Patent Application
20140251394
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 arms that extend from a central hub member.
2. Description of the Related Art
Large 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 more hubs connected with a plurality of movable structural members.
The interconnection between hubs and structural members, such as umbrella ribs, previously had been achieved in an inconvenient way that was not adapted for rapid or low-cost assembly. In general, such prior interconnections were achieved in manufacturing by assembling a hub with a large number of pins and fasteners and coupling the ribs one by one to the hub with these pins and fasteners prior to full assembly of the hub. This process was extremely labor-intensive, costly, and could not be achieved quickly to provide suitable assembly times. This process also involved a large number of subcomponents, which could be difficult to manage in a supply chain, as well as in the assembly process itself.
An aspect of at least one of the embodiments disclosed herein is the realization that the connection devices used in the assembly of shade structures, such as pavilions and umbrellas, can be improved to provide a more secure, quicker, and more reliable connection. Such devices can use fewer parts and be easier to manufacture than those devices of the prior art. Such improved connections can be particularly advantageous for large shade structures which can sometimes be unwieldy.
According to another aspect of at least one embodiment disclosed herein is the realization that prior art umbrella hubs 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 to expedite assembly have been suggested, 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 embodiment, an umbrella hub is provided that includes a hub body with an upper portion and a lower portion. The hub body extends between an outer periphery and a central aperture configured to receive an umbrella pole. The upper portion defines a lower region and a plurality of recesses disposed about an outer periphery of the upper portion. The lower portion defines an upper region and a plurality of slots. The slots are disposed generally about an outer periphery of the lower portion. The lower portion is connectable to the upper portion. The lower portion also comprises a support surface extending between the outer periphery and the slots. At least one of the upper and lower hub portions defines an interior recess. The hub also includes a first engagement section and a second engagement section disposed immediately adjacent to the first engagement section. The first and second engagement sections are formed by the slots and the recesses of the lower and upper hub portions. The first and second engagement sections each are configured to receive an end portion of an umbrella structural member. The hub also includes a locking component disposed at least partially within the interior recess of the at least one of the upper and lower hub portions when the upper hub portion is connected with the lower hub portion. The locking component comprises a ring member enclosed within the hub body and disposed about the central aperture, a first flange, and a second flange. The first flange extends outward from the ring member. The first flange has an aperture configured to receive a pin of an umbrella structural member. The aperture is disposed on a first side of one of the first engagement section. The second flange extends outward from the ring member. The second flange has an aperture configured to receive a pin of an umbrella structural member. The second flange is disposed on a second side of the first engagement section opposite the first flange. At least one of the first and second flanges is configured to be deflected when the umbrella structural member is being moved into the engagement section toward the central aperture of the hub and pins of the rib or strut contact the flanges.
Simultaneous deflection of two flanges of the locking component can be provided upon insertion of an umbrella structural member into the engagement sections. In this way, quick and efficient simultaneous locking of the pins (or other rotation members) in the locking component can be provided.
In another embodiment, an umbrella hub is provided that includes a hub body, a locking device, and a plurality of slots. The hub body extends between an outer periphery and a central aperture and is configured to receive an umbrella pole. The locking device is housed within the hub body and has lateral surfaces with apertures formed therethrough opening to an internal space in the hub body. The slots are disposed about the outer periphery of the hub body. The slots are defined in part by opposing lateral surfaces of the locking device. Radial outer portions of the locking device are deflectable upon assembly to permit rotation members of umbrella structural members with a lateral extent greater than the width of the engagement section to be inserted from the side of the hub.
In some embodiments, the hub also comprises a loading zone disposed adjacent to the outer periphery, the loading zone comprising a generally horizontal surface for resting a pivot pin of an umbrella structural member and a deflectable surface radially inward of the horizontal surface, the deflectable surface and the horizontal surface providing a pathway for engaging the umbrella structural member with the pivot zone. The pathway for engaging the umbrella structural member with the pivot zone can be provided in that the horizontal surface is at the same elevation as an aperture formed in a wall of the loading zone. In this way, direct radial and horizontal insertion of the umbrella structural member into the rib slots causes engagement of the umbrella structural member with the hub.
