RELATED APPLICATION(S)

The present application claims priority from Australian Provisional Patent Application No. 2013900012, filed 4 January 2013, the entire contents of which are incorporated herein by reference.

FIELD OF INVENTION

The present invention relates to generally to a profile of a picture frame assembly, and in particular, to frame assembly for a picture frame and method of forming a picture frame assembly that reduces material wastage and costs associated with forming a conventional picture frame profile.

BACKGROUND OF THE INVENTION

Picture frame assemblies come in a variety of types and sizes. Picture frames generally comprise a frame or border within which is mounted a picture, such as a photograph, which provides an aesthetic border around the picture and also provides a structure to hold and retain the picture in a position suitable for display.

Most picture frame assemblies generally comprise a rigid body having a central recess into which the picture is received. A window region is generally provided in the body of the frame assembly through which the picture is able to be viewed. The window may have a glass or plastic cover to protect the picture positioned in the window region. A backing member in the form of a piece of plywood, cardboard, or similar material is located within the recess to be positioned at the rear of the picture when the picture is located within the frame assembly. The backing member is generally shaped to conform to the shape of the recess so that the backing member acts to sandwich the picture between the backing member and the frame/glass for display.

The profile of a picture frame generally refers to the overall shape and design of the frame, The profile generally includes the height, width and rabbet, which receives the window and backing member.

Conventionally, timber picture frame profiles have been formed by processing a rectangular piece of dressed timber and removing a region of timber required to form a rebate around the central recess. The formation of a rebate in such a manner creates a degree of material wastage as well as a further processing step that increases the cost of manufacturing the profile.

Further, most conventional timber picture frame profiles are produced according to the length of the available timber or panel board. This is generally due to the fact that in order to cut the timber to specific sizes, off-cuts are created of random lengths and sizes, which are of little commercial value. Thus, such off-cuts are often disposed of as waste, adding more cost to the overall process of manufacturing timber picture frame profiles.

Thus, there is a need to provide a picture frame profile and a means for forming a picture frame profile that is simple and efficient and reduces raw material wastage.

The above references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the above prior art discussion does not relate to what is commonly or well known by the person skilled in the art, but assists in the understanding of the inventive step of the present invention of which the identification of pertinent prior art proposals is but one part,

STATEMENT OF INVENTION

The invention according to one or more aspects is as defined in the independent claims, Some optional and/or preferred features of the invention are defined in the dependent claims.

Accordingly, in one aspect of the invention there is provided a frame assembly comprising:

a plurality of profile members connectable to form the frame assembly, each profile member being formed from a sheet of material folded to form a rebate at a rear surface thereof; and

a backing member mountable to the frame assembly to be supported by said rebate.

Each profile member may be connectable at an end thereof to an adjacent profile member to form said frame assembly.

Each profile member, when folded, may define a front portion, outer side portion and inner side portion of the frame assembly.

Each profile member may have at least two grooves formed on a surface thereof to facilitate folding thereof, The rebate may be formed by a difference in length between the outer side portion and the inner side portion of each profile member when the profile member is folded.

The frame assembly may further comprise a retaining member attachable to an inner surface of the outer side portion of each profile member and which is configured to engage with the backing member to retain the backing member in position with respect to the frame assembly.

The retaining member may be made from a malleable material so as to be bendable to extend behind the backing member to retain the backing member in position with respect to the frame assembly.

In one form, when the profile member is folded, the outer side portion and the inner side portion may be in contact. In another form, when the profile member is folded, the outer side portion and the inner side portion are separated from each other a predetermined distance so as to form a channel between the outer side portion and the inner side portion, The predetermined distance may be substantially equivalent to the length of the front portion of the profile member.

One or more reinforcement members may be located within said channel to enhance the structural integrity of the folded profile member. The one or more reinforcement members may comprise one or more blocks configured to be snugly received within said channel.

According to another aspect of the present invention, there is provided a method of forming a picture frame assembly comprising the steps of: providing a plurality of individual profile members made from a predetermined length of sheet material; processing each profile member to form at least two grooves therein, each groove extending in a parallel manner along the length of each profile member; forming the profile member by folding each profile member along the grooves to form a three dimensional profile member having at least an outer side portion and a inner side portion and a front portion, whereby the outer side portion and the inner side portion are of different lengths so as to define a rebate along a rear surface of the formed profile member; and assembling each of the formed profile members in an abutting manner to form said frame assembly such that a recess is formed in a rear surface of the assembled frame assembly, said recess being defined by the rebates formed in each abutting profile member.

