A frame assembly system

Abstract

A frame assembly system comprising a first frame member 4, a second frame member 6, a stud 8, and a locking plate 10, wherein the stud is secured to an end of the first frame member such that the stud

Description

The present invention relates to a frame assembly system and, in particular to a system via which a frame may be assembled and disassembled quickly and easily. Conventionally, frames, such as window blind frames and window shutter frames, comprise a number of frame members (typically four such members) which are coupled together to form the frame. Adjacent frame members are typically connected together via corner brackets or via fixings. However, for a typical rectangular frame, four corner brackets are required, which increases the costs of such frames; and in cases where adjacent frame members are connected together via fixings, such as screws, the assembly of such frames is relatively time consuming and there is the risk of errors when connecting together the frame members. There is therefore a need for a frame assembly system which is cheaper, easier to use and / or reduces the risk of errors when assembling the frame. According to a first aspect of the invention, there is provided a frame assembly system comprising a first frame member, a second frame member, a stud, and a locking plate, wherein the stud is secured to, or forms part of, an end of the first frame member such that the stud projects beyond the end of the first frame member; the second frame member includes a second frame member body which defines a central channel therein; the second frame member body further defines a bore which opens into the central channel; the stud extends through the bore and a distal portion of the stud projects into the central channel; the locking plate is disposed within the central channel and engages the distal end of the stud and the locking plate has an unlocked configuration in which the stud is permitted to be displaced axially relative to the locking plate, and a locked configuration in which axial displacement of the stud relative to the locking plate is prevented. In this way, the bore(s) defined by the second frame member body may be aligned with the stud(s) secured to the end of the first frame member such that the second frame member is correctly positioned relative to the first frame member. Furthermore, the second frame member is coupled to first frame member simply by the engagement of the locking plate with the distal end of the stud. Such an arrangement is cheap to manufacture, easy to assemble and reduces the risks of an incorrect placement of the frame members, as a jig may be used to align the or each stud with the respective bore. In an embodiment of the invention, the stud defines a waisted portion and a terminal collar portion. Accordingly, the terminal collar is suitably provided at the distal end of the stud and the waisted portion is disposed between the terminal collar and the proximal end of the stud. In such embodiments, the waisted portion may define an engagement surface or portion of the stud. The terminal collar in such embodiments may form a stop surface. In a further embodiment of the invention, the locking plate includes a locking plate body that defines a first aperture through which the terminal collar is able to pass, and a second aperture which has a dimension that is less than the diameter of the collar. Thus, the collar may be unable to pass through the second aperture. Suitably, the dimension of the second aperture (e.g., the diameter or maximum dimension) is smaller than the diameter of the collar, but greater than the diameter of the waisted portion of the stud. In such embodiments, the waisted portion of the stud may be located within the second aperture, but the terminal collar prevents axial displacement of the stud relative to the locking plate in a direction away from the second frame member. Suitably, the first aperture is in communication with the second aperture, wherein the locking plate is moveable laterally relative to the waisted portion of the stud and in the unlocked configuration, the stud is aligned with the first aperture and in the locked configuration, the stud is aligned with the second aperture. In the context of the present invention, the term "laterally" is intended to mean in a plane perpendicular to the longitudinal axis of the stud. A locking plate in which the second aperture is in communication with the first aperture allows the locking plate to be slid over the stud when the first aperture is aligned with the stud (an unlocked configuration) and then moved laterally relative to the stud such that the waisted portion of the stud is received within the second aperture. In this configuration (a locked configuration), displacement of the stud in a direction away from the second frame member is prevented by engagement of the terminal collar with a portion of the locking plate body that surrounds the second aperture. In an embodiment of the invention, a resiliently deformable element is associated with the second aperture. In the context of the subject invention, the term "associated with" is intended to mean that at least a portion of the resiliently deformable element is aligned with at least a portion of the second