Patent Application
20230301406
The present invention is directed to an umbrella with a folding frame, and in particular to an umbrella with a frame having ribs that can be replaced.
Large collapsible umbrellas, such as patio umbrellas, may be in the form having a central support post or a side support post.
For a central supported umbrella, it includes a central support post having at its upper end a frame structure that supports a canopy made of a flexible material (e.g. fabric). Heretofore, that frame structure of umbrellas includes a network of ribs configured to allow the canopy material to span or stretch out in an opened state of the umbrella, and to collapse or fold into a closed state for stowing or when the umbrella is not in use. Generally, long ribs are pivotally connected at one end to an upper hub with the free ends of the long ribs extending from the long hub. Short ribs are pivotally connected at one end to a location along respective long ribs and pivotally connected at another end to a lower hub. The upper hub is fixed at the upper end of the post. The lower hub is slidable relative to the upper hub along the central support post, to move towards and away from the upper hub. In the collapsed state of the umbrella, the lower hub is moved away from the upper hub, and the long ribs and the short ribs are pivoted to collapse the long ribs and the short ribs towards the post. When the lower hub is raised towards the upper hub, the short ribs and the long ribs are pivoted to cause the long ribs and short ribs to extend from the respective hub outwards from the post, thereby extending the canopy material to provide under shading the canopy.
For a side supported umbrella (see, e.g., U.S. Pat. No. 10,136,709B2), it includes a side support post having an arm supported by and extending (e.g., cantilevered) from the post, whereby the extended end of the arm supports an upper hub of a frame structure that support a canopy. A lower hub is suspended below the upper hub. Long and short ribs are provided as in the central supported umbrella. The lower hub can be drawn towards and away from the upper hub, to operate the long and short ribs in a similar manner as discussed above in reference to the central supported umbrella.
A collapsible canopy frame structure brings challenges to structural integrity of the frame structure. Heretofore, in order to ensure the structural integrity of the frame structure, the pivot joints between the ribs to the respective upper and lower hubs and between the long and short ribs are implemented using rivets and the like to form the pivot joints. The pivot joints require manufacturing steps that cannot be automated at the point of manufacture. Once assembled, the frame structure is bulky, requiring higher shipping costs from point of manufacturing to users. In recent years, manufacturing and shipping costs have risen significantly. Points of manufacturing are moved to more remote locations, but that would exacerbate shipping costs.
Furthermore, once the overall frame structure including the upper and lower hubs and the long and short ribs are formed into an assembled unit, it cannot be easily disassembled, e.g., to replace a damaged rib. Hence, when a rib is damaged, e.g., bent or broken from use or by strong winds, the damaged rib cannot be replaced by the user. The umbrella would be declared damaged as a whole unit. The damaged umbrella would be tossed, ending in a landfill.
The frame structure may be reinforced with stronger parts and materials, but that would add to manufacturing and material costs, leading to higher shipping costs as well. Hence, a vicious cycle in past attempts to improve the integrity of umbrellas.
U.S. Pat. No. 10,292,466B2 purports to disclose a conceptual idea of removing and placing broken ribs at the hubs. However, the applicant is not aware that the disclosed concept has been proven commercially viable.
There is a need for a simple, reliable and easy to assemble umbrella assembly structure that balances the above noted concerns to optimizes structural integrity along with reduced manufacturing, shipping, and material costs.
The present invention provides a simple, reliable and easy to assemble collapsible umbrella frame structure that incorporates releasable, removable and/or replaceable quick connect rib sections, which addresses the above noted concerns to optimizes structural integrity along with reduced manufacturing, shipping, and material costs. Hereinafter, “releasable”, “removable” and/or “replaceable” connections or couplings are generally referred to as “releasable” couplings or connections, and more specifically connections and couplings of the type user finger operable quick connection without requiring using a tool. The inventive collapsible umbrella assembly can be easily assembled by a user for use and repaired with replacement rib sections after damage to the ribs in the frame structure.
In one aspect of the present invention, the inventive collapsible umbrella comprises a support structure, a frame structure supported by the support structure, comprising: a support hub; a plurality of long ribs, each comprising a first rib section and a second rib section releasably connected by a pivot rib coupler, wherein each long rib has an end releasably or fixedly coupled to an upper end of the support hub; a plurality of short rib sections in the form of a plurality of third rib sections, each third rib sections comprising a first end releasably coupled to the pivot rib coupler and a second end releasably or fixedly coupled to a lower end of the support hub, wherein each pivot rib coupler is configured to pivot the third rib section relative to the first and second rib sections that are releasably coupled to the pivot rib coupler.