The step of processing each profile member may comprise milling the at least two grooves in a surface thereof, each groove being a substantially V-shaped groove so as to function to form a hinge about which the profile member is folded. The step of forming the profile member may comprise folding the profile member at each said hinge.

Each of the formed profile members may be arranged to form a substantially rectangular frame assembly.

The step of forming the profile member may comprise reinforcing the assembled frame assembly by adding one or more reinforcement members to the profile members in at least a region where the profile members abut.

The step of forming the profile member may comprise a further step of applying a finish to the assembled frame assembly.

BRIEF DESCRIPTION OF THE DRAWINGS The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

Fig. 1 is a rear view of a profile of a picture frame assembly according to an embodiment of the present invention;

Fig. 2 is a cross sectional end view of an assembled picture frame employing the profile of Fig. 1;

Figs. 3a - 3c show front, end, and formed views respectively of a member of the profile of Fig. 1 ;

Figure 4 is a rear view of a profile of a picture frame assembly according to another embodiment of the present invention;

Figure 5 is a cross sectional end view of an assembled picture frame employing the profile of Fig. 4;

Figure 6a - 6c show front, end, and formed views respectively of a member of the profile of Fig. 4; and

Figure 7 is a perspective end of a member of the profile of Fig. 4 having strengthening blocks provided therewith in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE DRAWINGS

Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention.

The present invention will be described below in relation to a conventional picture frame assembly of the type having a frame body or profile defining a central recess into which a picture, such as a photograph or the like, is received and positioned for display. The recess has a rebate formed about the perimeter thereof, which acts as a means for receiving a backing member that functions to retain the picture in position. In order to complete the assembly, a glass panel or window is located in the recess to provide a means for viewing the picture from a front surface of the picture frame assembly and protecting the picture when displayed. However, it will be appreciated that the present invention could equally be applied to a variety of different types of picture frame assemblies, and still fall within the spirit of the present invention.

Referring to Fig. 1, a rear view of a profile 10 of a picture frame assembly according to one embodiment of the present invention is shown. The profile 10 is shown in the form of a rectangular profile; however, it will be appreciated that other shapes and configurations of the profile 10 are also envisaged. The profile generally comprises four members 12 that each define the sides, top and bottom of the profile 10. Each of the members 12 are configured to abut together at their ends to form a continuous perimeter of the profile 10 and may be secured at their ends by way of an adhesive or by a mechanical means, such as a tack, nail or the like. In this regard, a mitre joint may be provided, with each end of each member

12 bevelled at a 45° angle to form a 90° corner, as shown.

Referring to Fig. 2, a cross-sectional end view of picture frame assembly 11 incorporating the profile 10 of Fig, 1 is shown. The picture frame assembly 11 generally comprises a cover 14 in the form of a sheet of glass, plastic or the like that forms a window through which a picture can be viewed. The cover 14 is mounted within the recess of the assembly 11 such that it is supported on a rebate

13 formed at a rear surface of the profile 10.

In use, a picture (not shown) is placed on the inner sur face of the cover 14 such that it is viewable through the cover 14. A backing member 16 is then mounted over the rear surface of the picture such that the picture is located between the cover 14 and the backing member 16. The backing member is also shaped to be received within the recess so as to be supported by the rebate 13. A plurality of retaining members 18 are provided to retain the backing member 16 securely in position within the recess. The retaining members 18 typically engage with the profile 10 in region adjacent the rebate 13 and have a free end that is bendable so as to be manipulated to engage with a rear surface of the backing member 16 to hold the backing member 16 in position, as shown. The retaining members 18 may take a variety of forms; one such form is described in the Applicant's copending International PCT Patent Application No. PCT/AU2013/000253, the entire contents of which are incorporated herein by reference.

