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BACKGROUND OF THE INVENTION
This invention relates generally to a fabric mounting track and
particularly relates to such a track by means of which a fabric can be
mounted at the top and bottom of a wall or on a ceiling, while the fabric
hangs straight and slightly spaced from the wall.
Various systems have been devised in the past for mounting a fabric on a
wall. One of the simplest ways of accomplishing this is to provide
adhesive on the back of the fabric. The fabric can then be hung like
wallpaper. However, the dry wall must be primed to properly accept the
adhesive. The adhesive is hydroscopic and hence changes its properties and
its thickness with moisture. It is practically impossible to remove the
fabric without tearing it, and in addition the removal of the fabric and
the adhesive will damage the dry wall.
According to another prior art system, the fabric is simply nailed or
stapled to the dry wall, or else to a wooden strip which may be nailed to
the studs of the dry wall. In this case, the unsightly top of the
structure; that is, the nails or staples, must be hidden by welting. The
fabric cannot be removed, cleaned, and replaced, because it tears when it
is removed from the staples or nails. Staples are conventionally used, and
it is found that the wall may break at the horizontal line of the staples,
so that the wall has to be refinished.
Still another system is known as the FABRITRACK system. Here the track
consists of a plastic structure including a rectangular box-like portion
with an open slit at the top and a flat plate at the back. The top portion
of the slit of the box is turned over, either with a straight portion or
with a very small acute angular portion. The straight plate is nailed or
otherwise secured to a wall and the fabric is forced into the slot of the
box by a suitable tool. In addition, the front of the box is provided with
an adhesive material. Hence, the fabric is held both by the friction
created by the overturned top portion and by the adhesive material of the
box.
In the first place, it is rather difficult to insert the fabric into the
slit portion of the box. A tool might facilitate this operation. However,
it is still difficult to hold the fabric up against the wall in the
desired horizontal fashion. Due to the construction of the box, the fabric
is spaced a substantial distance from the wall. Furthermore, due to the
somewhat weak forces which hold the fabric by friction and adhesion, the
fabric may be unevenly mounted on the wall and may form folds or waves
instead of being straight, and may either tear or fall from the wall.
Finally, in accordance with still another system, known as the
"Stretch-Wall" system, individual panels are mounted on the wall. Each
panel has the size of 1'.times.4'. Such a system is rather expensive and
has the disadvantage that in order to fit a wall not of standard length, a
few smaller panels may be required, which may have to be specially made.
SUMMARY OF THE INVENTION
The fabric mounting track of the present invention positively holds the
fabric, not by friction but by means of a set of lancings punched out from
one of the two plates of which the track consists. Thus, the hinge lock
plate is provided with a substantially circular section, open at one end,
and a straight plate from which the lancings are punched out. The lancings
are substantially equally spaced, and periodically a substantially larger
lancing is provided, over which the fabric may be pulled and which pierces
the fabric. The back support plate has a straight intermediate portion
which is nailed to the wall or otherwise secured, for example to the studs
in the wall. One of its ends is also provided with a substantially
circular hinge portion of substantially larger diameter than that of the
hinge lock plate, so that it fits over the hinge of the hinge lock plate.
The back support plate is provided with a ledge forming an acute angle with
the straight portion thereof. The large lancings, when the back support
plate is rotated through 180.degree., will hook over the ledge to hold the
two plates together. At the same time, the small size lancings will impact
the ledge plate and hence force the lancings through the fabric, to hold
the fabric positively and without the use of friction.
A modification of the mounting track of the present invention has cuts
through the hinge portion of the back support plate and also through the
ledge, to facilitate bending the track to accommodate corners, curves, and
the like, of a wall. At the same time, the hinge lock plate may be cut
into individual sections corresponding to the cuts made through the back
support plate, so that the fabric will hang smoothly in a corner or curved
area.
Finally, a simplified version of the present invention consists of a single
strip of metal having both small size and large size lancings punched
therefrom. The strip is mounted to the wall by a strip of adhesive
material having adhesive on both surfaces. After the fabric has been
pierced by the large lancings, the metal strip is rotated through
180.degree. and the lancings are pressed into the wall.
