Spring-biased end caps for rod assembly and methods of use

Abstract

A spring-biased end cap for mounting a rod assembly is provided including an outer body, an inner body, and a spring engaging both the outer body and the inner body to change a position of the inner body relative to the outer body upon compression or expansion of the spring. A rod is received within the outer body and fixed to the inner body. In embodiments, the spring has a first end portion connected to the outer body, a second end portion capable of being connected to the inner body to connect the outer body to the inner body, and an intermediate portion extending within a cavity of the outer body. A rod assembly including the spring-biased end cap and a method of mounting a rod assembly using the spring-biased end cap are also provided.

Description

FIELD

This disclosure relates to support rods, and, more particularly, end caps for support rods.

BACKGROUND

Support rods are used horizontally to support shower curtains or drapery. They also are used vertically to hold baskets and other items. One common vertical use is a shower caddy. Typical support rods are adjustable and include an outer rod and an inner rod that slides telescopically in and out of the outer rod to adjust the overall length of the rods. A lock mechanism secures the outer and inner rods together when adjusted to the desired length.

Adjustable end caps can also be used with support rods to help secure the rods between their opposing support surfaces, such as walls. There is a need to improve adjustable end cap systems to simplify construction and use of the end caps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a rod assembly according to a first embodiment.

FIG. 2 is an exploded view of the rod assembly of FIG. 1.

FIG. 3 is a cross-sectional view of a portion of the rod assembly of FIG. 1 taken along line 3-3 of FIG. 1.

FIG. 4 is an inboard end perspective view of a spring-biased end cap of the rod assembly of FIG. 1.

FIG. 5 is an outboard end perspective view of the spring-biased end cap of FIG. 4.

FIG. 6 is a cross-sectional view of the spring-biased end cap of FIG. 4 taken along line 6-6 of FIG. 4.

FIG. 7 is an outboard end perspective view of an outer body of the spring-biased end cap of FIG. 4.

FIG. 8 is a cross-sectional view of the outer body of FIG. 7 taken along line 8-8 of FIG. 7.

FIG. 9 is the cross-sectional view of FIG. 8 illustrated with a mounting pad attached to the outer body.

FIG. 10 is an outboard end perspective view of an inner body of the spring-biased end cap of FIG. 4.

FIG. 11 is an inboard end perspective view of the inner body of FIG. 10.

FIG. 12 is a cross-sectional view of the inner body of FIG. 10 taken along line 12-12 of FIG. 10.

FIG. 13 is an outboard end perspective view of an end cap of the rod assembly of FIG. 1 that is not spring-biased.

FIG. 14 is a cross-sectional view of the end cap of FIG. 13 taken along line 14-14 of FIG. 13.

FIG. 15 is an outboard end perspective view of a spring-biased end cap according to a second embodiment.

FIG. 16 is an inboard end perspective view of the spring-biased end cap of FIG. 15.

FIG. 17 is a cross-sectional view of the spring-biased end cap of FIG. 15 taken along line 17-17 of FIG. 15.

FIG. 18 is a cross-sectional view of the spring-biased end cap of FIG. 15 taken along line 18-18 of FIG. 16.

FIG. 19 is a cross-sectional view of the spring-biased end cap of FIG. 15 taken along line 19-19 of FIG. 16, shown with the mounting pad and spring removed.

FIG. 20 is the cross-sectional view of FIG. 18, of the spring-biased end cap of FIG. 15, shown with the spring and the mounting pad removed.

FIG. 21 is the cross-sectional view of FIG. 17, of the spring-biased end cap of FIG. 15, shown with the spring-biased end cap coupled to a rod.

FIG. 22 is an outboard end perspective view of an outer body of the spring-biased end cap of FIG. 15.

FIG. 23 is an inboard end perspective view of the outer body of FIG. 22.

FIG. 24 is a cross-sectional view of the outer body of FIG. 22, taken along line 24-24 of FIG. 23.

FIG. 25 is an outboard end perspective view of an inner body of the spring-biased end cap of FIG. 15.

FIG. 26 is an inboard end perspective view of the inner body of FIG. 25.

FIG. 27 is a cross-sectional view of the inner body of FIG. 25 taken along line 27-27 of FIG. 25.

FIG. 28 is front perspective view of a rod assembly according to a third embodiment.

FIG. 29 is an inboard end perspective view of an end cap of the rod assembly of FIG. 28 that is not spring-biased.

FIG. 30 is an outboard end perspective view of the end cap of FIG. 29.

FIG. 31 is a cross-sectional view of the end cap of FIG. 29 taken along line 31-31 of FIG. 29.

DETAILED DESCRIPTION

With reference to FIG. 1, there is illustrated a rod assembly 10 with a hollow, inner rod 12 and a hollow, outer rod 14. The inner rod 12 is telescopically received in the outer rod 14 to adjust the overall length of the rod assembly 10. A lock mechanism (not shown) may be included to secure the inner rod 12 and the outer rod 14 together when adjusted to the desired length. The lock mechanism may include the lock mechanisms described in U.S. Pat. Nos. 10,959,559, 11,382,447, and U.S. Publication No. 2023/0277012, all of which are incorporated by reference herein in their entireties.

An end of the outer rod 14 is fitted with a first spring-biased end cap 30. An end of the inner rod 12 is fitted with a second end cap 20 that may or may not be spring-biased. The end caps 30, 20 engage opposing support surfaces.