In another embodiment, an umbrella assembly is provided that includes a hub body and a plurality of umbrella structural members. The hub body has a plurality of projections and a plurality of rib slots disposed between projections about an outer portion of the hub. A loading zone extends generally horizontally from the outer portion of the hub into the rib slots. The hub body also includes a plurality of apertures disposed in, and in some embodiments entirely through, sidewall surfaces of the slots. One umbrella structural member is disposed in each of the slots. The umbrella structural members include transversely extending pins (or other rotation member). The ends of the pins project through the sidewall apertures into the projections. The pins are retained in and able to pivot in the apertures.
In some embodiments, forces or loads from the structural members (e.g., pins of the ribs or struts) to the hub are born directly by a wall of a locking component and by a portion of the hub, e.g., by a portion of one of the flanges of the locking component and by an upward projection of the lower hub portion. By providing the direct load to the lower hub portion, the total load on the locking component can be reduced. This can make the locking component more robust and long lasting and/or enable the use of more materials that have less maximum load carrying capacity before failure to form this component.
In some embodiments, a portion of the loading zone is advantageously formed by a removable component that is deflectable in an area between the outer periphery and the apertures. In some embodiments, another portion of the removable component forms opposed sidewalls of the rib slots.
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:
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 rib of the 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 QUICK CONNECTOR FOR SHADE STRUCTURE, and in Applicant's U.S. Pat. No. 7,891,367, issued Feb. 22, 2011, entitled QUICK CONNECTOR HUB FOR SHADE STRUCTURE the entirety of the contents of both of which are incorporated herein by reference.
In some embodiments, the hub can be uniquely configured in a manner that reduces the cost for manufacture and assembly. For example, the hub can be made of as few as two parts, such as two halves of the hub that interconnect and attach to each other by the use of fastening means, such as screws, bolts, adhesives, or interlocking or pressure-fit elements on either of the parts of the hub. Further, the hub can be configured to include additional parts other than two halves. Such additional parts may serve to increase the functionality or otherwise enhance the physical characteristics of the hub. For example, the hub can include locking devices that facilitate the secure interconnection of the hub with a given umbrella rib. Exemplary embodiments of the same are provided herein to illustrate some of these principles.
The hub assembly can comprise a hub and an end of an umbrella rib. The hub of the assembly can be configured in any of the ways or combinations of the ways described herein to ensure that the umbrella rib is quickly and securely attached thereto while permitting relative rotational movement of the rib. Accordingly, the rib can be configured to include a structure on an end thereof such that the end of the rib can be connected with the hub.
In various umbrella assemblies, the rib 104 is disposed immediately beneath a shade structure, which can include a fabric cover or canopy (not shown). The rib 104 can be configured as an elongate member 106 with an inner end 108 and an outer end (not shown). The canopy will be draped over an upper surface of the rib 104 and will be coupled with the rib at least at or adjacent to the outer end of the rib. The outer end is disposed away from the hub 100 and the umbrella pole with which the hub is coupled when the umbrella assembly is open. The rib 104 pivots such that the outer end moves down to be adjacent to the umbrella pole beneath the hub 100 when the umbrella assembly is closed. The inner end 108 of the rib 104 has a rotation member 110 that is configured to engage the hub 100 when the rib 104 and hub 100 are coupled together. The rotation member 110 enables the above-noted pivoting of the rib 104 between the open and closed configurations. The rotation member 110 can include a substantially rigid pin that has sufficient length to extend into a hollow recess in hub 100 as discussed below. The pin can be a locating pin as discussed below. The pin can be arranged to extend generally parallel to the upper surface of the rib 104, e.g., through apertures on lateral sides thereof. The pin preferably has a circular periphery when viewed from its end and/or in transverse cross-section.
The hub 100 can includes a hub body 116 that extends between an outer periphery 120 and a central aperture 124. The central aperture 124 is configured to receive an umbrella pole (not shown). The hub body 116 comprises an upper portion 136 and a lower portion 138. The upper and lower portions 136, 138 are fastened together and house therein a locking component 140. The locking component 140 is configured to engage features of the umbrella rib 104 in a manner to secure the rib in place within the hub 100. For example, locking component 140 can receive lateral ends of the rotation member 110 and can prevent the rotation member 110 and the rib 104 from inadvertently coming out of the hub 100.