The novel features that are considered characteristic of this invention are
set forth with particularity in the appended claims. The invention itself,
however, both as to its organization and method of operation, as well as
additional objects and advantages thereof, will best be understood from
the following description, when read in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective of the preferred embodiment of the fabric
mounting track of the present invention;
FIG. 2 is a side elevational view on enlarged scale of the hinge lock
plate;
FIG. 3 is a side elevational view on enlarged scale of the back support
plate;
FIG. 4 is a side elevational view on still more enlarged scale of the end
portion of the ledge of the back support plate;
FIG. 5 is a side elevational view of the hinge lock and back support
plates, hinged together in the position for initially mounting the fabric
thereon;
FIG. 6 is a cross-sectional view of the track mounting system of the
invention, with a piece of fabric hanging therefrom and before the hinge
lock plate is finally locked into place;
FIG. 7 is a cross-sectional view similar to that of FIG. 6, with the hinge
lock plate locked into place and the small size lancings piercing the
fabric;
FIG. 8 is an elevational view similar to FIG. 1 but showing the fabric in
place and hanging from the track mounting system;
FIG. 9 is a view in perspective similar to that of FIG. 1 but illustrating
a modification where the back support plate is cut through its hinge
portion and ledge portion to facilitate bending thereof, as well as a few
hinge lock plates, each being of a size to cover the space between two
adjacent cuts;
FIG. 10 is a view in perspective of a single flat plate provided with
lancings and supported by an adhesive strip on a wall, or the like, with a
portion of fabric pierced by small and large size lancings;
FIG. 11 is a view in perspective, similar to that of FIG. 10 and showing
the fabric in place after the plate carrying the lancings has been rotated
through 180.degree.;
FIG. 12 is a cross-sectional view of a portion of the track mounting system
of FIG. 11 on enlarged scale to show a large lancing piercing the fabric
and wall; and
FIG. 13 is a view in perspective of an unlocking tool specially designed
for opening the fabric mounting track system of the invention as
illustrated in FIGS. 1 through 8 and 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and particularly to FIGS. 1 through 5, there
is illustrated a preferred embodiment of the present invention. As shown
particularly in FIGS. 1 through 4, the fabric mounting track of the
invention consists of two separate pieces; that is, a hinge lock plate 10
and a back support plate 11. The hinge lock plate 10 is provided at one of
its ends with a substantially circular portion 12, which of course is open
at one end, as shown. It is connected by a straight intermediate portion
13 to another straight portion 14 which forms an abtuse angle with the end
portion 15.
Punched from the end portion 15 of the hinge lock plate 10 are small size
and large size lancings, respectively 16 and 17. These lancings are
punched out from the straight end portion 15, as shown clearly in FIG. 1
at 18 for the small lancings and at 20 for the large lancings.
The back support plate 11 again has a hinge portion 22 at one of its ends,
terminating in an outermost portion 23 of still smaller radius. It
continues with a straight intermediate portion 24, which may be notched or
scored at 25 to provide a mark for nailing or mounting the back support
plate to a wall.
The straight portion 24 includes a ledge 26 which forms an acute angle with
the straight intermediate portion 24. It has a rearwardly extending
projection or nose 27, as shown particularly in FIG. 4, to provide a
positive support for the large lancings 17. The other free end of the back
support plate includes another straight portion 28, forming a smaller
acute angle with the straight intermediate portion 24 and terminating at
its outermost end in a backwardly extending portion 30, to facilitate
unlocking of the fabric mounting track when required after closing.
The manner of mounting a piece of fabric on the fabric mounting track of
the invention will now be explained, by means of FIGS. 5 through 7.
Initially, the fabric is mounted by piercing it by the large lancings 17,
in the position of FIG. 5. Subsequently, the hinge lock plate 10 is
rotated through almost 180.degree. to the position of FIG. 6. Now the
fabric 32 will hang over the free edge of the straight portion 15 of hinge
lock plate 10. The large lancing 17 is about to engage the ledge 26 of the
back support plate 11. When the hinge lock plate 10 is pressed toward the
back support plate 11, the structure illustrated in FIG. 7 is obtained.
