Patent Application
20150237977
1. Field of the Invention
This application relates to apparatuses and methods that facilitate efficient assembly of ribs and hubs of umbrellas and other structures with a plurality of elongate structural members that extend from a central hub member.
2. Description of the Related Art
Larger umbrellas, such as market umbrellas, generally include a frame-like structure that is used to support and distribute the weight of an upper portion of the umbrella as well as to enable the umbrella to be opened and closed as desired by the user. The frame-like structure of such umbrellas can take various forms, but often includes one or more hubs connected with a plurality of movable structural members.
Prior art methods of assembly of umbrella hubs and ribs are labor intensive. The process involves inserting a pin through an end portion of each rib of a set of ribs, positioning all of the rib ends in a lower portion of a hub, and then placing an upper portion of the hub over the rib ends so positioned. Finally, screws are advanced through upper and lower hub portions to attach the upper portion to the lower portion of the hub. While achieving the result of assembling the hub and ribs, this process is tedious and sometimes requires rework, for example if the ends of any of the ribs become misaligned before the upper hub portion is attached to the lower hub portion.
It would be beneficial to provide structures that enable quicker and less labor intensive assembly of umbrella assemblies, e.g., rib and hub assemblies. An aspect of at least one of the embodiments disclosed herein is the realization that connection devices used in the assembly of shade structures, such as pavilions and outdoor umbrellas, can be improved to provide a more secure, quicker, and more reliable connection. Such devices can be advantageously configured with fewer parts, making them easier to manufacture than devices in the prior art. Such improved connection devices can be particularly advantageous for large shade structures.
Another aspect of at least one embodiment disclosed herein is the realization that prior art umbrella hubs or hub assemblies include an excessive amount of individual components. For example, individual pins are often individually placed into a portion of the hub before portions of the hub are carefully assembled. This tedious manufacturing can be costly and frustrating. Therefore, embodiments disclosed herein seek to remedy this deficiency by providing a hub assembly that uses a reduced number of parts. Accordingly, the time and cost required for manufacturing the hub can be greatly decreased.
Another aspect of at least one of the embodiments disclosed herein is the realization that while some devices have been suggested to expedite assembly, such devices have been inadequate, for example lacking the ability to bear a full range of operational loads, which can be much higher than the weight of the components of the shade structure, particularly in windy conditions. As such, the members of a frame of a shade structure should be quickly, securely, and firmly interconnected so that the frame can properly support not only the weight of the various structural members and the canopy, but also the stresses and other forces that are common or possible during the use of such structures.
In one aspect, an umbrella assembly is provided that comprises an umbrella hub comprising an upper portion, a lower portion and a passage configured to be disposed about an umbrella pole. The upper portion includes a top surface that extends between the passage and an outer periphery of the hub. The lower portion includes a bottom surface that extends between the passage and the outer periphery of the hub. The umbrella hub also includes a first engagement position and a second engagement position. The first engagement position is configured to permit insertion of end portions of umbrella structural members into the hub. The first engagement position is provided by first relative movement of the upper and lower portions of the hub along an axis extending through the passage. The second engagement position is configured to retain end portions of umbrella structural members within the hub. The second engagement position is provided by second relative movement of the upper and lower portions of the hub along an axis extending through the passage.
In another aspect, an umbrella hub is provided that includes an upper portion, a lower portion, and a snap-together coupling. The upper portion includes a top surface that extends toward an outer periphery of the hub. The lower portion includes a bottom surface that extends toward the outer periphery of the hub. The snap-together coupling comprises a cantilever member that extends from one of the upper and lower portions across an interface between the upper and lower portions. The snap-together coupling comprising a plurality of recesses disposed on the other of the upper and lower portions. The cantilever member has a lateral portion adjacent to a free end thereof. The recesses are configured to receive the lateral portion of the cantilever member to define at least one of a partial assembly configuration and a full assembly configuration.
In another aspect, an umbrella hub assembly is provided that has a plurality of elongate ribs and a hub assembly. Each of the ribs has an inner end, an outer end, and a body extending therebetween along a longitudinal axis. The inner end has a transverse pivot member extending away from the longitudinal axis. The hub assembly includes an upper portion, a lower portion, and a rib end coupler. The upper portion has a lower surface partially defining a hub interface. The lower portion has an upper surface partially defining the hub interface. The rib end coupler, which is disposed at the hub interface, comprises a deflectable member and a retainer. The deflectable member is configured to be deflected to receive the transverse pivot member of one of the ribs in a first configuration of the rib end coupler. The retainer is configured to receive the deflectable member in a second configuration of the rib end coupler. In the first configuration of the rib end coupler, the upper and lower portions are coupled together and the retainer is disposed away from the deflectable member such that the deflectable member can be deflected in a first direction to permit the transverse pivot member to move into a coupled position. In the second configuration, the upper and lower portions are coupled together and the retainer is disposed immediately adjacent to the deflectable member such that the retainer prevents the deflectable member from being deflected in the first direction by an amount sufficient to permit the transverse pivot member to move out of the coupled position.