In some embodiments, the locking component 140 is a continuous member that is configured to receive and retain the rotation members 110 of each of a plurality of ribs 104 of an umbrella. The locking component 140 can be a unitary member that acts as a hub for the interconnection of all of the ribs of an umbrella. The upper and lower portion 136, 138 can be considered housings for the locking component 140 which performs the function of capturing and retaining the rotation members 110 of the ribs 104. The locking component 440 of the embodiment of
The upper portion 136 has a lower region 142 that partly defines a plurality of recesses 144. The recesses 144 are disposed about an outer periphery 120A of the upper portion 136. The outer periphery 120A has a peripheral surface 152 that extends about the outer periphery 120A to partially enclose a space within the hub 100. The peripheral surface 152 is configured such that a lower edge 154 thereof abuts an upper edge of the lower portion 138 of the hub 100.
As discussed further below, the width W of the recess 144 can be smaller at locations inward of the outer periphery 120A that at or adjacent to the peripheral surface 152. In one embodiment, the width W varies, e.g., decreases between the peripheral surface 152 and the portion of the hub 100 configured to receive and retain an umbrella pole. In one embodiment, the walls defining the width W are portions of the locking component 140. The walls defining the recess can be substantially fixed or can be deflectable in various embodiments. If a fixed wall embodiment, the rotation member 110 is configured to deflect into the rib. In a deflectable wall embodiment, the walls defining the width W are deflected by the rotation member 110 as the inner end 108 of the rib 104 is slid into the hub 100.
In some embodiments, the area in which the inner end 108 of the rib is received is formed in part by the upper portion 136, in part by the locking component 140, and in part by the lower portion 138 of the hub 100 as discussed below. As discussed further below, lateral surfaces of the locking component 140 are disposed adjacent to the stepped features of the upper portion 136. The lateral surfaces can be angled to decrease the width W of the space inward of the recess 144, between the direction from the peripheral surface 152 and an inner zone of the hub 100.
The lower portion 138 defines an upper region 170 and a plurality of slots 174. The slots 174 are disposed generally about an outer periphery 120B of the lower portion 138. The lower portion 138 is configured to be connected to the upper portion 136 by way of a plurality of screw holes formed on one or both of the upper and lower portions 136, 138. A peripheral surface of the lower portion 138 can have upper edges 178 to abut the lower edges 154 of the upper portion 136. The mating edges 154, 178 and the configuration of the upper and lower portions 136, 138 as well as the configuration of the locking component 140 cause the locking component to be mostly shrouded within the hub 100 and generally hidden at the outer periphery 120. Lateral surfaces of the locking component 140 are exposed between the slots and recesses 174, 144 such that they may receive and retain the rotation members 110.
A support structure, which can be a surface 190 extends between the outer periphery 120B and the slots 174. The support surface 190 extends into a space beneath the recesses 144.
The support surface 190 can include a generally radially directed projection that extends inwardly from a base 194 at the outer periphery 120B to a peak 198 adjacent to the lateral edge 188 of the slots 174. The circumferential width of the support surface 190 at the base 194 can be substantially equal to the distance that the rotation member 110 extends laterally from the rib 104. The support surface 190 can be bounded by a lateral surface 202 that extends from the base 194 toward the slots 174.
The support surface 190 provides a guiding or loading zone for sliding the rotation member 110 into place. In particular, as shown in
A plurality of engagement sections 220 shown in
The locking component 140 is disposed at least partially within the interior recess of at least one of the upper and lower hub portions 136, 138 when the upper hub portion is connected with the lower hub portion. The locking component 140 includes a ring member 240 enclosed within the hub body 116. The ring member 240 can include sleeve with a circular inner periphery and a spoke like outer configuration. The locking component 140 is substantially taller along the pole axis P than the rotation member 110 in order to be able to receive the rotation member in a mid-section of the spoke-like outer portion. The circular inner periphery can form a portion of a continuous inner boundary of the hub 100, which boundary can be configured to receive the umbrella pole. In some embodiments, one or both of the upper and lower portions 136, 138 at least partially enclose the circular inner periphery of the locking component 140. In other embodiments, the inner circumference of the ring member 240 is substantially larger than the outer circumference of the pole member.