In one embodiment, the pivot rib coupler comprises a straight pivot portion having a first end and a second end, and an angled pivot portion having an end pivotally connected to the straight pivot portion and an extended end, wherein a first end of the first rib section is releasably coupled to the first end of the straight pivot portion of the pivot rib coupler, and a first end of the second rib section is releasably coupled to the second end of the straight pivot portion of the pivot rib coupler, wherein the first end of the third rib section is releasably coupled to the extended end of the angled pivot portion of the pivot rib coupler.
In one embodiment, the support hub comprises an upper hub at the upper end of the support hub, and a plurality of upper pivot hub connectors each having an end pivotally coupled to the upper hub, wherein a second end of each first rib section is releasably or fixedly coupled to an extended end of a corresponding upper pivot hub connector; and a lower hub at the lower end of the support hub, and a plurality of lower pivot hub connector each having an end pivotally coupled to the lower hub, wherein a second end of each third rib section is releasably or fixedly coupled to an extended end of a corresponding lower pivot hub connector.
In one embodiment, the first end and the second end of the straight pivot portion of each pivot rib coupler, the extended end of the angled pivot portion of each pivot rib coupler, the extended end of each upper pivot hub connector, and the extended end of each lower pivot hub connector, are each an opened end configured as a coupling opening to receive an end of a corresponding one of the first, second and third rib sections.
The umbrella support structure may comprise a central support post, wherein the frame structure is supported at an upper end of the central support post, or a side support post and an arm cantilevered from the side support post, wherein the frame structure is supported at an extended end of the arm.
In one embodiment, the first end of each of the first rib sections, the second rib sections and the third rib sections are releasably coupled to the corresponding first, second and extended ends of the pivot rib coupler, the second end of each of the first rib sections is releasably coupled to the corresponding extended end of the upper pivot hub connector, and the second end of each of the third rib sections is releasably coupled to the corresponding extended end of the lower pivot hub connector, via a user finger operated releasable coupling that does not require using an external tool for a user to release the coupling.
In one embodiment, the releasable coupling comprises a push button spring clip at the first and second ends of each of the first and third rib sections, and the first end of each of the second rib section, and a complementary opening at the corresponding first, second and extended ends of the pivot rib coupler, extended end of the upper pivot hub connector and extended end of the lower pivot hub connector. To facilitate ease of use, the releasable coupling may comprise a double push button spring clip.
At least two of the first rib section, the second rib section and the third rib section may be similar in length and are interchangeable, to reduce part variations (e.g., the first and third rib sections may have similar length and interchangeable). In another embodiment, the first rib section, the second rib section and the third rib section are all similar in length and are interchangeable.
At least a portion at the respective ends of the various rib sections may be provided with a cross-sectional shape that is non-symmetrical about at least one axis in the sectional plane, to facilitate matching of the ends of the rib sections to complementary openings at the corresponding first, second and extended ends of the pivot rib coupler, extended end of the upper pivot hub connector and extended end of the lower pivot hub connector. In one embodiment, the cross-sectional shape conforms to a rounded top and generally flat bottom.
In a further embodiment, instead of releasably coupling to the upper end and lower end of the support bub as in the above described embodiments, each long rib has an end fixedly coupled to the upper end of the support hub, and each third rib sections comprises a second end fixedly coupled to a lower end of the support hub. As in the above described embodiments, an upper hub is provided at the upper end of the support hub and a plurality of upper pivot hub connectors each having an end pivotally coupled to the upper hub, wherein a second end of each first rib section is fixedly coupled to an extended end of a corresponding upper pivot hub connector; and a lower hub is provided at the lower end of the support hub and a plurality of lower pivot hub connectors each having an end pivotally coupled to the lower hub, wherein a second end of each third rib section is fixedly coupled to an extended end of a corresponding lower pivot hub connector.
The detailed description set forth below is intended as a description of the presently exemplary device provided in accordance with aspects of the present invention and is not intended to represent the only forms in which the present invention may be prepared or utilized. It is to be understood, rather, that the same or equivalent functions and components may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices and materials similar or equivalent to those described can be used in the practice or testing of the invention, the exemplary methods, devices and materials are now described.