In use, the spring-biased end cap 30 adjusts to provide sufficient tension between the rod assembly 10 and the opposing support surfaces so that the rod assembly 10 is securely held between the opposing support surfaces.

With reference to FIGS. 2-6, the spring-biased end cap 30 includes an outer body 32, an inner body or insert 34, and a spring 36. The inner body 34 is at least partially received within a cavity 46 of the outer body 32 and is movably coupled to the outer body 32 via the spring 36. Specifically, the spring 36 may be a helical compression spring and has a first end 37 couplable or coupled to the outer body 32 and a second end 38 couplable or coupled to the inner body 34 to thereby secure the outer body 32 to the inner body 34. An intermediate portion 39 of the spring 36 extends through the cavity 46 of the outer body 32 and permits displacement or a change of position of the inner body 34 and the outer body 32 relative to one another when the spring 36 compresses or expands.

With reference to FIGS. 3 and 6-8, the outer body 32 has an inboard end 42 for receiving the inner body 34 and the outer rod 14 (or the inner rod 12 in some configurations) and an outboard end 44 for engaging the support surface. The outer body 32 has a frustoconical outer profile, with the outer diameter of an outer wall 40 of the outer body 32 increasing from the inboard end 42 to the outboard end 44. In other configurations, the outer body 32 may be generally cylindrical or have other geometries (e.g., bell-shaped).

The inboard end 42 defines an opening and the hollow interior or cavity 46 which receives the inner body 34, the outer rod 14, and the spring 36. The cavity 46 may have a shape (e.g., frustoconical) generally corresponding to the outer profile of the outer body 32 at the inboard end 42. For example, an inner diameter of the cavity 46 may gradually increase from the inboard end 42 towards the outboard end 44. In other configurations, the cavity 46 may be substantially cylindrical with a uniform inner diameter. The cavity 46, as described further below, is dimensioned to receive and permit movement or displacement of the inner body 34, spring 36, and outer rod 14 relative to the outer body 32 so that the rod assembly 10 can adjust to an appropriate length to hold the rod assembly 10 in tension between opposing support surfaces.

The outer body 32 includes a lateral annular wall 50 extending radially inward from the outer wall 40. The lateral annular wall 50 provides a partial floor or inner boundary to the cavity 46 and defines a passage 52 therethrough. The passage 52 is open to the cavity 46 and is sized to securely receive a first end portion 37 of the spring 36. The passage 52 includes one or more internal grooves 54 sized and configured to engage and retain one or more coils of the spring 36. For instance, in one form the one or more grooves 54 define internal helical threading of the passage 52 to engage and retain the coils of the spring 36. The threading may be partial, discontinuous threading or may be continuous threading.

The grooves or threading 54 of the passage 52 may, for example, engage at least one coil of the spring 36, at least two coils of the spring 36, or three or more coils of the spring 36. The coils of the spring 36 may be retained by the grooves or threading 54 such that the retained coils, in use, are held from at least substantial translation within or out of the passage 52. In some embodiments, the grooves or threading 54 retain the coils so that compression or expansion of the retained coils is reduced or inhibited. In some embodiments, the coils are retained by the grooves or threading 54 to permit some compression or expansion, though at an amount that is less than the compression or expansion of the unretained coils of the intermediate portion 39 of the spring 36.

Retaining the first end portion 37 of the spring 36 in this manner supports, stabilizes, and positions the spring 36, and allows the spring 36 to thereby support, stabilize, and position the inner body 34 and the outer rod 14. Specifically, the passage 52 maintains the spring 36 along a central longitudinal axis Y of the outer body 32 and in a position substantially perpendicular to the inboard end 42 and the outboard end 44 and the mounting surfaces. In addition, this configuration keeps the spring 36 and the inner body 34 from becoming dislodged from the outer body 32 or falling out in both use, storage, and/or transportation of the rod assembly 10.

The passage 52 may be open to the outboard end 44 of the outer body 32. As illustrated, for instance, the passage 52 may extend continuously from a cavity 48 at the outboard end 44 to the cavity 46 at the inboard end 42. In this configuration, the cavity 48, passage 52, and cavity 46 may constitute a through-opening extending the entire length of the outer body 32. The cavity 48, in certain embodiments, allows the spring 36 to be adjusted further in the outboard direction if needed. For instance, springs of varying length and/or varying spring constants can be interchanged and used with the rod assembly 36 and adjusted so that the intermediate portion 39 of the spring 36 extending freely within the cavity 46 between the passage 52 and the inner body 34 extend an appropriate distance to provide suitable spring force and tension during mounting.

In one example, a spring having a length as illustrated in FIG. 6 extends through the entire passage 52, though not into the cavity 48, and a distance d the intermediate portion 39 extends is d₁, wherein d₁ results in a desirable amount of spring force or tension when the spring is compressed during mounting. In another example, a longer spring may be used, and terminal coils of the spring 36 can be threaded past the passage 52 into the cavity 48 to maintain the same distance d₁ the intermediate portion 39 extends. Using a longer spring that may extend in part into the cavity 48 permits the distance d to be adjusted to increase or fine-tune the amount of spring force when the spring is threaded to a corresponding position.