A member 12 of the profile 10 is shown in isolation in Figs. 3a - 3c. In the embodiment as shown, each of the members 12 are formed from medium density fibreboard (MDF) sheeting, having a thickness of between 3 - 5 mm. MDF is a common substrate used in the picture frame industry for backing members, easel struts, and the like and can be readily decorated or otherwise embossed to provide a variety of differing colours and textures according to individual tastes.

Each member 12 is typically cut to a desired length prior to processing. In the embodiment as shown in Figs. 3a and 3b, two grooves 20 are then milled in a surface of the member 12, immediately adjacent each other. The grooves 20 are in the form of V- grooves, and have a depth of approximately 2.5 mm, and function as a folding hinge to enable the member 12 to be folded into the configuration as shown in Fig. 3 c. As part of the manufacturing process, the grooves 20 may be formed at the same time as the member 12 is cut to its desired length. In this regard, following the formation of the grooves 20, the member 12 can be considered to comprise an outer side portion 24 that defines the external side surface of the formed profile, and an inner side portion 22 that defines the internal side portion of the formed profile 10.

As is shown in Fig. 3 c, in order to form the member 12 into the desired configuration, the inner side portion 22 is folded about the grooves 20 such that it is in contact with an inner surface of the outer side portion 24. As the inner side portion 22 is significantly shorter than the outer side portion 24, the rebate 13 is formed, as shown, namely by the end of the inner side portion 22. An adhesive or mechanical fastener, such as a tack or nail, is then provided to retain the inner side portion 22 in contact with the inner surface of the outer side portion 24 and the ends of the member 12 can then be formed to facilitate assembly of the members 12 to form the profile 10 as shown in Fig. 1, in a conventional manner. It will be appreciated that the formation of the members 12 of the profile 10 in the manner as discussed above does not require a further material removal step to form the rebate 13, as the rebate 13 is automatically formed upon folding the inner side portion 22 onto the outer side portion 24. It will be appreciated that by reducing the step of forming the rebate in the profile 10, the time in whichi to form the profile is increased and material wastage through the removal of material to form the rebate 13 is reduced.

Turing to Fig. 4, a rear view of an alternative profile 30 according to an alternative embodiment of the present invention is shown. The profile 30 is also shown in the form of a rectangular profile; however, it will be appreciated that other shapes and configurations of the profile 30 are also envisaged. The profile generally comprises four members 32 that each define the sides, top and bottom of the profile 30. Each of the members 32 are configured to abut together at their ends to form a continuous perimeter of the profile 30 and may be secured at their ends by way of an adhesive or by a mechanical means, such as a tack, nail or the like. In this regard, a mitre joint may be provided, with each end of each member 32 bevelled at a 45° angle to form a 90° corner.

In the embodiment of the profile 10 as shown in Figs, 1 - 3c, the profile is substantially thin, with the thickness defined as being twice the thickness of the material used to form the member 12, as the material is folded back onto itself. Such a frame assembly 11 may be ideal for displaying certificates or small photos as the profile will be approximately 6 mm, where the MDF sheet has a thickness of approximately 3 mm.

Referring to Fig. 5, a cross-sectional end view of picture frame assembly 11a incorporating the profile 30 of Fig. 1 is shown. In this embodiment, the picture frame assembly 11a is formed to have a wider face presentation than is the case in picture frame assembly 11 shown in Figs. 1 - 3c described above.

As for the previously described arrangement, the picture frame assembly 11a generally comprises a cover 14 in the form of a sheet of glass, plastic or the like that forms a window through which a picture can be viewed. The cover 14 is mounted within the recess of the assembly 11a so as to be supported on a rebate 13 formed at a rear surface of the profile 30.

In use, a picture (not shown) is placed on the inner surface of the cover 14 such that it is viewable through the cover 14. A backing member 16 is then mounted over the rear surface of the picture such that the picture is located between the cover 14 and the backing member 16. The backing member is also shaped to be received within the recess of the assembly 11a and supported on the formed rebate 13. A plurality of retaining members 18 are provided to retain the backing member 16 securely in position upon the formed rebate 13. The retaining members 18 typically engage with the body of profile 30 in the region adjacent the rebate 13 and have a free end that is bendable so as to be manipulated to engage with a rear surface of the backing member 16 to hold the backing member 16 in position, as shown in Fig. 5. As previously discussed, the retaining members 18 may take a variety of forms; one such fonn may be as described in the Applicant's co-pending International PCT Patent Application No. PCT/AU2013/000253, the entire contents of which are incorporated herein by reference.