Here the large lancings 17 hook over the projection or nose 27 of the
ledge 26, while the small lancings 16 subsequently impact the ledge 26 to
pierce the fabric 32. The fabric will subsequently cover the outermost
edge portion 30 of the back support plate 11.
It will now be evident that the fabric is positively retained by the
respective lancings 16 and 17 and is now capable of withstanding a pull of
ten to twelve pounds per inch, which is necessary to obtain a good stretch
of the fabric. Actually, up to 20 pounds' pull per inch may be exerted
against the mounting track of the invention, to provide a fabric which
smoothly covers the wall and which can be pushed against the wall without
disturbing its smooth appearance.
Preferably, the fabric is backed by a polyester fiberfill batting,
obtainable, for example, from Rohm and Haas in Philadelphia, PA. Other
types of batting may also be used. Such a batting provides a vapor barrier
inside the room to furnish superior insulation and substantially reduce
heat loss. Other suitable insulation would be polyester or fiberglass
which may have an acrylic latex coating. These materials are flameproof.
They actually provide better insulation than pure goose down, because
goose down is hydroscopic and when wet is out-performed by polyester
fiberfill, which does not lose its loft and insulating value.
Hence, it will be seen that by using batting of the type described, the
upper edge 33 of the fabric will cover the outer edge 30 of the back
support plate.
The finished product is illustrated in FIG. 8. The mounting track may be
opened again, with a suitable tool which is inserted between the tops of
the two plates 10 and 11.
Since some of the dimensions are rather critical, by way of example the
dimensions of a suitable track are given herein. The hinge lock plate has
a total length of 1.585". The radius of curvature of the hings portion 12
is 0.172". The straight portion 13 has a length of about 0.2". The
straight intermediate portion 14 has a projected length of 0.490" and the
straight end portion 15 has a length of 0.873". The straight portion 14
makes an acute angle of 40.degree. with a vertical through the straight
portion 15. Accordingly, the hinge portion 12 is spaced from a plane
passing through the end portion 15.
Concerning the back support plate 11, the hinge portion 22 has a radius of
0.188" and the outermost end 23 has a radius of 0.100". The notch 25 is
spaced from the curved portion 22 by 0.669". The ledge 26 makes an acute
angle of 30.degree. with the straight portion 24. The straight portion 28
makes an obtuse angle of 15.degree. with the straight portion 24, while
the outermost end 30 make an obtuse angle of 10.degree. with a line
parallel to the straight portion 24.
The length of the small size lancings 16 is about 3/8 inch, while that of
the large size lancings 17 is 1/2 inch.
The lancings are spaced apart at out one inch center to center, and are
made by a triangular punch forced through the straight portion 15. When
the small lancings hit the ledge 26, the fabric is pierced by shear action
and the two plates have a pressure fit, because the large lancings 17 hook
over the ledge portion 27.
If the fabric should be substantially thinner than the normal fabric, it
may be useful to back up the fabric with a suitable adhesive, which in
this case does not serve the purpose to mount the fabric to the wall but
only to stiffen the fabric for easier mounting.
The mounting track of the invention may be used for mounting the fabric top
and bottom on a vertical wall. Similarly, it may be used to mount a fabric
on the ceiling. Where two mounting tracks meet each other at a corner of
90.degree., the back support plate may be cut near the corners so that
both sets of mounting tracks can be accommodated.
In some cases the wall may not be straight, but may be curved. In such a
case, the fabric mounting track of the invention may still be used, by
treating it as shown in FIG. 9, modified for curfing.
Here the back support plate 40 is provided with cuts 41 through the hinge
portion 22, the cuts being spaced a suitable distance apart, commensurate
with the amount of bending to be accomplished. Similarly, the ledge 26
should be cut as shown at 42, each of the cuts 42 being in the same plane
as that of the cuts 41. These cuts permit bending of the back support
plate to the desired degree. At the same time the hinge lock plate 44 may
be cut into suitable pieces, each of which will extend to one of the cuts
41. Otherwise, the fabric is secured as previously described.
Nevertheless, the mounting track retains its full structural strength.