The outboard end 44 is open and defines the cavity 48. The lateral annular wall 50 may define a partial annular floor or inner boundary to the cavity 48. The outer wall 40 of the outer body 32 forms an annular face 45 at the outboard end 44 that may engage a perimeter portion of a mounting pad 57 (FIG. 9). The outboard end 44 also defines an annular recess 56 outboard of and about the cavity 48 shaped to receive the perimeter portion of the mounting pad 57 (FIG. 9). The mounting pad 57, for example, may have a disc configuration and may protrude past the annular face 45 in some embodiments. The mounting pad may be coupled to the recess 56 and/or annular face 45, for example by gluing or welding. The mounting pad may be a softer material that engages the mounting surface with enhanced friction to prevent slipping therebetween.

With reference to FIGS. 3, 6 and 10-12, the inner body 34 has a first end portion 62 and a second end portion 64. The first end portion 62 defines a passage 66 for receiving the second end portion 38 of the spring 36. The inner body 34 is defined in part by an outer wall 60 that may have an annular configuration. The outer wall 60 is generally cylindrical at the first end portion 62. The second end portion 64 may be generally frusto-conical. For example, at the second end portion 64, the outer wall 60 may angle or taper radially inwardly relative to the outer wall 60 at the first end portion 62 such that the second end portion 64 has a smaller outer diameter than the first end portion 62. An angled surface 79 thus defined at the second end portion 64 facilitates insertion of the inner body 34 into the outer rod 14. In some embodiments, the second end portion 64 of the inner body 34 may protrude from the outer body 32 when the spring 36 is in its neutral (non-compressed) position (see FIGS. 4 and 6), with the transition to the angled surface 79 generally aligned with the edge of the inboard end 42 of the outer body 32.

The second end portion 64 may be open at its end with a hollow interior or passage 77. In some embodiments, the hollow interior 77 of the second end portion 64 and the passage 66 at the first end portion 62 are continuous with one another and define a continuous central through-opening along the entire length of the inner body 34.

The first end portion 62 has an outer diameter that is slightly smaller than the inner diameter of the outer rod 14 so that the outer rod 14 is coaxially received over the inner body 34 with a friction fit. The first end portion 62 may also include an annular flange 78 extending radially from the outer wall 60. The inner body 38 may be inserted into the outer rod 14 until the annular flange 78 abuts an end of the outer rod 14. Thus, the annular flange 78 prevents further insertion of the inner body 34 into the outer rod 14.

In some configurations, the spring-biased end cap 30 may be alternatively configured to receive the inner rod 12 instead of the outer rod 14. In this case, the inner body 34 may be sized to permit a friction fit with the inner rod 12.

The passage 66 for receiving the second end portion 38 of the spring 36 may include a first portion 68 with threading or grooves 76. In some embodiments, there may be a second portion 70 without threading or grooves inboard of the first portion 68. In some embodiments, both portions may have threading or grooves or there may be a single threaded or grooved portion that receives the second end portion 38 of the spring 36 without an additional portion.

The first portion 68 is sized to receive and retain the second end portion 38 of the spring 36. Specifically, the first portion 68 includes one or more grooves or internal helical threading 76 configured to engage and retain one or more coils of the spring 36. The threading may be partial, discontinuous threading or may be continuous threading.

The grooves or threading 76 of the first portion 68 may, for example, engage at least one coil of the spring 36, at least two coils of the spring 36, or three or more coils of the spring 36, and may have a function like the grooves or threading 54 of the passage 52 of the outer body 32. The coils of the spring 36 may be retained by the grooves or threading 76 such that the retained coils, in use, are held from at least substantial translation within or out of the passage 52. In some embodiments, the grooves or threading 76 retains the coils so that compression or expansion of the coils is reduced or inhibited. In some embodiments, the coils are retained by the grooves or threading 76 to permit some compression or expansion, though at an amount that is less than the compression or expansion of the unretained coils of the intermediate portion 39 of the spring 36.

The second portion 70 of the passage 66 may define a substantially cylindrical space sized to receive and retain one or more terminal coils of the spring 36. In some configurations, the second portion 70 is sized to retain at least one, at least two, or at least three coils of the spring 36. The second portion 70 may be sized to retain the coils of the spring 36 therein in a compressed configuration. The inner diameter of the second portion 70 may be slightly larger than the outer diameter of the spring 36 to closely engage and retain the spring 36. In addition, the second portion 70 may be bound in part by an annular step 72 extending radially inwardly from the outer wall 60 between the first end portion 62 and the second end portion 64 of the inner body 34. The spring 36 may abut the annular step 72. In some configurations, the annular step 72 is replaced by a lateral wall that entirely closes off the second portion 70 from the second end portion 64. In certain embodiments, the second portion 70 may have a function like cavity 48 of allowing space for the spring to occupy if the distance d₁ the intermediate portion 39 of the spring 36 extends needs to be adjusted.

Like the passage 52 of the outer body 32, the passage 66 of the inner body 34 supports and retains the spring 36 so that it is not dislodged during use, storage, and/or transportation. Further, in some embodiments, a substantial portion of the coils of the spring 36 are retained or secured within the passage 52 of the outer body 32 and the passage 66 of the inner body. In embodiments, at least 20% of the spring may be retained or secured within the passage 52 of the outer body 32 and the passage 66 of the inner body 34. In other embodiments, at least 30% of the spring may be retained or secured in this manner, at least 40%, or at least 50%. This helps to maintain the spring 36, inner body 34, and outer rod 14 in a connected, aligned, coaxial position along central longitudinal axis Y, and substantially perpendicular to the lateral wall 50 and the mounting surfaces, all while enabling movement between the outer body 32 and the inner body 34.

