Folding structure with improved locking system

Abstract

The present invention is a folding structure having an improved locking mechanism. In one embodiment, the folding structure comprises a plurality of legs and a hinge mechanism, the hinge mechanism comprising a plug hinge removably connected to a slider hinge between a first position at which the structure is substantially collapsed and a second position at which the structure is substantially open and the plug hinge is locked to the slider hinge. The hinge mechanism may further comprise a release cap engaged with the slider hinge and having a pair of buttons. Depression of the buttons unlocks or releases the plug hinge from the slider hinge, allowing the folding structure to be collapsed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 60/672,889 filed on Apr. 19, 2005, now pending, which is hereby incorporated by reference in its entirety into this specification.

BACKGROUND OF THE INVENTION

Folding structures, such as tents and cabanas, utilize various mechanisms to hold the structure in the open or unfolded position. U.S. Pat. Nos. 2,864,389; 4,945,936; and 6,021,795 each disclose what is commonly referred to as an “umbrella” type folding structure. The folding structures described in those patents employ a hinge mechanism consisting of a lower hub that is manually moved upwards into engagement with an upper hub to unfold a plurality of legs to open the structure. In those conventional devices, the lower and upper hubs are not secured or locked together when the folding structure is open, leading to a potential unwanted collapse of the folding structure.

SUMMARY OF THE INVENTION

One object of the present invention is to provide a folding structure for use as a cabana, tent, or the like that employs a more positive and secure hinge mechanism to provide safer and quicker folding of the structure.

The present invention is directed to a folding structure for use as a cabana, tent, or the like. In one embodiment, the folding structure comprises a plurality of legs and a hinge mechanism comprising a plug hinge removably connected to a slider hinge between a first position where the structure is substantially collapsed and a second position where the structure is substantially open and the plug hinge is locked to the slider hinge. The plug hinge comprises a pair of flexible tabs having ridge portions that ride on a tapered wall of the slider hinge as the plug hinge is brought into engagement with the slider hinge. Upon complete engagement of the plug hinge with the slider hinge, the ridge portions of the flexible tabs snap into locked engagement with a lip portion of the slider hinge. The hinge mechanism may further comprise a release cap having a pair of buttons that, when pressed, contact and move the ridge portions of the flexible tabs off the lip portion to disengage the plug hinge from the slider hinge, whereby the folding structure may be collapsed. Snap engagement of the ridge portions of the flexible tabs of the plug hinge with the lip portion of the slider hinge provide a positive and secure hinge mechanism to maintain the structure in the open position. The buttons on the release cap provide a fast and easy means to release or disengage the plug hinge from the slider hinge and thus collapse the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description of the invention will be more fully understood with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of the folding structure according to the present invention shown in an open or erect position and having a fabric enclosure attached thereto for use as a cabana, tent or the like;

FIG. 2 is a cut-away perspective view of the folding structure in a partially folded or collapsed position wherein a plug hinge of a hinge mechanism is fully disengaged from a slider hinge of the hinge mechanism,

FIG. 3 is an exploded view of the hinge mechanism;

FIG. 4 is a perspective view of the upper portion of folding structure in a substantially collapsed or folded position, with the plug hinge fully disengaged from the slider hinge;

FIG. 5 a perspective view of the top portion of the folding structure in an open or erect position with the plug hinge in secured or locked engagement with the slider hinge;

FIG. 6 is a partial cut-away perspective view of the folding structure showing the plug hinge disengaged from the slider hinge;

FIG. 7 is a partial cut-away perspective view of the folding structure showing the plug hinge of the hinge mechanism in secured or locked engagement with the slider hinge;

FIG. 8 is an enlarged view of Section A of FIG. 7;

FIG. 9 is a cross-sectional view of a retaining plug showing end portions of a rope tied into a knot that is securely retained within the retaining plug;

FIG. 10 is a perspective view of the plug hinge;

FIG. 11 is a front elevational view of the plug hinge;

FIG. 12 is a side elevational view of the plug hinge;

FIG. 13 is a top plan view of the plug hinge;

FIG. 14 is a cross-sectional view taken along line A-A of FIG. 13;

FIG. 15 is a perspective view of the slider hinge;

FIG. 16 is a front elevational view of the slider hinge;

FIG. 17 is a top plan view of the slider hinge;

FIG. 18 is a cross-sectional view taken along line B-B of FIG. 17;

FIG. 19 is a perspective view of the release cap;

FIG. 20 is a front elevational view of the release cap;

FIG. 21 is a top plan view of the release cap; and

FIG. 22 is a cross-sectional view taken along line A-A of FIG. 21.