Finally, a much simplified and less expensive fabric mounting track is
illustrated in FIGS. 10 to 12. Here the mounting track consists of a
single piece; that is, a flat metal strip 46. In this modification the
fabric need not be provided with batting. Also, there is no need to
prepare the wall, and even a rough wall may be used, thus constituting a
true dry hang system without using any adhesive. The metal strip 46 is
again provided with lancings, shown at 47 and 48. The metal strip 46 is
secured to a double-faced adhesive tape 50, of which the free end 51 may
be stuck to the wall. The fabric 32 may then be secured to the lancings 47
and 48 by simply piercing the fabric with the lancings, as shown in FIG.
10. The metal strip 46 is then rotated through 180.degree. with the tape
50 serving as a hinge, whereupon the lancings 47 and 48 will pierce the
wall 53.
Also, a double-faced reinforced adhesive tape is used over the length of
the lancings against which the fabric is pressed, to insure that the
fabric hangs straight. Such a tape will resist a pull in shear. It is
feasible to provide the adhesive tape 50 with a covering strip which
extends beyond the metal plate 46 when it is in the position of FIG. 11.
This tape serves for the easy removal of the metal plate 46 and the fabric
thereon.
Preferably, the hinge lock plate 10 and the back support plate 11 consist
of aluminum, which may be extruded directly into the form shown in FIGS. 2
and 3, but without lancings. The metal plate 46 of FIGS. 10 to 12 may
consist of a thin steel sheet, to reduce its weight; besides, the plate 46
need not be extruded.
Referring now to FIG. 13, there is illustrated an unlocking tool for
opening particularly the fabric mounting track of the invention. It is
specially designed for the embodiment of the invention illustrated in
FIGS. 1 through 8, as well as the modification of FIG. 9.
As shown in FIG. 13, the unlocking tool 56 includes a handle 57 and an
enlarged front portion 58 which terminates in a protrusion or lip 60
substantially normal to the plane of the elongated front portion 58.
The tool is, for example, inserted with its lips 60 into the space 55
between the upper end portion 30 of the hinge lock plate and the upper end
portion 15 of the back support plate, this space being designated 55 in
FIG. 7. Thus, the lip 60 is inserted into this space 55 and thereupon the
handle is rotated through a plane substantially normal to that of the
unlocking tool. This action will cause the two plates 11 and 12 to unlock.
In carrying out this operation it is essential that the tool does not
engage or mar the ceiling. To this end, the tool may be bent by hand as
showr at 61, to an extent commensurate with the job at hand; that is, from
the distance between the mounting track and the ceiling.
Preferably the unlocking tool 56 is of unitary construction and consists of
sheet metal which is capable of being bent to avoid hitting the ceiling of
the room to be covered with the fabric. By way of example, a tool which
has been found to be suitable for the unlocking operation has a total
length of 6.5", the handle having a length of 5" and a width of 5/8". The
width of the front portion 58 may be 17/8" and the length of the lip 60
may be 3/16". The thickness of the sheet metal may be 1/16".
There has thus been disclosed a fabric mounting track system which permits
to hold the fabric positively by hanging the fabric on lancings punched
out from one of the plates of the track. Since the track plates are of
metal, they will withstand a substantial pull of fabric when the fabric is
pulled straight.
The hinge lock plate may be cut periodically through the hinge portion and
the ledge thereof to permit curfing, to accommodate portions of the wall
which may not be flat. In that case the hinge back plate may also be cut
into portions that will fit between the cuts of the back support plate.
Further, a simplified version of the fabric mounting track is shown, which
consists of a single piece of metal provided with lancings of different
sizes. The system of the present invention is characterized by its
reliability and by the feature of allowing removal of the fabric for
cleaning and replacing or exchanging. In addition, with the system of the
present invention, the fabric may be installed at a price which is
approximately one-tenth that of the other systems on the market.
Finally, an unlocking tool has been disclosed to facilitate unlocking of
the locked mounting track.
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