In one embodiment, a plurality of flanges is provided with each of the flanges extending outwardly from the ring member 240. The flanges can include a first flange 244, a second flange 248 and a third flange 252. The first flange 244 preferably extends outward from the ring member 240 and has an aperture 260 formed therein. The aperture 260 is or can form a portion of a retention structure. The aperture 260 is configured to receive the rotation member 110, e.g., a pin.
Among the many advantages of the embodiments herein are the rib retaining functions of the locking component 140. In this regard, the locking component 140 can act as rib retention component. The rib retention component or rib retainer is separable from the upper portion 136 and lower portion 138 of the hub 100. The aperture 160 is surrounded by a continuous surface of the locking component 140. The continuous surface prevents movement of the pin and rib 104 radially out of the hub. The continuous surface also prevents movement parallel to the direction P (see
The structure of the hub 100 and the locking components 140 are such that a robust and convenient quick connect hub construction is provided. As noted above, the locking component 140 is elongated along the axis P such that the rotation members 110 can be retained directly in the flanges 244, 248, 252. The material extending above and below the aperture 260 provide a bracing effect to the flanges 244, 248, 252. As a result, typical inward and outward forces during an expected duty cycle will not result in breakage of the flanges. More particularly the portions 268A, 268B (discussed below) can resist breakage due to outward force due to this bracing effect. The hubs disclosed herein are advantageous in providing unique combinations of quick assemble capability with a robust, strong design. These structures improve over designs where deflectable members may be used to block egress of a rib but that are not well braced or supported and may be subject to breakage due to concentration of stress in small lands of material.
The second flange 248 preferably extends outward from the ring member 240. The second flange 248 preferably has an aperture 260 configured to receive the rotation member 110. The second flange 248 is disposed on a second side of the first engagement section 220A opposite the first flange 244. When one of the ribs 104 is fully inserted into the slot 174, the rotation member 110 extends laterally on both sides of the rib and into apertures 260 in the first and second flanges 244, 248.
The third flange 252 preferably extending outward from the ring member 240. The third flange 252 preferably has an aperture 260 configured to receive the rotation member 110. The third flange 252 is preferably disposed on a side of the second engagement section 220B adjacent to the first flange 244. The group of three flanges 244, 248, 252 repeat around the perimeter of the ring member 240.
The first and third flanges 244, 252 preferably have first elongate generally radially extending portions 264A, 264B that extend outward of the ring member 240. The first portions 264A, 264B extend along directions such that outer portions thereof are farther apart from each other circumferentially than inner portions thereof. In some embodiments, an angle a is formed between the first portions 264A, 264B. The first and third flanges 244, 252 preferably also have second portions 268A, 268B that extend generally radially. The second portions 268A, 268B can be formed such that they extend along directions non-parallel directions. The outer portions of the second portions 268A, 268B preferably are closer to each other circumferentially than inner portions of the second portions 268A, 268B. This configuration provides a V shape that is inwardly sloped at the open end of the V. The inwardly sloped aspects of the V preferably extend along the lateral surface 202 of the support surface 190.
The first and second flanges 244, 248 provide a convenient engagement and retention structure in combination with the support surface 190 and the second portion 268A of the first flange 244 and a corresponding second portion 272 of the second flange 248. In a preassembled state, the rib 104 is placed adjacent to the support surface 190. The rotation member 110 is disposed on the support surface 190. Further inward radial motion of the rotation member 110 causes the rotation member 110 to be brought into contact with the second portions 268A, 272. The second portion 268A, 272 are ramped surfaces from the perspective of the rib 104 that create progressively more force between the second portion 268A, 272 and the rotation member 110 and/or deflection of the second portion 268A, 272 by further advancement. In one embodiment, the flanges 244, 248 are rigid and are not deflectable such that as the rib 104 and the rotation member 110 move inwardly in the engagement sections 220 the rotation members 110 move into the body of the rib 104. Once the rib passes the boundary between the second and first portions 268A, 272 the rotation member 110 un-retracts or extends outward into the apertures 260.