All publications mentioned are incorporated by reference for the purpose of describing and disclosing, for example, the designs and methodologies that are described in the publications that might be used in connection with the presently described invention. The publications listed or discussed above, below and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.
The present invention provides a simple, reliable and easy to assemble collapsible umbrella assembly structure that incorporates releasable, removable and/or replaceable quick connect rib sections, which addresses the above noted concerns to optimizes structural integrity along with reduced manufacturing, shipping, and material costs. The inventive collapsible umbrella assembly can be easily assembled for use and repaired with replacement rib sections after damage to the ribs in the frame structure. The present invention balances and optimizes structural integrity along with reduced manufacturing, shipping, and material costs.
As illustrated by the figures, the inventive collapsible umbrella U comprises a support structure SS, a frame structure FS supported by the support structure SS, comprising: a support hub H; a plurality of long ribs L, each comprising a first rib section L1 and a second rib section L2 releasably connected by a pivot rib coupler RC, wherein each long rib L has an end releasably coupled to an upper end of the support hub H; a plurality of short rib sections S in the form of a plurality of third rib sections S3, each comprising a first end releasable coupled to the pivot rib coupler RC and a second end releasably coupled to a lower end of the support hub H, wherein each pivot rib coupler RC is configured to pivotal the third rib section S3 relative to the first and second rib sections L1, L2 that are releasably coupled to the pivot rib coupler RC.
A canopy C comprising a flexible material (e.g., canvas, fabric, etc.) is supported on the frame structure FS, with the flexible material spanning over the long ribs L. Once assembled, the collapsible umbrella U can be operated to open/extend or close/collapse the canopy C in similar fashion as known collapsible umbrellas.
In one embodiment, the first end E1 and the second end E2 of the straight pivot portion SC of each pivot rib coupler RC, the extended end EX of the angled pivot portion AC of each pivot rib coupler RC, the extended end of each upper pivot hub connector UHC, and the extended end of each lower pivot hub connector LHC, are each an opened end (i.e., a coupling opening CO) sized and configured to receive an end of a corresponding one of the first, second and third rib sections L1, L2, S3.
To facilitate ease of assembly of the rib sections to the complementary components, the releasable coupling may be of the type generally referred to as a double push button spring clip BSC.
While the illustrated embodiment depicts the push button spring clip provided at the end portion of the rib section (L1, L2, S3) and the hole RH is provided at the wall of the coupling opening CO, their locations can be swapped without departing from the scope and spirit of the present invention.
While the illustrated embodiment depicts the push button spring clip to be a double push button spring clip, a single push button spring clip may be used, in which case a first button at the end of the rib section is depressed directly by a user in order to insert the end portion into or withdrawn the end portion from the coupling opening.
The replaceable rib sections L1, L2, S3 may be of same or different lengths, depending on the size of the frame structure for the desired collapsible umbrella.
To reduce part variations, at least two of the first rib section, the second rib section and the third rib section L1, L2, S3 may be similar in length and are interchangeable. For example, the first and third rib sections L1, S3 may be of similar length and interchangeable. In another embodiment, the first rib section L1, the second rib section L2 and the third rib section S3 are all similar in length and are interchangeable.
In another embodiment depicted in
In another embodiment, rib sections L1, L2, S3 may be configured with other cross-sectional profiles. For example, instead of tube-shaped beams having cross-section of closed walls, open wall cross-section, such as generally channel-shaped (e.g., U-shaped or V-shaped) beams may be adopted for the rib sections. Alternatively, beams having cross-sections of other geometrical shapes, such as I-shaped, rectangle-shaped, triangle-shape, etc., cross-sections, may be adopted for the rib sections.
In another embodiment, the rib sections may have different cross-section profiles. For example, the first and second rib sections may have similar cross-section profile, and the third rib section may have a cross-section profile different from that of the first and second rib sections.
While the above described embodiments include complementary coupling openings and rib section ends of similar cross-sectional profile shapes, the cross-sectional profile of the end portion of the rib section and the coupling opening do not need to be similar to be complementary. For example, an I-shaped cross-section of the rib section may be received in a complementary coupling opening that has a rectangular cross-section profile.