DESCRIPTION OF THE INVENTION

Referring to FIG. 1-5, the present invention is directed to a device or structure 10 that may be easily manipulated between an open and locked position (FIG. 1) and a folded or collapsed position (FIG. 2). Folding structure 10 generally comprises legs 28, 30, 32, and 34 (FIG. 4) pivotally connected to a hinge mechanism 52 (FIG. 1). As best seen in FIG. 2, each of legs 28, 30, 32, and 34 comprise an upper leg section 36 connected to a lower leg section 38 by a hinge 40 that allows the lower leg section 38 to be folded upon upper leg section 36 in a conventional fashion. As best shown by FIGS. 4 and 5, folding structure 10 further comprises extending arms 44, 46, 48, and 50 each having an outer end pivotally connected to the sliding hinge 42 on the upper leg section 36 and an inner end pivotally connected to a plug hinge 54 (to be described) of the hinge mechanism 52. Folding structure 10 may include a fabric enclosure 12 for use as a cabana, tent, or the like. As shown in FIG. 1, fabric enclosure 12 may comprise, for example, a front panel 14 having a flap 16, a side panel 20, and (as shown in FIG. 2) side and rear panels 18 and 23, and a floor panel 22. Fabric enclosure 12 may be attached to folding structure 10 by a plurality of straps 24, in conventional fashion (FIG. 1). As best shown in FIG. 3, the hinge mechanism 52 generally comprises a plug hinge 54, a slider hinge 70, and a release cap 88. As will be described more fully below, the plug hinge 54 is moveable between a first position, with the folding structure 10 open or erect and the plug hinge 54 locked with the slider hinge 70 (FIGS. 1 and 5), and a second position, with the folding structure 10 partially or fully collapsed and the plug hinge fully disengaged from the slider hinge (FIGS. 2 and 4). The release cap 88 may be engaged with the slider hinge 70 and comprise first and second buttons 92 and 94. As will be described more fully below, depressing the buttons 92 and 94 unlocks or releases the plug hinge 54 from the slider hinge 70, allowing the folding structure 10 to be folded or collapsed. The hinge mechanism 52 may further comprise a rope 106 attached to plug hinge 54, which may be pulled to bring the plug hinge 54 into locked engagement with the slider hinge 70.

Referring to FIGS. 6 and 10-14, plug hinge 54 comprises a base portion 56 (FIG. 10) and a plurality of mounting flanges 66 extending outwardly from and formed as part of the base portion 56. Mounting flanges 66 are pivotally connected with the extending arms 44, 46, 48, and 50 by conventional means such as fittings and pins. Plug hinge 54 further comprises first and second tab portions 58 and 62 extending upwardly from and formed as part of the base portion 56. As best shown by FIG. 14, first and second tab portions 58 and 62 comprise tapered walls 59 and 63, respectively. First and second tab portions 58 and 62 further comprise an annular-shaped protrusion or ridge portion 60 and 64, respectively, disposed upon the tapered walls 59 and 63, respectively. As will be described more fully below, upon complete engagement of plug hinge 54 with slider hinge 70, ridge portions 60 and 64 are flexed and snap into secure or locked engagement with a lip portion 82 (to be described) of slider hinge 70.

Referring to FIGS. 6-8 and 15-18, slider hinge 70 comprises a body portion 72 (FIG. 15) having a lower end portion 74, an upper end portion 76, and an internal passage-way or thru-hole 78. Thru-hole 78 is provided to receive first and second tab portions 58 and 62 of plug hinge 54. As shown in FIG. 18, thru-hole 78 has a tapered annular inner wall 80 adapted to receive and mate with tapered walls 59 and 63 of first and second tab portions 58 and 62 of plug 54. As best shown by FIG. 15, slider hinge 70 further comprises an annular-shaped lip or rim portion 82 formed at upper end portion 76 of base portion 72. Slider hinge 70 further comprises mounting flanges 84 adapted to pivotally connect with the upper portions of upper leg sections 36 of legs 28, 30, 32, and 34. Slider hinge 70 further comprises a plurality of mounting protrusions or tabs 86 disposed at lower end portion 74 of body portion 72. As will be described more fully below, and as shown in FIGS. 3 and 15, tabs 84 serve as a means for securely mounting release cap 88 on slider hinge 70. As plug hinge 54 is brought into engagement with slider hinge 70, the ridge portions 60 and 64 of the tab portions 58 and 62 ride upon the tapered wall 80 of the slider hinge 70, causing the tab portions 58 and 62 to become deflected and biased.(Not shown in the drawings). As best shown by FIGS. 7 and 8, upon complete engagement of plug hinge 54 with slider hinge 70, ridge portions 60 and 64 of tab portions 58 and 62 snap into locked engagement with lip portion 82 of slider hinge 77, securing and locking hinge mechanism 54 in place in order to maintain the structure 10 in the open position.

Referring to FIGS. 6-8 and 19-22, release cap 88 comprises a housing portion 90 and two opposing flexible and resilient push buttons 92 and 94 formed as part of housing portion 90. Each of buttons 92 and 94 comprises an inner wall portion 96 and an outer wall portion 98 [FIG. 22]. Release cap 88 further comprises a pair of mounting slots 102 adapted to engage with mounting tabs 86 of slider hinge 70 to secure release cap 88 to slider hinge 70 [FIG. 15]. Release cap 88 further comprises a pair of rope openings 104 formed at the top of mounting slots 102. As seen in FIG. 8, depression of the buttons 92 and 94 cause the inner walls 96 to contact and moves inwardly the ridge portions 60 and 64 of the tab portions 58 and 62 off the lip portion 82, thereby disengaging plug hinge 54 from slider hinge 70 and allowing folding structure 10 to be collapsed. Unlike conventional folding structures, buttons 92 and 94 provide a fast and easy means to release or disengage the plug hinge 54 from the slider hinge 70, to allow collapse of the structure 10.

Referring to FIGS. 3 and 9, the hinge mechanism 52 may further comprise a retaining plug 114. Retaining plug 114 generally comprises a housing 114 having a lower portion 116 and a passageway or thru-hole 118. Retaining plug 114 is adapted to be inserted within base portion 56 of plug hinge 54 [FIG. 3] to provide a means for retaining or securing the ends of rope 106 within and to the plug hinge 54. After being threaded thru openings 104 of release cap, thru-hole 78 of slider hinge 70, and hole 57 of plug hinge 54, the end portions 108 of rope 106 are threaded thru the passage way 118 and tied into a knot 110 that will reside within the lower portion 116. As upper portion 112 of rope 106 is pulled upwards, plug hinge 54 is brought into engagement with the slider hinge 70, and the upper length of rope 106 may be left hanging or otherwise unused.

The plug hinge 54, slider hinge 70, release cap 80, and retaining plug 114 may be made from conventional plastic materials and fabricated by conventional molding processes. Legs 28, 30, 32, and 34 may be made from conventional materials such as spring steel, plastic, metal rods and fabricated by conventional molding processes. Fabric enclosure 12 may be made from conventional textile fabrics such as nylon and fabricated by conventional molding processes.

Many modifications and variations may become apparent in light of the above teachings. By way of example only, in lieu of the flexible tabs the plug hinge may include spring-loaded buttons that extend outward from the plug hinge. The spring-loaded buttons may retract into the plug hinge as it is pulled into the slider hinge. The slider hinge or release cap may include detents into which spring-loaded buttons will extend as the plug hinge reaches the extent of its travel into the hinge assembly, so as to lock the plug hinge in the hinge assembly. Release buttons on the hinge assembly can then engage the spring-loaded buttons to force them back out of the detents and thereby release the plug hinge. Other engagement means, including arrangements wherein the plug hinge may engage about the outside of the hinge assemble are contemplated. Additionally, various arrangements of the support and extending arms may be employed to provide various configurations to the folding structure. Further, the pulling means may be other than a rope or cord: e.g., a flexible rod, a ring, or other mechanism whereby the plug hinge and hinge assembly are moved toward one another for engagement. In short, the present invention may be embodied in other specific forms without departing from the spirit and/or scope of the specification and appended claims.

Claims

1. A folding structure comprising a plurality of legs and a hinge mechanism, said hinge mechanism comprising a plug hinge engagable with a slider hinge between a first position in which the folding structure is substantially collapsed, and a second position in which the folding structure is substantially open with said plug hinge locked to said slider hinge to maintain the structure in its open position.

2. The folding structure of claim 1, wherein said hinge mechanism further comprising a first button adapted to release said plug hinge from said slider hinge to allow return of the structure to its folded position.

3. The folding structure of claim 2, wherein said plug hinge comprises a first tab portion releasably engaged with said slider hinge.

4. The folding structure of claim 3, wherein said slider hinge comprises a lip portion releasably engaged with said first tab portion of said plug hinge.

5. The folding structure of claim 4, wherein said first tab portion comprises a ridge portion removably connected with said first tab portion of said plug hinge and depression of said first button causes said first tab portion to be disengaged from said ridge portion.

6. The folding structure of claim 5, wherein said first button comprises an inner surface and depression of said first button causes said inner surface to push said ridge portion of said first tab portion off said lip portion of said slider hinge.

7. The folding structure of claim 6, wherein said plug hinge further comprises a second tab portion having a ridge portion removably connected with said lip portion of said slider hinge.

8. The folding structure of claim 7, further comprises a second button having an inner surface and depression of said second button causes said inner surface of said second button to push said ridge portion of said second tab portion off said lip portion of said slider hinge.

9. The folding structure of claim 8, wherein said first and second tab portions of said plug hinge are flexible and resilient.

10. The folding structure of claim 9, wherein said slider hinge comprises an internal hole.

11. The folding structure of claim 10, wherein said first and second tab portions extend within said internal hole of said slider hinge when said ridge portions of said first and second tab portions are engaged with said lip portion.

12. The folding structure of claim 11, wherein said first and second tab portions are deflected upon said insertion into said internal hole of said slider hinge and said ridge portions of said first and second tab portions snap into engagement with said lip portion of said slider portion.

13. The folding structure of claim 12, further comprising a release cap engaged with said slider hinge; said first and second buttons being formed as part of said release cap.

14. The folding structure of claim 13, wherein said internal hole of said slider hinge comprises a taped annular wall and said insertion of said first and second tab portions of said plug hinge into said internal hole of said slider hinge causes said ridge portions of said first and second tab portion to ride upon said tapered annular wall and deflect said first and second tab portions.

15. The folding structure of claim 14, wherein each of said first and second tab portions comprise an upwardly extending tapered wall adapted to be inserted within said tapered annular wall of internal hole of said slider hinge.

16. The folding structure of claim 15, wherein said lip portion of said plug hinge is annular shaped.

17. The folding structure of claim 16, wherein said ridge portions of said plug hinge are annular shaped.

18. The folding structure of claim 17, wherein said first and second tab portions of said plug hinge are elongated and annular shaped.

19. A method of folding and opening a structure comprising the steps of:

(a) providing the structure with a plug hinge, a slider hinge, and a release cap having a first button;

(b) moving said plug hinge into locked engagement with said slider hinge to hold the structure in the open position;

(c) depressing said first button to disengage said plug hinge from said slider hinge; and

(d) collapsing said folded structure.

20. The method of claim 19, wherein said step of moving said plug hinge into locked engagement with said slide hinge comprises the step of pulling a rope connected to said plug hinge.