As illustrated in FIGS. 3 and 6, while a first end portion 37 of the spring 36 is retained in the passage 52 and a second end portion 38 is retained in the passage 66, the intermediate portion 39 of the spring 36 extends freely within the cavity 46 of the outer body 32 between the passage 52 and the passage 66. Specifically, the intermediate portion 39 extending freely within the cavity 46 includes two or more coils that, in use, permit compression or expansion of the spring 36 and permit displacement of the inner body 34 and the outer body 32 relative to one another.

For instance, in a neutral, non-mounted position of the spring-biased end cap 30 and of the spring 36 (e.g., prior to mounting the rod assembly 10 and spring-biased end cap 30 to a mounting surface), the intermediate portion 39 of the spring 36 is fully extended and the first end 62 of the inner body 34 is a first or initial distance d₁ from the lateral wall 50 of the outer body 32. In a mounted position of the spring-biased end cap 30 and of the spring 36, the intermediate portion 39 of the spring 36 is compressed to some extent and the first end 62 of the inner body 34 is a second distance d₂ from the lateral wall 50 of the outer body 32, where d₂ is less than d₁. In some embodiments, in the mounted position in which the spring 36 is compressed, the inner body 34 may be drawn entirely or almost entirely into the outer body 32 such that little to no portion of the inner body 34 (e.g., the second end portion 64) is protruding from the outer body 32.

It will be appreciated that the more d₂ is decreased relative to d₁ the more the amount of tension between the rod assembly 10 and the mounting surfaces is increased when the rod assembly 10 is mounted.

With reference to FIG. 3, the cavity 46 may have a diameter larger than both the inner body 34 and the outer rod 14 to facilitate movement of the inner body 34 and the outer rod 14 within the cavity 46 when the spring compresses or expands. There may be an annular gap or space 46a between the outer rod 14 and the wall of the cavity 46 when the outer rod 14 is received on the inner body 34 so that the outer rod 14 and the inner body 34 do not contact the outer body 32. Alternatively, the gap 46a could be so small that there is light frictional contact between the inner body 34 and the outer rod 14 to aid in guiding reciprocating movement of the outer rod 14 relative to the inner body 34.

With reference to FIGS. 13-14, the end cap 20 may be a non-spring-biased end cap. However, in some embodiments the end cap 20 may be a spring-biased end cap like spring-biased end cap 30, or another type of adjustable end cap (e.g., a rotating adjustable end cap). In the illustrated embodiment, the end cap 20 is a non-spring-biased end cap having an inboard end 82 for receiving the inner rod 12 (or, in some embodiments, the outer rod 14) and an outboard end 84 for mounting to one of two opposing support surfaces. In certain embodiments, the non-spring-biased end cap 20 may be a single piece with a body 80 having the same or similar outer profile as the outer body 32 of the spring-biased end cap 30. As illustrated, the body 80 has a frustoconical outer profile, with the outer diameter of the body 80 increasing from the inboard end 82 to the outboard end 84. In other configurations, the body 80 may be generally cylindrical or have different geometries (e.g., bell-shaped). The inboard end 82 is open and defines a hollow interior or passage 86 which receives the inner rod 12. Specifically, the passage 86 may be sized and shaped to receive an end of the inner rod 12 with a friction fit. The passage 86 may include one or more longitudinally extending tapered fins or ribs 90 to enhance the frictional engagement with the inner rod 12 within the passage 86.

The outboard end 84 is open and defines a cavity 88. A lateral wall 92 may define a floor to both the cavity 88 and the passage 86 and separate the cavity 88 from the passage 86. The outboard end 84 defines an annular face 85 to engage the mounting surface. The outboard end 84 also defines an annular recess 87 about an opening to the cavity 88 that receives a perimeter portion of a mounting pad like the mounting pad 57 shown in FIG. 9 in the spring-biased end cap 30. The mounting pad may be coupled to the recess 87, for example by gluing or welding.

With reference to FIGS. 1-3, a method of mounting a rod assembly 10 may have the following steps. An end of the inner rod 12 may be inserted into the end cap 20 until a secure friction fit is obtained. An end of the outer rod 14 may be inserted into the cavity 46 of the spring-biased end cap 30 in engagement with the inner body 34. Specifically, the inner body 34 is inserted into the outer rod 14 with a friction fit securing the outer rod 14 to the inner body 34. In some embodiments, the inner body 34 may be inserted into the outer rod 14 until the outer rod 14 abuts the annular flange 78 of the inner body 34. It will be appreciated that in other embodiments the inner rod 12 engages the spring-biased end cap 30 and the outer rod 14 engages the end cap 20, and that the end cap 20 could be a second spring-biased end cap or a non-spring-biased end cap.

The inner rod 12 may then be partially inserted into or extended from the outer rod 14 until the combined length of the inner rod 12 and the outer rod 14 is a length that is appropriate for mounting the rod assembly between two opposing mounting surfaces. Specifically, the inner rod 12 and outer rod 14 should be coarsely adjusted to a length of the rod assembly 10 such that the rod assembly 10 including the end caps 20, 30 is slightly longer than the distance between the two opposing mounting surfaces. A lock mechanism may be used to lock the inner rod 12 and outer rod 14 to the desired length so that the inner rod 12 and outer rod 14 are fixed from movement relative to one another and at the adjusted length.