The umbrella support structure SS may comprise a central support post P, wherein the frame structure FS is supported at an upper end of the central support post P, as depicted in the illustrated embodiment, or a side support post (not shown) and an arm cantilevered from the side support post, wherein the frame structure FS is supported at an extended end of the arm. For example, the inventive frame structure features of the present invention may be adopted in a side supported umbrella, such as the one disclosed in U.S. Pat. No. 10,136,709B2, which is incorporated by reference herein.
It is appreciated that for a particular umbrella support structure that is partially assembled with a hub structure, different lengths of rib sections may be selectively chosen to assemble a frame that can accommodate canopies of different sizes. For example, the second rib section extending from and pivot rib coupler may be chosen to have a shorter or longer length to accommodate a canopy of a smaller or larger area, respectively.
In a further embodiment, instead of releasably coupling to the upper end and lower end of the support bub as in the above described and illustrated embodiments, each long rib L has an end fixedly coupled to the upper end of the support hub H, and each third rib sections S comprises a second end fixedly coupled to a lower end of the support hub H. As in the above described embodiments, an upper hub UH is provided at the upper end of the support hub H and a plurality of upper pivot hub connectors UHC each having an end pivotally coupled to the upper hub UH, wherein a second end of each first rib section L1 is fixedly coupled (e.g., using rivets, epoxy, bolts, screws, etc.) to an extended end of a corresponding upper pivot hub connector UHC; and a lower hub LH is provided at the lower end of the support hub H and a plurality of lower pivot hub connectors LHC each having an end pivotally coupled to the lower hub LH, wherein a second end of each third rib section S3 is fixedly coupled (e.g., using rivets, epoxy, bolts, screws, etc.) to an extended end of a corresponding lower pivot hub connector LHC. For example, instead of using finger operated releasable couplings as in the previously disclosed embodiments, the second end of each of the first and third rib sections L1, S3 can be inserted into a complementary opening at the extended end of the corresponding upper and lower pivot hub connectors UHC, LHC and said second end may be fastened to said opening at the extended end of the upper and lower pivot hub connectors UHC, LHC by rivets, expoxy, bolts, screws, etc. or a combination of such fasteners.
The inventive frame structure for the collapsible umbrella achieves at least the following advantages over the prior art:
a. The quick connect coupling of the rib sections to the hub structure allows the collapsible umbrella frame to be easily assembled at the point of use, thus not have to rely on full assembly of the collapsible umbrella frame at the point of manufacture.
b. The collapsible umbrella frame structure can be partially assembled at the point of manufacture with the hub structure assembled to the support structure or part thereof, which results in a smaller package that would reduce significant shipping costs compared to shipping costs imposed on a more bulky fully assembled umbrella frame structure.
c. The removable, replaceable and/or interchangeable rib sections permits repairing of damaged rib of an umbrella frame by replacing the damaged rib section, thus not leading to premature waste of the rest of the umbrella.
d. The rib sections facilitate inventory management, with potentially lesser part variations. Having rib sections of similar lengths leads to less variation in rib sections. Further, for the same partially assembled core support structure and hub structure, different size rib sections can be used to assemble a frame structure that can accommodate different size canopies to assemble umbrella of different sizes. So, it would not be necessary to maintain inventory of complete umbrella assemblies of different size canopies. Different size canopies can be accomplished by using rib sections of desired lengths with the same core partially assembled frame structure.
e. User may decide to change the size of the canopy without having to purchase an entire new umbrella including fully assembled frame structure. User may simply replace some of the rib sections (e.g., the second rib sections extending from the pivot rib coupler) and replace the canopy.
e. The rib sections may be sold as replacement parts, thus generating more revenue for the seller.
f. The rib sections facilitate warranty replacement of only damaged rib sections, instead of having to replace an entire umbrella with only a damage rib, thus lessen the burden on fulfillment of warranty claims by the seller/manufacturer and potentially improving customer satisfactions.
While the present invention has been described above in connection with the illustrated embodiments, the scope of patent invention covers all possible present and future variations and improvements that is apparent from the disclosure above. While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit, scope, and teaching of the invention. Accordingly, the disclosed invention is to be considered merely as illustrative and limited in scope only as specified in the appended claims.
| Number | Date | Country | |
|---|---|---|---|
| 63251418 | Oct 2021 | US |
