Free-standing window screen fabrication system

Abstract

A free-standing window screen fabrication system for releasably mounting a screen fabric or other pliable sheet material on a free-standing screen frame in such a manner as to self-tighten the fabric or material during installation. A screen is disposed and held securely in place between a screen frame extrusion member and a trim mold. The screen frame extrusion defines a mounting surface disposed below and parallel to an exterior face. The screen frame extrusion further defines an interior channel for receiving one end of a connector, a plurality of screen frame extrusions being secured in an end-to-end fashion to define a free-standing screen frame. A mounting rib extends along the mounting surface and terminates below the exterior face in the preferred embodiment. A bead is defined at the terminal edge of the mounting rib to serve as a locking mechanism. The trim mold defines a channel opening on the bottom surface thereof to closely receive the mounting rib of the screen frame extrusion. A plurality of retention barbs are formed in the channel to engage the mounting rib bead in order to prevent inadvertent removal of the trim mold from the mounting rib.

Having thus described the aforementioned invention, I claim:  
     
         1 . A free-standing screen frame comprising: 
 a plurality of screen frame extrusions secured in an end-to-end fashion and cooperating to form a frame opening, each said screen frame extrusion defining at least one mounting surface and at least one mounting rib extending upwardly from said mounting surface and parallel to an interior edge of said screen frame extrusion, said mounting rib defining a bead along a terminal edge of said mounting rib, each said screen frame extrusion further defining an interior channel defined along a length thereof;    a plurality of connectors for securing said plurality of screen frame extrusions in a fixed relationship to define a screen frame, each of said plurality of connectors defining a first elongated member and a second elongated member, said first elongated member for being received within said interior channel defined by a one of said plurality of screen frame extrusions, said second elongated member for being received within said interior channel defined by another of said plurality of screen frame extrusions;    a screen disposed across said frame opening; and    a plurality of trim mold extrusions configured to closely receive said mounting rib of said screen frame extrusion, each of said plurality of trim mold extrusions defining a bottom surface and a channel opening thereon and extending into said trim mold extrusion a depth substantially equal to a height of said mounting rib, said channel defining a plurality of retention barbs for engaging said mounting rib bead, whereby said trim mold extrusion is prevented from inadvertent removal when said screen frame extrusion mounting rib is received within said trim mold extrusion channel and said screen is retained from movement therein, and further whereby said screen is self-tightened as said trim mold is engaged with said screen frame extrusion.    
     
     
         2 . The free-standing screen frame of  claim 1  wherein said screen frame extrusion further defines an exterior face above and parallel to said mounting surface, and a vertical surface extending between and perpendicular to said exterior face and said mounting surface, whereby said mounting rib is disposed substantially parallel to said vertical surface, and whereby said mounting rib terminates below said exterior face.  
     
     
         3 . The free-standing screen frame of  claim 2  wherein each of said plurality of trim mold extrusions further defines an exterior face disposed substantially co-planar with said screen frame extrusion exterior face when said screen frame extrusion mounting rib is received within said trim mold extrusion channel.  
     
     
         4 . The free-standing screen frame of  claim 1  wherein said screen frame extrusion defines a symmetrical configuration having a first said mounting rib for mounting a first said screen and a second said mounting rib for mounting a second said screen.  
     
     
         5 . The free-standing screen frame of  claim 1  wherein said screen is fabricated from a mesh-type screen selected to allow air flow therethrough.  
     
     
         6 . The free-standing screen frame of  claim 1  wherein said screen is fabricated from a sheet material selected to prevent airflow therethrough.  
     
     
         7 . The free-standing screen frame of  claim 1  wherein said screen is interchangeable and is fabricated from either of a mesh-type screen selected to allow air flow therethrough and a sheet material selected to prevent airflow therethrough.  
     
     
         8 . A method for fabricating a free-standing screen including a screen frame and at least one trim mold extrusion, said screen frame constructed from a plurality of screen frame extrusions, each said screen frame extrusion cooperating to form an opening across which is positioned said screen, each said screen frame extrusion defining at least one mounting surface and at least one mounting rib extending upwardly from said mounting surface and parallel to an interior edge of said screen frame extrusion, said mounting rib defining a bead along a terminal edge of said mounting rib, each said screen frame extrusion further defining an interior channel defined along a length thereof, said plurality of screen frame extrusions being secured one to another in an end-to-end fashion using a plurality of connectors, each of said plurality of trim mold extrusions being configured to closely receive said mounting rib of said screen frame extrusion said screen, said trim mold extrusion defining a bottom surface and a channel opening thereon and extending into said trim mold extrusion a depth substantially equal to a height of said mounting rib, said channel defining a plurality of retention barbs for engaging said mounting rib bead, said method comprises the steps of: 
 a) connecting each of said plurality of screen frame extrusions using said plurality of connectors to fabricate a screen frame defining a frame opening;    b) positioning said screen over said opening defined by said screen frame;    c) placing a one of said at least one trim mold extrusion over said mounting rib of a cooperating one of said at least one screen frame extrusion to position said channel over said mounting rib;    d) pressing said trim mold to engage said mounting rib in said channel with said screen positioned between;    e) pulling said screen to gently tighten said screen over said screen frame opening;    f) placing a further of said at least one trim mold extrusion over said mounting rib of a cooperating one of said at least one screen frame extrusion to position said channel over said mounting rib;    g) pressing said further trim mold extrusion to engage said mounting rib in said channel with said screen positioned between;    h) repeating steps e) through g) until each of said at least one trim mold has been pressed into engagement with a cooperating one of each of said at least one screen frame extrusion mounting rib, whereby as said further of said at least one trim mold and each subsequent said at least one trim mold is engaged, said screen is self-tightened.    
     
     
         9 . The method of  claim 8 , after said step of repeating steps e) through g), further comprising the step of: 
 i) trimming excess of said screen from around an exterior perimeter defined by each of said at least one trim mold extrusion.