Molded plastic unibody display frame

[0002] This application is related to prior, co-pending provisional application serial No. 60/277,241 filed on Mar. 20, 2001. This application claims priority under 35 U.S.C. §119 from prior application Ser. No. 60/277,241.

[0003] A field of the invention is plastic display frames. Another field of the invention is plastic injection molding.

[0004] The purchase of a display frame is based primarily upon appearance and price. A low cost plastic frame could provide an important market for impulse or ancillary purchases. There are a variety of discount stores, photo processing stores, and souvenir stores that could successfully market a plastic display frame having a pleasant appearance.

[0005] An example success has been an acrylic frame that traps a small photo between two clear acrylic surfaces. The surfaces are shaped to also form a stand. The entire frame is a single plane of material folded into a shape to form the stand and the two clear acrylic surfaces. Except at the point of folding, the frame is open on all sides. A photo is presented without a visual border to highlight a photo inserted into the frame.

[0006] A molded unibody plastic display frame formed from a single, contiguous piece of plastic accepts and borders a photograph or similar media. The frame includes a media insertion slot and holds a picture, or other thin and flat media, with a traditional framing border around the media when it is inserted into the frame. Preferred features include an integral hinged stand/and or hangers. A preferred stand and backing portion include locking portions to lock the stand into a predetermined free-standing display angle. Geometry of the preferred frame permits it to be formed in a single plastic mold injection. A variety of sizes, colors, and decorative features are possible to include in a frame of the invention.

[0007] FIG. 1A is a front view of a preferred embodiment display frame;

[0008] FIG. 1B is a back view of the preferred embodiment display frame shown in FIG. 1A;

[0009] FIG. 1C is top view of the preferred embodiment display frame shown in FIGS. 1A and 1B;

[0010] FIG. 2 shows partial view of an interlocking edge for two preferred embodiment display frames.

[0011] FIG. 3A is a back view of an alternate preferred embodiment display frame;

[0012] FIG. 3B is a front view of the FIG. 3A display frame;

[0013] FIG. 3C is a section taken along line A—A;

[0014] FIG. 3D is an enlarged section taken along line B—B; and

[0015] FIG. 3E is an enlarged section taken along line C—C.

[0016] A display frame of the invention is formed from a single, contiguous piece of plastic. This allows the frame to be molded in a single step injection molding process. The frame geometry permits a traditional appearance, e.g., including a media border, despite its simplicity and low cost. Features such as a stand may be included, while the geometry of the frame of the invention has its shape, contour and size completely determined by contours of a mold used to form the frame. Various plastics and plastic colors are possible.

[0017] A preferred embodiment display frame is shown in FIGS. 1A-1C, which are respective front, back and top views of a preferred embodiment display frame. A backing portion 10 includes a flat surface 12 (FIG. 1A) defined in a first plane. The flat surface 12 is flat over a substantial portion of its surface area, but may have a number of material gaps, holes, slots etc. This permits, for example, the formation of a preferred stand 14 defined within the backing portion. In the preferred embodiment, the stand 14 is held by thinned material retainers 16, which may be broken to permit the stand to be opened away from the backing portion 10. The overall size of the frame and backing portion may vary, and should be selected to hold a flat media of a predetermined size. As an example, the frame can be dimensioned to hold popular 4″×6″ photographs.

[0018] When inserted, media of a predetermined size will also be held around its front edges by a framing portion 18. The framing portion 18 extends from the backing portion 10, but is turned back toward the backing portion 10 to define a media border 20. In other words, around edges of the frame, the backing portion 10 and framing portion 18 blend into each other. There is a gap between the surface 12 of the backing portion and a flat surface 22 of the framing portion that is in a second plane generally parallel to the plane of the surface 12. The gap forms channels 23 (see FIG. 3C) that accept edges of the media. The channel size is chosen to suit the preselected media. It may have a sufficient width for any essentially flat media, e.g., photos, invitations, instructions, awards, name plates, etc.

[0019] One of the frame sides lacks a channel, but includes an open slot 24. The open slot 24 is formed in the top of the exemplary embodiment, but may formed on another side (including the bottom side). The slot 24 is achieved by use of a cam and slide during the injection molding process. The cams move into place prior to injection of liquid resin, then move out of position prior to ejection of a formed frame from a mold. The backing portion 10 also includes openings 26.

[0020] The slot 24 accepts predetermined sized media, which may be slid into the frame through the slot or removed by sliding out through the slot 24. When a media of a predetermined size is slid in through the slot, it is retained in the channels 23 formed by the gap between the surface 12 and the surface 22. Preferably, there is also at least one crush rib 25 formed in the slot 24. In the preferred embodiment, two crush ribs 25 serve to maintain the slot spacing between the backing portion 10 and the framing portion 18. Within the border 20 is an open viewing area. The open viewing area defined by the border 20 permits viewing of at least a substantial portion of media. A customary quantity of the edge may be covered. As the frame may be formed from any number of plastics that may be colored to suit a preferred use, the border 20 frames media in a traditional manner. Preferably, the frame and border are sized to cover at least a portion of all four edges of a four-sided media, for example. This presents the traditional framing appearance.