In one embodiment, the rotation members 110 are fixed in the lateral direction. At least one of the flanges 244, 248, 252 are deflectable within the hub. In a preassembled state, the rib 104 is placed adjacent to the support surface 190. The rotation member 110 is disposed on or over the support surface 190. Further radially inward motion of the rotation member 110 causes the rotation member to be brought into contact with the second portions 268A, 272, which are ramped from the perspective of the rotation members 110. The force applied by the rotation members 110 causes deflection of the flange(s) 248, 252 or the flanges 244, 248. As the rib 104 is advanced between the flanges 248, 252 the rotation member 110 deflects the second portions 268A, 272 away from the slot 174 in which the rib is positioned. Once the rib 104 passes the boundary between the second and first portions 268A, 264A the rotation member 110 enters the apertures 260 which permits the deflected flange 244, 248 to return to the un-deflected state (as shown in
A second raised section 288 is provided on the base surface 280. The section 288 can be disposed substantially entirely on one, a plurality or all of the projections of the lower portion 138 that separates adjacent slots 174 from each other. The raised section 288 preferably provides a support disposed between the ring member 240 and the outer periphery 120B of the lower portion 138. The raised section 288 also preferably provides a support disposed between adjacent engagements sections 220.
The raised section 288 can have structures to provide supportive functions of retaining the rib 104 in the hub 100. In some embodiments, the raised section 288 has one or more, e.g., two, projections 292 to resist the pulling out of the ribs 104. The first and second projections 292 extend toward the first and third flanges 244, 252.
In various embodiments the portions 268A, 268B, 272 of the flanges 244, 248 deflect as the rib 104 is being inserted into the engagement sections 220.
The raised portion 288 preferably also has one or more lateral surfaces to limit deflection of the first portions 264A, 264B of the flanges 244, 248. For example the raised portion 288 can be a support comprising a first lateral surface 298 disposed behind the first flange 244 to minimize movement of the first flange toward the third flange 252 and away from the first engagement section 220A. The raised portion 288 preferably also comprises a second lateral surface 302 disposed behind the third flange 252 to minimize movement of the third flange toward the first flange and away from the second engagement section 220B.
In one variant the locking component 440 includes flanges 444, 448, 452. Flanges 444, 448 are disposed to be on opposed sides of an engagement section 420 of the hub 400. Second portions 468, 472 of opposing flanges are displaceable by a pin or other rotation member 110 to enable a structural member such as the rib 104 to enter the engagement section 420. When the rib 104 is disposed in the engagement section 420, the rotation member 110 is disposed through an aperture A in a wall of the flanges 444, 448. The locking component 440 defines a space 450 between opposing flanges of adjacent engagement sections 420. The space 450 receives an end of the rotation member 110. In one embodiment, an abutment 480 is integrated into the locking component 440. A gap G is defined between the abutment 480 and the flange 444. The gap G is just larger than the length of the rotation member 110 to minimize play in the position of the rib 104 relative to the hub 440, as discussed above.
A plurality of abutments 480 can be disposed in the space 450, e.g., symmetrically about a radius of the locking component 440 extending midway between the flanges 444, 452. In one embodiment, a brace 482 is provided in the space 480 between the flanges 444, 452. The brace 482 can be any structure that extends between, e.g., continuously between, the flanges 444, 452. The brace 482 can be configured as an annulus with an inner diameter that is sized to receive a screw or similar fastener that is advance through the upper and lower portions 436, 438.
The brace 482 and the raised portion 288 can serve similar functions. In one embodiment, the abutment 480 projects radially outward from an outer portion of the brace 482 to radial location of the apertures A in the flanges 444, 452. The structure of the brace 482 substantially prevents the inner portions of the flanges 444, 452 from flexing while permitting sufficient flexing of the outer portion of the flanges 444, 452 so that the rotation members 110 of the rib 104 can deflect the outer portions, as discussed above.
The off-set configuration of the outer portion 444B enables the support structure to be received in the recess 488 so that the outer wall of the assembled lower portion 438 and locking component 440 provides a flush lateral wall of an engagement section 420, as shown in
The hub 400 also differs from the hub 100 in that at least a majority the locking component 440 is housed in the lower portion 438. As such, the stepped profile of the upper portion discussed above in connection with
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.