aperture. For example, the second aperture may be defined, at least in part, by the resiliently deformable element. The resiliently deformable element suitably forms a snap-fit coupling with the waisted portion of the stud. A snap-fit coupling between the resiliently deformable element and the waisted portion of the stud ensures a positive coupling and provides a haptic feedback to a user that the locking plate is in its locked configuration. It may also prevent an unintentional displacement of the locking plate from its locked configuration to its unlocked configuration. The resiliently deformable element may comprise a pair of opposed resiliently deformable legs. For example, the legs may define a stud receiving portion which receives therein a part of the waisted portion of the stud. Suitably, the resiliently deformable element is C-shaped. In order to secure the or each stud to the end of the first frame member, the stud may comprise a stud body which defines therethrough a channel. In such embodiments, the stud may be secured to the end of the first frame member by a fixing which passes through the channel defined by the stud body. In such embodiments, the fixing does not interfere with the engagement between the stud and the locking plate. It will be appreciated that a distal end portion of the fixing may project from a proximal end of the stud. Thus, the frame assembly system may further include one or more fixings via which the or each stud is secured to the end of the first frame member. Alternatively, the stud may define a coupling portion via which it is secured to the first frame member. For example, the coupling portion of the stud may define or carry a threaded element, whereby the stud may be screwed into a receiving portion of the first frame member. In order to receive the distal end portion of the fixing or a connecting portion of the stud, the first frame member may include a body portion which defines therein a bore which receives therein the distal end of the fixing or the connecting portion of the stud. The body portion is suitably located at one or both ends of the first frame member. For example, the body portion may extend the entire length of the first frame member. Such a body portion may also provide support or reinforce the first frame member. In an embodiment of the invention, the fixing includes a threaded portion at its distal end and the fixing forms a threaded coupling with the bore defined by the first frame member body portion. It will be appreciated that the use of a single stud may permit the first frame member to rotate relative to the second frame member. Accordingly, the frame assembly system of the invention may include two or more studs. For example, the system may include two studs, wherein both studs are secured to an end of the first frame member in a spaced apart relationship; the second frame member body may define two bore which open into the central channel; both studs may extend through respective bores and a distal portion of each stud projects into the central channel; a locking plate may engage the distal end of a respective one of each of the studs (i.e., the frame system may include two locking plates, wherein each locking plate engages a respective one of the studs); or a single locking plate may engage both of the studs and has an unlocked configuration in which each stud is permitted to be displaced axially relative to the locking plate and a locked configuration in which axial displacement of each stud relative to the locking plate is prevented. In such embodiments, having a pair of studs disposed in respective bores prevents or minimises rotation of the first frame member relative to the second frame member. It will be appreciated that a single locking plate may be used in connection with both studs. For example, the locking plate may include a pair of spaced apart first apertures and pair of spaced apart second apertures. In such embodiments, each first aperture may be in communication with a respective one of the second apertures, wherein the locking plate is moveable laterally relative to the waisted portion of the studs and in the unlocked configuration, the studs are aligned with a respective one of the first apertures and in the locked configuration the studs are aligned with a respective one of the second apertures. In order to locate the locking plate(s) within the central channel defined by the second frame member body, the central channel may be open at at least one end. For example, the central channel may be open at both ends. In such embodiments, the system may further include one or more covers which selectively close an open end of the central channel. For example, the central channel may be opened by removing the cover from one end, the or each locking plate may be disposed within the central channel and engaged with the or each stud, and then the central channel may be closed by replacing the cover. The or each cover may be coupled to the second frame member body, for example via a friction coupling or a snap-fit coupling. As noted above, the frame suitably includes four frame members (e.g., a top frame member, a bottom frame member and a pair of opposed side frame members). In such embodiments, the system suitably includes a pair of spaced apart