[0021] As mentioned above, the backing portion 10 need not be a continuous flat surface. It may have holes and structures defined in it. There needs to remain material sufficient to provide structural integrity, however. The overall shape of the backing portion 10 and the framing portion 18 must provide structural support for the frame to maintain its shape and allow it to stand up or be hung or suspended.

[0022] In the preferred embodiment, the frame may be stood up in two free-standing orthogonal positions by the stand 14. A thumb depression 28 allows a person to grasp and gain leverage on the stand 14 to enable it to be pulled out for a first time use by breaking the low strength thinned material retaining portions 16. Once released, the stand 14 is movable to an angled position. It rotates about a living hinge 30, thin material permitting controlled deformation over a limited range. A ridge 32 or enlargement near the hinge 30 can act as a stop to define an end of the movement range for the stand. Tolerances around the stand 14 provide an interference type fit with the backing portion 10, allowing it to be stored back into a generally planar relationship with the backing portion 10. Other options are hook and loop, e.g., Velcro, adhesive, or magnet mounting aids 33, adhered to the frame after it is molded or during the molding process. Optional preferred hangers 34 are formed in a like fashion to the stand 14. The hangers 34 may be moved away from the backing portion 10 to permit hanging of the frame in two orthogonal positions. A perforation is another type of mounting aid 33 that may be formed in the backing portion 10 in an appropriate position, e.g. top center. Such a perforation or hole can accept a hook, a nail, or other similar object to permit the frame to be hung on a flat surface.

[0023] Outer edges of the frame may include interconnection structures. For example, as shown in FIG. 2, one side of the frame could include a male post 35 and the other a female cup 36. Such interconnection structures permit multiple frames to be interconnected to form fanciful displays including multiple frames. The interconnection structures can also facilitate mounting the frame into a holder, to form a frame album or mass storage unit.

[0024] Referring again to FIGS. 1A-1C, preferred features simplify the molding process and add structural integrity. There are uniform wall thickness openings 38. As will be appreciated by artisans, maintaining uniform wall thickness in a molded article will serve to maintain overall shape integrity. Warping is inhibited. The openings 38 prevent the framing portions from having a wall thickness exceeding that of other elements. The openings 26 permit a straightforward mold shape to form the channel between the backing portion 10 and the framing portion. Additionally, in the portion of a mold facing the front portion, a lifter inserted for forming the framing portion on an opposite end of the frame from the media insertion slot 24 is kept simple as it need not extend into corners. The openings 26 permit channels 23 in sides 40 to be formed from shapes on the opposite side of the mold.

[0025] The preferred embodiment of FIGS. 1A-1C has a simple stand 14. The stand 14 has a free range of movement, limited by material elasticity, and possibly a stop 32. When the stand 14 is used to free-stand the frame on a surface, the angle of free-standing may vary or be undesirable. Another embodiment is shown in FIGS. 3A-3E, that illustrate a frame of the invention having stand 42 including a preferred locking mechanism 44. In viewing FIGS. 3A-3E, like reference numerals have been used for portions of the FIGS. 3A-3E frame that are like those used in the FIGS. 1A-1C embodiment.

[0026] The locking mechanism 44 permits the frame to free-stand at a predetermined angle. A preferred angle of 30° between the stand 42 and the frame presents the frame a traditional viewing angle. The locking mechanism 44 is best seen in FIGS. 3D and 3E, partial cross sections respectively taken along lines B—B and C—C. The locking mechanism 44 includes two teeth 46 and two shoulders 48. The teeth 46 lock together and the shoulders 48 abut when the stand 42 is rotated just past 150° about a hinge 50. The hinge 50 is a length of reduced thickness material. Its length is chosen to permit the required amount of rotation, e.g., the exemplary 150° of rotation. The teeth 46 and shoulders 48 are large enough to oppose the tendency of the stand to rotate back toward its position of 0° rotation, i.e., flush within the back portion 10 as seen in FIG. 3A and in the partial cross section B—B of FIG. 3D. Opposition of this tendency locks the stand into the preferred position of 30° from the bottom of the frame. Other sized and positioned teeth can obtain different angles, as will be appreciated by artisans. Preferably, the teeth 46 include angled surfaces 52. The angled surfaces 52 permit a user to apply force and obtain release of the stand 42 from the locked free-stand position. The stand 42 also includes ribs 54 to provide additional rigidity.

[0027] While specific embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.

[0028] Various features of the invention are set forth in the appended claims.