In another embodiment, a method of assembling umbrella components is provided. In the method, a first portion of an umbrella hub is advanced toward a second portion of the umbrella hub to a first position in which the first and second portions of the umbrella hub are engaged for assembly. An end of a rib is inserted laterally into an engagement portion of the hub to dispose a pivot member of the end of the rib adjacent a rib end coupler. The rib end coupler is actuated to permit the pivot member to be advanced into the rib end coupler. The first portion of the umbrella hub is locked to the second portion of the umbrella hub to retain the pivot member in the rib end coupler.
Various embodiments can broadly encompass an umbrella hub with a plurality of assembly position, which can retain multiple portions of the umbrella hub engaged together for assembly purposes. For example, the portions can be held close together but with a gap permitting pivot member of ribs to be advanced through a gap between the portions. This facilitates assembly because the ends of the ribs will be at least partially retained. Also, the portions of the hub can retain their relative position without the assembler having to hold them together in an assembly position. Thereafter, the hub can be fully coupled in another position, which may be referred to as a fully assembled or a locked position. In this position, the rib ends (and pivots disposed therein) can be held securely enough to withstand normal operational loads and a full duty cycle.
In other broad aspects, hub assembly includes novel locking components that facilitate snap-together assembly of the hub. The locking components can include mating protrusions and recesses. The locking components can include one or more tapered posts that can project across an interface zone between multiple, e.g., two hub components. One or more tapered recesses can be provided to receive the tapered posts. Deflection of one or both of the posts and recesses can enable positioning of the tapered post in the recesses to provide locking of the hub portions. In one arrangement, deflection of the recess can be enabled by one or more slits or other structure enhancing the deformation in or deformability of a wall adjacent to the recess. In certain cases, the tapered posts and recesses provide a robust connection between hub components in at least one of a partially and fully assembled configuration.
Certain embodiments have one or more cantilevered hooks that project across an interface zone between multiple, e.g., two hub components. The cantilever hook(s) and mating recess(es) provide one or more secure couplings between the hub portions. In some cases, each hook includes a plurality of recesses where each recesses defines a discrete configuration for assembly and/or operation.
In certain embodiments, the locking components can be of different types, e.g., can include at least one deflectable hook and recess coupling and at least one tapered post and narrow passage coupling.
Various innovative methods of manufacture also arise from the disclosure herein. In particular, a hub can be partially assembled with a snap-together process. Thereafter, rib ends can be inserted into a retained configuration within the hub. This permits each of a plurality, e.g., two, three, four, five, six, seven, or eight or more ribs to be sequentially assembled. When all ribs are in place and confirmed to be properly assembled the hub can be fully assembled, e.g., locked together, such that the rib ends are retained during final assembly and operation of the umbrella. Past methods involved placing all ribs on a portion of a hub before coupling a second portion over the rib ends. While this worked, it could be inefficient and required great care because the partial assembly could be disrupted requiring extensive re-work.
Any feature, structure, or step disclosed herein can be replaced with or combined with any other feature, structure, or step disclosed herein, or omitted. Further, for purposes of summarizing the disclosure, certain aspects, advantages, and features of the inventions have been described herein. It is to be understood that not necessarily any or all such advantages are achieved in accordance with any particular embodiment of the inventions disclosed herein. No aspects of this disclosure are essential or indispensable.
The abovementioned and other features of the inventions disclosed herein are described below with reference to the drawings of the preferred embodiments. The illustrated embodiments are intended to illustrate, but not to limit the inventions. The drawings contain the following figures.
While the present description sets forth specific details of various embodiments, it will be appreciated that the description is illustrative only and should not be construed in any way as limiting. Furthermore, various applications of such embodiments and modifications thereto, which may occur to those who are skilled in the art, are also encompassed by the general concepts described herein. Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually inconsistent.
In accordance with embodiments described herein, there are provided various configurations of a hub and hub assembly that can be used with an umbrella support structure, such as an umbrella or pavilion, to facilitate the rapid and secure fastening of structural ribs with a hub or other structure. As described in greater detail herein, the hub and hub assembly can incorporate various features such that a secure connection with a structure, such as a mounting member of a hub of an umbrella, can be obtained. Additional details and features of related umbrella rib connectors and assemblies are illustrated and described in Applicant's U.S. Pat. No. 7,703,464, issued Apr. 27, 2010, entitled and in Applicant's U.S. Pat. No. 7,891,367, issued Feb. 22, 2011, entitled the entirety of the contents of both of which are incorporated herein by reference.