The rod assembly 10 may then be mounted by first holding the end cap 20 (e.g., a non-spring-biased end cap) against a first mounting surface and then bringing the other end of the rod assembly 10 and the spring-biased end cap 30 towards a second opposing mounting surface. Since the rod assembly 10 is slightly longer than the distance between the two opposing mounting surfaces, the outer body 32 of the spring-biased end cap 30 may then be pushed in the direction of the end cap 20 to compress the spring 36 and move the outer body 32 relative to the inner body 34 and the rest of the rod assembly 10, thereby shortening the length of the rod assembly 10 until it fits between the two opposing mounting surfaces and both end caps 20, 30 are engaging the mounting surfaces. After releasing the rod assembly 10, the compressed spring 36 extends to a slightly less compressed state to force the end caps 20, 30 securely against the mounting surfaces. That is, the spring 36 finely adjusts the rod assembly 10 for a secure fit between the mounting surfaces. The compressed spring 36 exerts force on the outer body 32 of the spring-biased end cap 30 and the inner body 34 of the spring-biased end cap 30 to hold the rod assembly 10 in tension between the mounting surfaces.

The rod assembly 10 may alternatively be mounted by first holding the outboard end 44 of the spring-biased end cap 30 against the first mounting surface as the opposite end of the rod assembly 10 with the end cap 20 is brought towards the second opposing mounting surface. The end cap 20 or the inner rod 12 is then pushed in the direction of the spring-biased end cap 30, which moves the outer rod 14 and inner body 34 of the spring-biased end cap 30 to compress the spring 36 and thereby shorten the length of the rod assembly 10 until it fits between the two opposing mounting surfaces and both end caps 20, 30 are engaging the mounting surfaces.

As noted above, greater compression of the spring provides greater tension when the rod assembly 10 is mounted. As such, adjusting the total length of the rod assembly 10 such that the intermediate portion 39 of the spring 36 becomes fully or nearly fully compressed in the mounting position may be desirable for achieving a firm and secure hold on the mounting surfaces.

In certain embodiments, the method may also finetune the amount of spring force generated by the spring by changing the distance d₁ the intermediate portion 39 of the spring 36 extends in the neutral position of the spring 36, wherein d₁ may be approximately equated to the initial distance between the first end 62 of the inner body 34 and the lateral wall 50 of the outer body 32. Changing the distance d₁ may be accomplished by adjusting the amount of the spring 36 that is threaded through the passage 52. It can also be accomplished by adjusting the amount of the spring extending into the cavity 48 beyond the passage 52 or extending into the passage 66 (e.g., the second portion 70 thereof) of the inner body 34. Alternatively, or in addition to, the distance d₁ may be adjusted by using a longer spring and permitting the inner body 34 to protrude out further from the outer body 32 in the neutral position.

The force provided by the spring-biased end cap 30, in some embodiments, has an effect on the locking mechanism between the rods 12, 14, such as one of the locking mechanisms described in U.S. Pat. Nos. 10,959,559, 11,382,447, and U.S. Publication No. 2023/0277012, all of which are incorporated by reference herein in their entireties. For example, the above-noted activity of the spring-biased end cap 30 may also force the locking mechanism into a more secure or locked state of the two rods 12, 14 relative to each other.

The rod assembly 10 may be horizontally or vertically mounted and may be used for supporting curtains over a window or as a shower rod for supporting a shower curtain. Other non-limiting uses may be as a closet pole for hanging clothes or as a shower caddy.

With reference to FIGS. 15-17, there is illustrated another spring-biased end cap 130. Many features of the spring-biased end cap 130 are like those discussed above for the spring-biased end cap 30. Common features are denoted with the same number except the number will begin with a “1” for the spring-biased end cap 130. To the extent some of the common features are not specifically referenced in the description of spring-biased end cap 130, the description of the same features present in spring-biased end cap 30 are incorporated by reference.

With reference to FIGS. 1 and 15-17, the spring-biased end cap 130 may be used in rod assembly 10, for example, in place of spring-biased end cap 30 and/or end cap 20. The spring-biased end cap 130 is fitted to inner rod 12 or outer rod 14 and, in use, engages one of two opposing support surfaces. Like the spring-biased end cap 30, in use, the spring-biased end cap 130 adjusts to provide sufficient tension between the rod assembly 10 and opposing support surfaces so that the rod assembly 10 is securely held between the opposing support surfaces.

The spring-biased end cap 130 includes an outer body 132, an inner body or insert 134, and a spring 136. The inner body 134 is at least partially received within a cavity 146 of the outer body 132 and is movably coupled to the outer body 132 via the spring 136. Specifically, the spring 136 may be a helical compression spring and may have a first end portion 137 coupled to the outer body 132 and a second end portion 138 coupled to the inner body 134 to thereby secure the outer body 132 to the inner body 134. An intermediate portion 139 of the spring 136 extends through the cavity 146 of the outer body 132 and permits displacement or a change of position of the inner body 134 and the outer body 132 relative to one another when the spring 136 compresses or expands.

With reference to FIGS. 17 and 21-24, the outer body 132 has an inboard end 142 for receiving the inner body 134 and the outer rod 114 (or the inner rod in some configurations) and an outboard end 144 for mounting to the support surface. In the illustrated embodiment, the outer body 132 is bell-shaped or curved, with the outer diameter of an outer wall 140 of the outer body 132 increasing from the inboard end 142 to the outboard end 144. The outer wall 140 may be tapered to define the bell-shape. In other configurations, the outer body 132 may be generally cylindrical or have other geometries (e.g., frustoconical).

The inboard end 142 is open and defines the hollow interior or cavity 146 which receives the inner body 134, the outer rod 114 (or the inner rod), and the spring 136. The cavity 146 may be substantially cylindrical with a uniform inner diameter, as illustrated. In other embodiments, the shape of the cavity 146 may follow the bell curve of the outer body 132, gradually increasing from the inboard end 142 towards the outboard end 144. The cavity 146, as described further below, is dimensioned to receive and permit movement or displacement of the inner body 134, spring 136, and outer rod 114 relative to the outer body 132 so that the rod assembly 10 can adjust to an appropriate length to hold the rod assembly in tension between opposing support surfaces.

With reference to FIGS. 17-20 and 22, the outer body 132 includes a lateral wall 150 extending radially inwardly relative to the outer wall 140 and defining a bottom or inner boundary of the cavity 146. A post 153 may extend into the cavity 146 at a central portion of the lateral wall 150. In embodiments, the post 153 is formed integrally with the lateral wall 150 and thus extends from the lateral wall 150. The lateral wall 150 and post 153 may share a central opening 155. The lateral wall 150 may have one or more cut-outs 158 therein spaced about the post 153 to permit air flow through the outer body 132. For instance, in the illustrated embodiment, there are three such cut-outs 158. In some embodiments, the post 153 may be a separate component from the lateral wall 150 that is fixed (e.g., welded) to the lateral wall 150.

The post 153 extends into the cavity 146 and functions to anchor or retain the first end 137 of the spring 136 within the outer body 132. Specifically, the post 153 is sized so that it can be inserted into the spring 136, with the spring 136 wrapped around the post 153. One or more barbs 193 project from or near a terminal end of the post into the cavity 146. The barbs 193 extend radially outwardly from the post 153, each including an inclined side surface 193a that angles or curves radially outwardly in the direction of the lateral wall 150 and a bottom surface 193b that extends perpendicular to the post 153. The barbs 193 may also have a degree of flexibility. In some cases, the inclined side surfaces 193a and/or the flexibility of the barbs facilitate insertion into coils of the spring 136 when the post 153 is being inserted into the spring 136. In addition, when the post 153 is inserted into the spring 136, the inclined side surfaces 193a of the barbs 193 may be positioned to support one or more coils of the spring 136 (as shown best in FIG. 18). As such, the barbs 193 may be positioned relative to one another at a pitch corresponding to the pitch of the coils of the spring 136.

The barbs 193 further function to retain the spring 136 on the spring-biased end cap 130 so that the spring 136 is not easily or unintentionally uncoupled from the end cap 130. In the illustrated embodiment, the spring 136 is installed in the end cap 130 so that one or more of the coils of the spring 136 are past the barbs 193 and the bottom surfaces 193b of the barbs 193 prevent the coils from passing back over the barbs 193. The barbs 193 keep the spring 136 securely attached to the post 153 and the end cap 130 during routine use of the end cap 130. In certain embodiments, the post 153 and/or positioning of the barbs 193 may permit the spring 136 to be unthreaded or unwound from the post 153 if needed (e.g., to replace the spring or adjust the amount of coils of the spring 136 extending freely within the cavity 146).

In embodiments, the post 153 may extend into a plurality of distinct post extensions 194 or fingers, each post extension 194 including one of the barbs 193 at an end thereof. For example, there may be three post extensions 194 and three barbs 193. The post extensions 194 and barbs 193 may be arranged about the central opening 155 of the post 153. The post extensions 194 may have different lengths and thus extend at different amounts into the cavity 146 so that the barbs 193 are positioned to correspond to the pitch of the spring 136. In certain configurations, the post extensions 194 and/or barbs 193 may be flexible, e.g., configured to deflect slightly inwardly when inserted into the spring 136.

In some embodiments, the post 153 may not extend into a plurality of distinct post extensions 194 and instead defines a cylindrical wall or body having one or more barbs 193 at an end thereof.

In some embodiments, the coils of the spring 136 wrapped around the post 153 past the barbs 193 undergo some amount of compression or expansion during use when the spring-biased end cap 130 is mounted. In certain configurations, the amount of compression or expansion of the coils of the spring 136 retained by the barbs 193 is less than the amount of compression or expansion of the coils of the intermediate portion 139 of the spring 136 that extend freely through the cavity 146. In some configurations, there is little or no compression or expansion of the coils that are past the barbs 193.

Anchoring or retaining the spring 136 on the post 153 in the above-described manner supports, stabilizes, and positions the spring 136, and allows the spring 136 to thereby support, stabilize, and position the inner body 134 and the outer rod 114. Specifically, the post 153 maintains the spring 136 along a central longitudinal axis L of the outer body 132 and in a position substantially perpendicular to the inboard end 142 and the outboard end 144 and the mounting surfaces. In addition, this configuration keeps the spring 136 and the inner body 134 from becoming dislodged from the outer body 132 or falling out in both use, storage, and transportation of the spring-biased end cap 130.

The outboard end 144 is open and defines a cavity 148. An annular wall 151 depends from the lateral wall 150 at the periphery of the lateral wall 150, extending into the cavity 148. An annular face 145 defined by the outer wall 140 at the outboard end 144 and an annular recess 156 outboard of and about the cavity 148 are shaped to engage a perimeter portion of a mounting pad 157. As illustrated, the mounting pad 157 may be coupled to or engage the annular face 145, the annular recess 156, and an end surface 152 of the annular wall 151. In some embodiments, the annular wall 151 includes a plurality of projections 152a (FIG. 22) extending axially and radially inwardly from the annular wall 151 and defining increased surface area at the end surface 152 for seating the mounting pad 157. The mounting pad 157 may be coupled to the above-noted portions of the outer body 132 by, for example, gluing or welding.

With reference to FIGS. 25-27, the inner body 134 is substantially the same as inner body 34, including a passage 166 for receiving the second end portion 138 of the spring 136 and having an outer diameter sized to coaxially receive the outer rod 14 over the inner body 134 with a friction fit. Since the features of inner body 134 are like those of inner body 34, the description of the features of inner body 34 are incorporated by reference herein.

The spring-biased end cap 130 has a similar functionality and use as described above with respect to spring-biased end cap 30, and, thus, the above description of these aspects is also incorporated by reference herein.

The inner body 134 and the outer body 132 may have other configurations other than those illustrated and described above. Specifically, the inner body 134 and the outer body 132 may be configured differently with respect to how each element couples to or engages the spring 136. For instance, in some approaches, the spring 136 is anchored or coupled to both the inner body 134 and the outer body 132, as described above. In other approaches, the spring 136 may be anchored or coupled to only one of the inner body 134 or the outer body 132. For instance, the spring 136 may be secured to the outer body 132 (for example, via post 153 or threaded/grooved passage 52) but may not be secured to the inner body 134. Instead, for instance, the passage 166 of the inner body 134 may be open without any retaining features (e.g., grooves or threads), and the spring 136 coupled to the outer body 132 is simply inserted into the passage 166 of the inner body 134 during use.

In another approach, the spring 136 may be secured to the inner body 134 (for example, within a grooved or threaded passage 66), but may not be secured to the outer body 132. For instance, a passage (e.g., such as passage 52 described above) in the outer body 132 may not have any retaining features such as grooves or threading to secure the spring 136 to the outer body 132. The spring 136 may simply be inserted relatively loosely into such a passage (or, alternatively, with a slight friction fit). In some configurations, a post such as post 153 may be used, though without any retaining features such as barbs or hooks. The post may instead be used to center or position the spring 136 within the outer body 132 instead of to couple or secure the spring 136 to the outer body. In some approaches, the spring 136 may simply abut an inner wall of the outer body 132, with or without a positioning means. In these approaches in which the spring 136 is not secured to both the outer body 132 and the inner body 134, the outer body 132 may be relatively loose in relation to the inner body 134 and the rest of the rod assembly in an unmounted condition, though the components would be held together in tension in a mounted condition.

In embodiments, any of the spring-biased end caps described herein may be packaged so that the outer body, inner body, and spring are already coupled together. In other embodiments, the outer body and the spring are initially coupled together without being coupled to the inner body. The inner body is configured so that it couplable to the spring during installation and use of the end cap in a rod assembly by a user. In some cases, the inner body may already be inserted into the rod via a friction fit, and the method of installing the spring-biased end cap and rod assembly includes the user coupling the inner body already connected to the rod to the spring (e.g., by threading the spring into the inner body via internal threads disposed in the inner body or some other mechanism) to connect the inner body to the outer body. In some cases, the inner body is initially separate from both the outer body and the rod and the user makes the connections. In still another embodiment, the inner body and the spring may be initially coupled together (and, optionally, also attached to a rod) without being coupled to the outer body and the outer body is configured so that it is couplable to the spring during installation and use of the end cap (e.g., by threading the spring into the outer body or some other mechanism).

FIG. 28 illustrates another rod assembly 210. Many features of the rod assembly 210 are similar to those discussed above for the rod assembly 10. Common features are denoted with the same number except the number will begin with a “2” for the rod assembly 210. To the extent some of the common features are not specifically referenced in the description of rod assembly 210, the description of the same features present in rod assembly 10 are incorporated by reference.

The rod assembly 210 is a shower caddy that is mounted vertically (for example, from a floor to a ceiling). The rod assembly 210 includes a first end cap 220 and a second end cap 230, at least one outer rod 214, and at least one inner rod 212. In some embodiments, instead of an outer rod and an inner rod, there may be multiple rods that are the same diameter which are connected to each other via tapered ends of each rod.

One or more locks 298 may lock adjacent rods together at a desired combined length and/or support baskets 297. The locks 298 and baskets 297 may include the locks and baskets disclosed in U.S. Publication No. 2023/0277012 which is incorporated by reference herein in its entirety. Other locking mechanisms between the rods may also be used in the rod assembly 210, such as those described in U.S. Pat. Nos. 10,959,559 and 11,382,447, which both are incorporated by reference herein in their entireties.

The rod assembly 210 has at least one spring-biased end cap. In the illustrated embodiment, the first end cap 220 is a non-spring-biased end cap and the second end cap 230 is a spring-biased end cap. However, in some approaches both the first end cap 220 and the second end cap 230 may be spring-biased end caps.

The spring-biased end cap 230 may be the same as spring-biased end cap 30 or 130, described above, or include any of the variations described above. The rod assembly 210 having at least one spring-biased end cap 230 is installed and functions in the same manner as described above.

With reference to FIGS. 29-31, the first end cap 220 is, in some embodiments, a non-spring-biased end cap. In the illustrated embodiment, the non-spring-biased end cap may include a body 280 having an outer annular wall 280a that is generally bell-shaped, having an outer diameter that gradually increases from an inboard end 242 of the body 280 to an outboard end 244. Other profiles, e.g., frustoconical, cylindrical, etc. are possible. An inner cup 292 is disposed radially inward of the outer annular wall 280a, defining an opening or cavity 286 for receiving one of the inner rod 212 or outer rod 214 with a friction fit. The inner cup 292 is defined in part by an inner annular wall 280b that has a first end that merges with the outer annular wall 280a adjacent the inboard end 242 of the main body 280 and a second end that extends concentrically within an outboard cavity 280c defined by the outer annular wall 280a at the outboard end 244. As illustrated, the inner cup 292 may be generally cylindrical, though other profiles are possible.

The cavity 286 of the end cap 220 may include one or more longitudinally extending tapered fins or ribs 290 to increase the friction fit force between the rod and the cavity 286. The end cap 220 may also include a mounting pad 257 similar to the mounting pads 57, 157 described above that is coupled to portions of the main body 280 at the outboard end 244, for example, at an annular recess 256 and/or at an outboard surface 292a of the inner cup 292.

Other non-spring-biased end caps may also be used, such as, for example, the threaded and free-spinning end caps disclosed, for example, in U.S. Publication No. 2023/0277012 which is incorporated by reference herein in its entirety.

While there have been illustrated and described particular embodiments of the present invention, those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Claims

1. An end cap for mounting a rod to a surface, the end cap comprising: an outer body having an outboard end for engaging a surface and an inboard end defining an opening and a first cavity for receiving a rod;an inner body capable of being received at least in part within the first cavity; anda spring having a first end portion sized to be connected to the outer body and a second end portion sized to be connected to the inner body to connect the outer body to the inner body, the spring further having an intermediate portion configured to change a relative displacement between the inner body and the outer body upon compression or expansion of the spring,wherein the first end portion of the spring is sized to be connected to the outer body with an engagement with a post of the outer body projecting into the first cavity of the outer body such that the engagement resists disengagement of the spring from the post.

2. The end cap of claim 1, wherein the first end portion of the spring is wrapped around the post and the post includes a plurality of barbs that prevent the spring from falling off the post.

3. The end cap of claim 2, wherein each of the plurality of barbs include an angled side surface, and the angled side surfaces of the plurality of barbs are positioned relative to one another corresponding to a pitch of the spring.

4. The end cap of claim 1, wherein the post comprises a plurality of fingers, each of the fingers including a barb to prevent the spring from separating from the post.

5. The end cap of claim 1, wherein the second end portion is capable of being connected to the inner body by engaging one or more grooves in a passage of the inner body.

6. The end cap of claim 5, wherein the one or more grooves define threading of the passage that is capable of engaging one or more coils of the second end portion of the spring.

7. An end cap for mounting a rod to a surface, the end cap comprising: an outer body having an outboard end for engaging a surface and an inboard end defining an opening and a first cavity for receiving a rod;an inner body capable of being received at least in part within the first cavity; anda spring having a first end portion sized to be connected to the outer body and a second end portion capable of being connected to the inner body to connect the outer body to the inner body, the spring further having an intermediate portion configured to change a relative displacement between the inner body and the outer body upon compression or expansion of the spring,wherein the second end portion is capable of being connected to the inner body by engaging one or more grooves in a passage of the inner body,wherein the passage includes a first portion containing the one or more grooves and a second portion without grooves that is capable of receiving one or more terminal coils of the spring.

8. The end cap of claim 1, wherein the first end portion of the spring is connected to the outer body by engaging one or more grooves in a passage of the outer body.

9. The end cap of claim 1, wherein the inner body includes an outer wall having a first end section that is substantially cylindrical and a second end section that is substantially frustoconical.

10. A rod assembly comprising: a first rod and a second rod that are adjustable relative to one another to adjust a total length of the rod assembly along a longitudinal axis; anda first end cap and a second end cap attachable to the first rod and the second rod,the first end cap including an outer body, an inner body, and a spring couplable to both the outer body and the inner body to allow movement of the inner body relative to the outer body along the longitudinal axis upon compression or expansion of the spring,wherein a first end portion of the spring is sized to be coupled to the outer body by engaging a post of the outer body projecting into a first cavity of the outer body, the post having a leading edge that is angled.

11. The rod assembly of claim 10, wherein at least one of the outer body and the inner body includes one or more grooves for coupling the spring to the first end cap.

12. The rod assembly of claim 10, wherein the inner body includes a passage having a first section including threading and a second non-threaded section, both the first section and the second non-threaded section being configured to receive a portion of the spring within the inner body.

13. The rod assembly of claim 10, wherein the outer body has an outboard end for engaging a mounting surface and an inboard end having an opening defining the first cavity for receiving the first rod or the second rod, the inner body being movable within the first cavity via the spring, and wherein the first rod or the second rod is sized to receive and engage the inner body in a friction fit so that the first rod or the second rod is movable with the inner body.

14. An end cap for mounting a rod to a surface, the end cap comprising: an outer body having an outboard end for engaging a surface and an inboard end for receiving a rod, the outboard end comprising a first cavity and a cylindrical wall projecting within the first cavity, the inboard end defining an opening and a second cavity for receiving the rod;an inner body capable of being received at least in part within the second cavity; anda spring having a first end portion sized to be connected to the outer body and a second end portion capable of being connected to the inner body to connect the outer body to the inner body, the spring further having an intermediate portion configured to change a relative displacement between the inner body and the outer body upon compression or expansion of the spring.

15. The end cap of claim 14, the outer body comprising an inner wall that defines a bottom of the first cavity and a bottom of the second cavity, the cylindrical wall projecting into the first cavity perpendicularly from the inner wall.