first frame members (e.g., the top and bottom frame members) and a pair of spaced apart second frame members (e.g., the opposed side frame members), wherein at least one stud is secured to each end of each of the first frame members; each of the second frame members includes a second frame member body which defines therein a central channel which extends the entire length of each second frame member; each second frame member body defines at least one bore at one end of the second frame member which opens into the central channel and at least one bore at the opposite end of the second frame member which opens into the central channel; and each of the first frame members is coupled at one end to one of the second frame members and is coupled at its opposite end to the other of the second frame members via a coupling formed between a locking plate and one or more respective studs. The frame of the invention is suitably a window covering frame or a window shutter frame. Accordingly, the frame assembly system is for use in the assembly of a window blind frame or a window shutter frame. According to a second aspect of the invention, there is provided a method of assembling a frame, the method including providing a frame assembly system according to the first aspect of the invention as defined anywhere herein; disposing the or each stud through the bore defined by the second frame member body wherein the distal end of the or each stud projects into the central channel; disposing the locking plate into the central channel; engaging the locking plate with the or each stud; and configuring the locking plate in its locked configuration. For example, in embodiments in which the locking plate includes a locking plate body which defines a first aperture through which a terminal collar of the stud is able to pass, and a second aperture which has a dimension that is less than the diameter of the collar, wherein the first aperture is in communication with the second aperture, the method may include the step of aligning the first aperture with the stud, disposing the locking plate over the stud such that the locking plate body is aligned with the waisted portion of the stud, and displacing the locking plate laterally relative to the stud until the waisted portion of the stud is disposed within the second aperture defined by the locking plate body. In a further embodiment, the method may include forming a snap-fit coupling between the stud and the locking plate. The method may further include attaching the or each stud to one end of the first frame member. Such a step may include inserting a fixing through a bore defined through the stud and securing the stud to one end of the first frame member via the fixing. As noted above, the fixing may be a screw. Accordingly, the method may include screwing the stud to the end of the first frame member. The skilled person will appreciate that the features described and defined in connection with the aspects of the invention and the embodiments thereof may be combined in any combination, regardless of whether the specific combination is expressly mentioned herein. Thus, all such combinations are considered to be made available to the skilled person. An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 shows an exploded view of a frame assembly system according to the first aspect of the invention; Figure 2 shows a cross-sectional view of an assembled frame assembly system as shown in Figure 1; Figures 3a and 3b show views of a locking plate which forms part of the frame assembly system shown in Figure 1; and Figures 4a and 4b show views of a stud which forms part of the frame assembly system shown in Figure 1. For the avoidance of doubt, the skilled person will appreciate that in this specification, the terms "up", "down", "front", "rear", "upper", "lower", "width", etc. refer to the orientation of the components as found in the example when installed for normal use as shown in the Figures. Figure 1 shows an exploded view of a frame assembly system 2 according to the invention. The system 2 comprises a first frame member 4, a second frame member 6, a pair of studs 8 and a locking plate 10. The second frame member 6 includes a frame body which defines a pair of bores 6a that open into a central channel 6b, which is also defined by the frame body. The first frame member 4 includes an upper reinforcing element 14a and a lower reinforcing element 14b. Each of the upper and lower reinforcing elements 14a, 14b define respective bores which receive therein a respective threaded portion of a screw fixing 12 The system 2 further includes a cover plate 16 which selectively closes one end of the central channel 6b. Figure 2 shows a cross-sectional view through an assembled system 2. As can be seen from Figure 2, one of the studs 8 is fixed to the upper reinforcing element 14a via one of the screw fixings 12 and the other of the studs 8 is fixed to the lower reinforcing element 14b via the other of the screw fixings 12. Each of the studs 8 passes through a respective one of the bores 6a and a distal portion of the studs extend into the central channel 6b. The locking plate 10 engages both of the studs 8 and prevents displacement of the studs 8 away from the second frame member 6 out of their respective bores 6a. The