The upper portion 142 has a lower surface partially defining a hub interface 182. The lower portion 146 has an upper surface 186 partially defining the hub interface 182. The rib end coupler 150 is disposed at the hub interface 18 and comprises a deflectable member 190 and a retainer 194. The deflectable member 190 is configured to be deflected to receive the transverse pivot member 108C of one of the ribs 108 in a first configuration of the rib end coupler 150.
Preferably the retainer 194 and the mating surface 212 generally match. For example the mating surface 212 can have a generally convex structure and the retainer 194 can include a generally concave surface. This arrangement permits the retainer 194 to securely receive the mating surface 212 in a fully assembled or locked configuration, which is shown in
Stated another way, the retainer 194 is configured to receive the deflectable member 190 in a second configuration of the rib end coupler 150. In the first configuration of the umbrella assembly 116 and of the rib end coupler 150 illustrated by
The foregoing discussion has been with regard to a single rib end coupler 150. In certain embodiments each rib 108 is retained by a pair of rib end couplers 150. A rib end coupler 150 can be disposed on each side of a corresponding engagement section 154. See, e.g., the location of a pair of deflectable members 190 adjacent to the lower portion 154A of an engagement section as illustrated in
After all of the transverse pivot member 108C are received within the deflectable members 190 the upper portion 142 and the lower portion 146 can be urged one or both toward the other to the position of
The foregoing description provides the recesses 224A, 224B on the lower portion 146 and the protrusions 228 on the upper portion 142. The opposite arrangement is also possible, wherein the recesses 224A, 224B are disposed on the upper portion 142 and the protrusions 228 on the lower portion.
The protrusions 228 and recesses 224A, 224B provide a first set of securement devices as discussed above.
The wide portion 264B can have any suitable configuration. For example, the wide portion 264B can have a generally constant width between the tapered portion 264A and the top surface of the upper portion 142. The wide portion 264B of the recess 264 can be substantially cylindrical above the tapered portion 264A.
In one method of assembly, a surface of the tapered member or portion 272 is positioned between the cylindrical portion of the recess 264 and the lower surface of the upper portion 142 of the hub assembly 116. For example the tapered portion 272 can be placed in contact with the tapered portion 264A of the recess 264. When in this position, the transverse pivot member 108C of one or a plurality of ribs can be assembled into the partially assembled hub assembly 116. This position or configuration can also include the protrusion 228 engaging the upper recess or locking recess 224A in the first engagement position discussed above. In one method, a surface of the conical or tapered member or portion 272 is positioned within the cylindrical portion of the passage or recess 264 when the retainer 194 is brought into close proximity with the deflectable member 190. This position or configuration can also include the protrusion 228 engaging the lower recess 224B in the second engagement position discussed above.
The hub assembly 116 preferably is configured such that the protrusion 228 can be advanced from the tapered portion 264A to the wide portion 264B without requiring a large amount of force. One approach to facilitating assembly in this way is to configure the portion in which the recess 264 is formed (e.g., in the upper portion 142) to change shape as the tapered portion 272 is advanced in the recess 264. For example, in one embodiment the walls 290 surrounding the passage or recess 264 are deflectable upon movement of the hub assembly 116 from a first engagement position (e.g., partially assembled as in
Among the many advantages of the structures herein is providing a snap-together coupling in connection with the hub assembly 116. The projection 228 is an example of a cantilever member that can extend from one of the upper and lower portions 142, 146 across the interface 182 between the upper and lower portions. The recesses 224A, 224B form a series of recesses disposed on the other of the upper and lower portion 142, 146. The cantilever member has a lateral projection, e.g., in the form of the lateral projection 236 adjacent to a free end thereof. The recesses 224A, 224B are configured to receive the lateral projection of the cantilever member to define a partial or full assembly configuration. These arrangements are capable of being provided by hand force and eliminate the previous use of tools and reduce or minimize the need for rework because even in the partially assembled configuration the pivot members 108C will not pull out of the position between the pivot facing surface 216 and the interface 182.
Further securement of the upper and lower portions 142, 146 can be provided by a plurality of snap together feature 320, 324. The features can include hooks disposed on the upper portion 142 with radial protrusion configured to engage recess disposed on the lower portion 146. The features 320, 324 are preferably configured to be disengaged in the first (partially assembled) configuration discussed above and to be securely engaged in the second (fully assembled) configuration discussed above.
In one embodiment, a substantially continuous inner periphery is provided within a central aperture 332 of the hub assembly 116. The central aperture 332 is that configured to receive the umbrella pole 104 in use. The continuous inner periphery is provided by the projections 228 being received between curved plate-like members 336 disposed opposite the projections 228. For example, if the projections 228 are on the upper portion 142 the members 336 are disposed on the lower portion 146. If the projections 228 are on the lower portion 142 the members 336 are disposed on the upper portion 146. The members 336 are shown on the lower portion 146 in
Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combination or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.