As discussed previously, the front face presentation 30a of the profile 30 is greater than the front face presentation 10a of the profile 10 of Figs. 1 - 3c. This is achieved by forming each of the individual members 32 in the manner as shown in Figs. 6a - 6c, as will be discussed as follows.

Turning firstly to Fig. 6a, in the embodiment as shown, each of the members 32 is formed from medium density fibreboard (MDF) sheeting, having a thickness of between 3 - 5 mm. Each member 32 is typically cut to a desired length prior to processing and two grooves 40 are then milled in a surface of the member 12, separated by a distance 'X'. The grooves 40 are in the form of V-grooves, and have a depth of approximately 2.5 mm, to function as a folding hinge to enable the member 32 to be folded into the configuration as is shown in Fig. 6c. As part of the manufacturing process, the grooves 40 are typically formed at the same time as the member 32 is cut to its desired length. In this regard, following the formation of the grooves 40, the member 32 can be considered to comprise an outer side portion 42 that defines an outer side edge surface of the formed profile 30, a front portion 44 that defines a front surface of the formed profile 30, and an inner side portion 46 that defines the inner side edge surface of the formed profile 10. It will be appreciated that the width of the front face presentation 30a of the formed profile 30 can be simply altered by altering the distance 'X' between the grooves 40 and the distance between the grooves 40 and the edge of the member 32.

As is shown in Fig. 6c, in order to form the member 32 into the desired configuration, the front portion 44 and the inner side edge portion 46 is folded about the grooves 40 to form a J-shaped cross-section as shown. In this regard, the front portion 44 defines the front face presentation 30a of the formed profile 30, with the different in length between the outer side portion 42 and the inner side portion 46 defining the rebate 13, upon which the cover 14, picture and backing member 16 are supported.

With the profile 30 as is shown in Figs. 4 and 5, the wider face presentation of the formed profile may have reduced strength at the corners, where the individual members 32 join. In order to enhance the strength of the profile 30 at these regions as well as along the entire length of the members 32, short blocks of material 50, such as wooden blocks or the like, are placed in the channel formed between the outer side portion 42 and the inner side portion 46, as shown in Fig. 7, and as shown as the ghosted lines in Fig. 4.

For improved strength of the profile 30, only one block 50 may be provided at the mitre joint between adjacent members 32. The block 50 will support the profile 30 at the mitre joint to provide an enlarged surface at the mitre joint between abutting members 32 for gluing or other mechanical fastening, as may be desired.

In embodiments where the profile 30 is particularly long, such as may be the case when the profile is used to frame posters and the like, the blocks 50 may be strategically positioned along the length of the members 32 at spaced intervals as shown in Fig. 7. Such an arrangement ensures that the profile has sufficient strength along its length and width.

It will be appreciated that the frame profiles as formed by the present invention, employ a single thin piece of material that is folded to form the profile, Such a means for forming a picture frame assembly reduces raw material wastage and provides a simple and effective means for reducing manufacturing costs. The nature of the exposed profile surfaces provide a convenient surface for applying cosmetic or aesthetic enhancement to the profile by way of painting, embossing to form a desirable surface finish of the frame assembly in accordance with a purchaser's taste. As the finishing is applied only to exact length of the members 12, 32, wastage of finishing products is also minimised.

The application of the finish required for a picture frame profile is a complicated procedure typically due to the fact that the finish must be applied over a three dimensional object. Usually this requires complex printing or profile wrapping processes with specialised materials that are expensive, labour intensive and create a further opportunity for waste due to defects in the process. Given the nature of the present invention whereby the profile is formed by a single thin piece of material folded into position, the present invention requires only a flat lamination process in one dimension to apply such a finish, and as such, the process is simple and is less prone to faults occurring, as there are no special properties required in the laminate material. This enables the use of a wide variety of materials, including all manner of papers, synthetics, vinyls, metals and fabrics.

Throughout the specification and claims the word "comprise" and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word "comprise" and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise,

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the frame assembly uppermost.

It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention.