical. 
     An alternate embodiment of the present invention shown in FIGS. 5 and 6 are substantially the same as the embodiment of FIGS. 3 and 4 except that the tensioning edge 16 on the tensioning member 14 is positioned outwardly of the second tensioning edge 48 on the cover frame 18. Despite this alternate placement of edges 16 and 48, the flexible sign face 20 is completely tensioned as shown in the closed position for the cover frame in FIG. 6. 
     Another embodiment of the invention is illustrated in FIGS. 7 and 8 which differs from the embodiment of FIGS. 3 and 4 by positively fixing the outer edge of flexible face 20 to an inner surface of an L-shaped cover frame 18, by a rigid binder strip 28 which is fixed to the inner surface by bolts 29 with the edge of sign face 20 trapped between the binder strip and the cover frame. To adjust the tensioning effect of edges 16 and 48, a removable plate shaped shim 47 may also be provided on the surface of cover frame 18 which faces main frame 10, and engages gasket 46. In the embodiment of FIGS. 7 and 8, the second tensioning edge 48 is also on a hook-shaped projection of cover frame 18 which curves toward the main frame 10. 
     FIGS. 9 and 10 illustrate an embodiment of the invention wherein a cover frame 19 having a U-shaped cross section defines an inner recess which receives and fixes the outer edge area of a flexible sign face 20 using a binder strip 28 and rivets 31. 
     As cover frame 19 is moved from its open position shown in FIG. 9 to its closed position shown in FIG. 10, the inner surface of sign face 20 engages a first tensioning edge 56 of a substantially U-shaped tensioning channel 50. A tensioning bolt 58 which is received in a hole in the wall of main frame 10 and which is threaded into a blind threaded bore in tensioning channel 50 is then rotated to move the channel downwardly in FIGS. 9 and 10. This slides edge 56 against the inner surface of sign face 20. A tensioning finger 52 with an additional tensioning edge is thus moved into the recess of cover frame 19. This increases the tension applied to flexible face 20 until, in an extreme position, part of the sign face is trapped between edge 56 and a further edge 54 on cover frame 19. The tensioning edge on tensioning finger 52 further contributes to the complete tensioning of sign face 20 changing the direction of sign face 20 a second time near the binder 28. 
     The tensioning channel 50 and cover frame 19 have inclined mating surfaces 67 which slide against each other as the channel 50 is moved, to urge the cover frame 19 in close engagement against the main frame 10. 
     The embodiment of FIG. 11 utilizes a cover frame 60 having a recess 62 which can be used to receive an L-shaped corner key (not shown) for fixing four cover frame sections which are utilized to form the rectangular cover frame 60. The edge of sign face 20 is trapped between a binder 28 and an inner projection of cover frame 60. In the closed position for the sign (not shown) a bolt 38 is threaded into a threaded insert 44 having an outer tapered pin 45 which is shaped to closely mate the tapered surfaces 64 in an inner projection of cover frame 60. This tends to center and outwardly bias the cover frame 60 on the rigid main frame 10. As shown in FIG. 12, the cover frame 60 with the pretensioned sign face 20 is inwardly deflected in the solid line position. By engaging the incline surfaces 64 over the tapered pins 45 which are spaced around the cover and main frames, the cover frame 60 is pulled and braced outwardly into its closed rectangular dot-dash position in FIG. 12. 
     A similar embodiment is illustrated in FIG. 13 where a wedging block 66, which is either continuous or intermittent along the main frame 10, has bevelled edges and mates within a recess 68 of a cover frame 61. In the embodiment of FIG. 13, the outer edge portion of sign face 20 is fixed onto cover frame 61 by a broad binder 28 and using the same tightening bolt 38 which is threaded into the insert 44 for fixing the cover frame to the main frame. 
     FIGS. 14 and 15 disclose an embodiment wherein an intermittent tensioning bar 70 having a tapered outer edge is engaged into the hole 72 of a cover frame 71. An edge 73 of cover frame 71 always engages the inner surface of frame face 20 which has an outer edge portion that is fixed by a binder 28 and bolt 29 to the cover frame. An access opening 74 in the edge area of sign face 20 provides access for a tool to engage and rotate bolt 8, which engages threaded sleeve 44 for fixing the cover frame to the main frame 10. A removable L-shaped cover member 76 is bolted to an outer leg of the channel shaped cover member 71 to cover the outer edge portion of sign face 20 for cosmetic purposes. 
     The completion of tensioning in the embodiment of FIGS. 14 and 15 is achieved by insertion of the tapered tensioning bar 70 into corresponding slot shaped holes 72 of the cover frame 71. 
     FIGS. 16 and 17 disclose an embodiment of the invention wherein an channel shaped cover frame is fixed to the outer edge portion of sign face 20 in a manner similar to the embodiment of FIGS. 14 and 15. The outer leg of the channel shaped cover member 71 carries a circular bearing 78 which rotatable receives a hinged cover and final tensioning device 86 which carries a tensioning edge 87. Tensioning device 86 is pivotable from its position shown in FIG. 16 to its position shown in FIG. 17 where edge 86 bears down onto the outer surface of sign face 20 completing the tensioning of the sign face. The position is retained by a bolt 38 which is screwed into a threaded insert 44 fixed to the main frame 10. Tensioning is thus achieved between edges 73 and 87. A shear block 82 is also fixed, for example, by welding to the face plane of the main frame 10, to bear against an inner surface of cover frame 71 to keep the cover frame spread when it is fixed onto the main frame. 
     FIGS. 18 and 19 show a still further embodiment of the invention wherein spaced springs 92 pretension the outer edge portion of sign face 20 to a cover frame 90 and over a tensioning edge 93 thereof. A face retainer 98 is bolted to the cover frame 90 to further trap the outer edge area of sign face 20. 
     A wedge-shaped recess 94 is provided through cover frame 90 for receiving a wedge 96 which helps spread and brace the cover frame 90 as it is fixed to the main frame 10 by tightening bolts 38 into threaded inserts 44. 
     The embodiment of FIGS. 20 and 21 utilizes a cover frame 100 which has a substantially rectangular cross section with an inner rectangular opening accessible through an access slot 98 by the outer edge area of sign face 20 which is fixed to a rocker 102 by rivets 104 extending through eyelets in the sign face 20. Rocker 102 has a circular ridge 106 which is pivotally mounted in a circular recess on an inner surface of cover frame 100. A tensioning projection 108 is positioned on rocker 102 at a location opposite from the sign face edge with respect to the circular ridge 106. Projection 108 extends through a slot shaped opening 97 in the cover frame 100 which provides access to the facing surface or plane of main frame 10. By tightening bolt 38 into threaded insert 44 as shown in FIG. 21, projection 108 is pressed against the face surface of main frame 10 causing the rocker 102 to pivot clockwise on its circular ridge 106 thereby pulling sign face 20 over tensioning edge 99 of cover frame 10 to complete the tensioning of the sign face. A spacer 95 is provided between opposite walls of the cover frame 100 to prevents its being collapsed as the bolt 38 is tightened. 
     While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.