cover plate 16 closes the bottom end of the central channel 6b. Figures 3a and 3b show in more detail the locking plate 10. The locking plate 10 includes a locking plate body 20 which defines a pair of spaced apart first apertures 22a, 22b and a pair of spaced apart second apertures 24a, 24b. One of the first apertures 22a is in communication with a respective one of the second apertures 24a, and the other of the first apertures 22b is in communication with the other of the second apertures 24b. A gap defined between an axis of the first aperture 22a and an axis of the first aperture 22b is equal to the spacing between the upper and lower reinforcing elements, and the diameter of the first apertures 22a, 22b is greater than the largest diameter of the studs 8. The second aperture 24a is defined by a C-shaped element 26 and the second aperture 24b is defined by a corresponding C-shaped element 30. The locking plate body 20 defines arcuate channels 34a, 34b adjacent to the ends 28a, 28b of the C-shaped element 26 and the C-shaped element 26 is formed from a resiliently deformable polymer, whereby the ends 28a, 28b of the C-shaped element 26 may be deflected outwards into the arcuate channels 34a, 34b. Similarly, locking plate body 20 defines arcuate channels 36a, 36b adjacent to the ends 32a, 32b of the C-shaped element 30 and the C-shaped element 30 is formed from a resiliently deformable polymer, whereby the ends 32a, 32b of the C-shaped element 30 may be deflected outwards into the arcuate channels 36a, 36b. Figures 4a and 4b show in more detail one of the studs 8. Each stud 8 includes a stud body 40 which defines a distal end collar 42 (i.e., a terminal collar) and, spaced therefrom, a central collar 46. Defined between the distal end collar 42 and the central collar 46 is a cylindrical waisted portion 44. Each stud body further defines a central bore 48. The central bores is sized to receive therein a screw fixing 12. The diameter of the distal end collar 42 is less than the diameter of the first apertures 22a, 22b defined by the locking plate body 20, but greater than the diameter of the second apertures 24a, 24b. In contrast, the waisted portion 44 has a diameter that is just less than the diameter of the second apertures 24a, 24b. In this way, the locking plate 10 may be arranged such that the first apertures 22a, 22b are aligned with the studs. The locking plate 10 may then be displaced towards the proximal end of the studs 8 until the locking plate body 20 is coplanar with the waisted portion 44 of the studs 8. The locking plate may then be displaced laterally with respect to the studs. The waisted portion 44 of each stud urges the ends 28a, 28b, 32a, 32b of the C-shaped elements 26, 30 to deflect outwards into the respective arcuate channels 34a, 34b, 36a, 36b. Further displacement of the locking plate 10 in the same direction aligns the waisted portion 44 of each stud 8 with the second apertures 24a, 24b and the ends 28a, 28b, 32a, 32b of the C-shaped elements 26, 30 snap back to their rest configurations. The diameter of the distal end collar 42 being greater than the diameter of the respective second apertures 24a, 24b prevents the axial displacement of the studs 8 away from the locking plate 10 and the C-shaped elements 26, 30 resist the lateral displacement of the locking plate in a direction that would re-align the studs 8 with the respective first apertures 22a, 22b. As the locking plate 10 prevents axial displacement of studs 8 when the studs 8 are aligned with the respective second apertures 24a, 24b, the engagement of the studs 8 with the locking plate also prevents displacement of the first frame member 4 away from the second frame member 6. To assembly the frame assembly system, each screw fixing 12 is inserted through the central bore 48 of a respective one of the studs 8 and the stud is fixed to the upper reinforcing element 14a or the lower reinforcing element 14b of the first frame member 4. The first frame member 4 is then displaced towards the second frame member 6 and the studs 8 are inserted through the respective bores 6a until the end of the first frame member 4 contacts a side portion of the second frame member 6. In this configuration, the distal end collar 42 and the cylindrical waisted portion 44 project into central channel 6b defined by the second frame member body. The locking plate 10 is inserted into the central channel 6b from its open bottom end and the first apertures 22a, 22b are aligned with the studs 8. The locking plate 10 is then urged towards the first frame member 4 until it contacts a wall portion of the second frame member 6. In this configuration, the locking plate body 20 is coplanar with the waisted portion 44 of each of the studs 8. The locking plate 10 is then urged upwards until the waisted portion 44 of each of the studs 8 forms a snap-fit coupling within the respective second apertures 24a, 24b. This prevents the first frame member 4 being moved away from the second frame member 6. Additionally, the use of two studs 8 prevents or minimises the ability of the first frame member 4 to twist or rotate relative to the second frame member 6. Finally, the cover plate 16 closes the bottom end of the central channel 6b. This also prevents access to the locking plate 10.

Claims

1. A frame assembly system comprising a first frame member, a second frame member, a stud, and a locking plate, wherein the stud is secured to an end of the first frame member such that the stud projects beyond the end of the first frame member; the second frame member includes a second frame member body which defines a central channel therein; the second frame member body defines a bore which opens into the central channel; the stud extends through the bore and a distal portion of the stud projects into the central channel; the locking plate is disposed within the central channel and engages the distal end of the stud and has an unlocked configuration in which the stud is permitted to be displaced axially relative to the locking plate, and a locked configuration in which axial displacement of the stud relative to the locking plate is prevented.

2. A frame assembly system according to Claim 1, wherein the distal end of the stud defines a waisted portion and a terminal collar.

3. A frame assembly system according to Claim 2, wherein the locking plate includes a locking plate body which defines a first aperture through which the terminal collar is able to pass, and a second aperture which has a dimension that is less than the diameter of the terminal collar.

4. A frame assembly system according to Claim 3, wherein the first aperture is in communication with the second aperture, wherein the locking plate is moveable laterally relative to the waisted portion of the stud and in the unlocked configuration, the stud is aligned with the first aperture and in the locked configuration the stud is aligned with the second aperture.

5. A frame assembly system according to Claim 3 or Claim 4, wherein a resiliently deformable element is associated with the second aperture, wherein the resiliently deformable element forms a snap-fit coupling with the waisted portion of the stud.

6. A frame assembly system according to Claim 5, wherein the resiliently deformable element includes a pair of opposed resiliently deformable legs.

7. A frame assembly system according to Claim 6, wherein the resiliently deformable element is C-shaped.

8. A frame assembly system according to any of Claims 1 to 7, wherein the stud includes a body which defines therethrough a channel and the frame assembly system further includes a fixing which is disposed within the channel, wherein a distal portion of the fixing projects from the proximal end of the stud.

9. A frame assembly system according to Claim 8, wherein the first frame member includes a body portion which defines therein a bore, and the projecting distal portion of the fixing is secured with the bore.

10. A frame assembly system according to Claim 9, wherein the fixing includes a thread at its distal end and the fixing forms a threaded coupling with the bore.

11. A frame assembly system according to any of Claims 1 to 10, wherein the system includes two studs, wherein both studs are secured to an end of the first frame member in a spaced apart relationship; the second frame member body defines two bores which open into the central channel; both studs extend through their respective bores and a distal portion of each stud projects into the central channel; the locking plate engages the distal end of both of the studs and has an unlocked configuration in which each stud is permitted to be displaced axially relative to the locking plate and a locked configuration in which axial displacement of each stud relative to the locking plate is prevented.

12. A frame assembly system according to Claim 11, wherein the locking plate includes a pair of spaced apart first apertures and pair of spaced apart second apertures.

13. A frame assembly system according to Claim 12, wherein each first aperture is in communication with a respective one of the second apertures, wherein the locking plate is moveable laterally relative to the waisted portion of the studs and in the unlocked configuration, the studs are aligned with a respective one of the first apertures and in the locked configuration the studs are aligned with a respective one of the second apertures.

14. A frame assembly system according to any of Claims 1 to 10, wherein the system includes two studs and two locking plates, wherein both studs are secured to an end of the first frame member in a spaced apart relationship; the second frame member body defines two bores which open into the central channel; both studs extend through their respective bores and a distal portion of each stud projects into the central channel; each locking plate engages the distal end of a respective one of the studs and has an unlocked configuration in which the stud is permitted to be displaced axially relative to the respective locking plate and a locked configuration in which axial displacement of each stud relative to the respective locking plate is prevented.

15. A frame assembly system according to any of Claims 1 to 14, wherein the central channel of the second frame member is open at one end, and the system further includes a cover which selectively closes the open end of the second frame member central channel.

16. A frame assembly system according to any of Claims 1 to 15, wherein the system includes a pair of spaced apart first frame members and a pair of spaced apart second frame members, wherein at least one stud is secured to each end of each of the first frame members; each of the second frame members includes a second frame member body which defines therein a central channel which extends the entire length of each second frame member; each second frame member body defines at least one bore at one end of the second frame member which opens into the central channel and at least one bore at the opposite end of the second frame member which opens into the central channel; and each of the first frame members is coupled at one end to one of the second frame members and is coupled at its opposite end to the other of the second frame members via a coupling formed between a locking plate and one or more respective studs.

17. A frame assembly system according to any of Claims 1 to 16, wherein the frame is a window blind frame or a window shutter frame.

18. A method of assembling a frame, the method including providing a frame assembly system 5 according to any of Claims 1 to 17; disposing the or each stud through the bore defined bythe second frame member body wherein the distal end of the or each stud projects into the central channel; disposing the locking plate into the central channel; engaging the locking plate with the or each stud; and configuring the locking plate in its locked configuration.14

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