Fabric Shade Assembly with Pockets and Associated Methods of Making and Use

Abstract

A shade assembly adapted to hold a photovoltaic panel thereon includes a shade panel. A first pocket part formed of a substantially clear plastic is connected to the shade panel along a plurality of first pocket edges thereof, a first pocket opening being defined between the shade panel. The first pocket part dimensioned to accommodate insertion of a first end of the photovoltaic panel therein. A second pocket part is also connected to the shade panel along a plurality of second pocket edges thereof, a second pocket opening being defined between the shade panel. The second pocket part is dimensioned to accommodate insertion of a second end of the photovoltaic panel therein. The first and second pocket part openings are substantially opposed. A closure flap extends between the first and second pocket parts and operable to cover the first and second pocket openings.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser. No. 61/146,438 filed on Jan. 22, 2009, the contents of which are herein incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to fabric shade assemblies.

BACKGROUND OF THE INVENTION

Shade assemblies, such as umbrellas, have long been employed to protect people, animals and equipment from the sun's rays. Thus, by design, a large amount of solar energy is incident on the fabric of the shade assemblies. This energy is at least partially reflected or otherwise dissipated to minimize its impact beneath the shade assembly.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a fabric shade assembly having pockets for removably holding photovoltaic panels thereon. A fabric shade assembly according to the present invention, together with suitable photovoltaic panels, advantageously allows at least a portion of the solar energy incident on the shade assembly to be converted to electrical power.

According to an embodiment of the present invention, a shade assembly adapted to hold a photovoltaic panel thereon includes a shade panel. A first pocket part formed of a substantially clear plastic is connected to the shade panel along a plurality of first pocket edges thereof, a first pocket opening being defined between the shade panel. The first pocket part dimensioned to accommodate insertion of a first end of the photovoltaic panel therein. A second pocket part is also connected to the shade panel along a plurality of second pocket edges thereof, a second pocket opening being defined between the shade panel. The second pocket part is dimensioned to accommodate insertion of a second end of the photovoltaic panel therein. The first and second pocket part openings are substantially opposed. A closure flap extends between the first and second pocket parts and operable to cover the first and second pocket openings.

According to a method aspect, the first end of the photovoltaic panel is inserted under the first pocket part through the first pocket opening. The photovoltaic panel is then flexed and the second end of the photovoltaic panel is inserted under the second pocket part through the second pocket opening. The closure flap is closed to cover the first and second openings.

These and other objects, aspects and advantages of the present invention will be better appreciated in view of the drawings and following description of a preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fabric shade assembly having pockets with photovoltaic panels arranged therein, with hidden components shown in broken lines;

FIG. 2 is a partially exploded top view of the shade assembly of FIG. 1, without photovoltaic panels in the pockets;

FIG. 3 is a detail view of one of the pockets of FIG. 1, with a closure flap in an open position and without a photovoltaic panel; and

FIG. 4 is a detail view of a portion of the pocket of FIG. 3, with the closure flap in a closed position and with a photovoltaic panel location shown in broken lines.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to FIGS. 1 and 2, a fabric shade assembly 10 has a plurality of pockets 12 located thereon. Each pocket 12 is formed from a substantially transparent material and is adapted to removably hold a photovoltaic panel 14 therein. Advantageously, the shade assembly 10 is arranged in an umbrella configuration, with a plurality of segments 18 arranged around a central support 20. A plurality of lateral supports 22 radiate from the central support 20 to spread and support the segments 18.

The segments 18 are formed from a plurality of substantially identical first and second shade panels 26, 28. The first panels 26 and second panels 28, and the pockets 12 arranged thereon, are substantially mirror images of each other.

The structure of each pocket 12 is substantially identical; for efficiency only one pocket 12 will be described in detail. Referring to FIG. 3, the pocket 12 includes a first part 40 and a second part 42. The first and second parts 40, 42 are both formed of a substantially transparent material that is attached to the underlying panel 26(28). The first part 40 further includes a closure flap 44 at one end thereof. The closure flap 44 is flexible relative to the rest of the first part 40 so as to selectively cover and uncover the second part 42. A fastener, such as a hook and loop fastener, a snap or other fastener, can be arranged between the flap 44 and the second part 42 to releasably secure the flap 44 to the second part 42.

Advantageously, the first and second parts 40, 42 and the panel 26(28) have interfacing plastic surfaces and are connected by plastic welding. The first part 40 has a first weld 50. Preferably, the first weld 40 extends around three edges of the first part 40, leaving a first opening 52 under the flap 44. The first weld 40 does not extend to the flap 44, leaving the flap 44 free to bend relative to the rest of the first part 40. The first part 40 and the flap 44 can thereby be formed integrally from a single piece of the material.

The second part 42 has a second weld 54. The second weld 54 extends around three edges of the second part 42, leaving a second opening 56 substantially opposed to, and spaced apart from, the first opening 52. Additionally, a cord gap 60 is formed in the second weld, preferably opposite a portion of the second opening 56.

Referring to FIG. 4, in use, the pocket 12 removably holds the photovoltaic panel 14 to the panel 26(28). With the flap 44 raised (see FIG. 3), a first end of the photovoltaic panel 14 is inserted under the first part 40 through the first opening 52, and a second end or base 62 of the photovoltaic panel 14 is inserted under the second part 42 through the second opening 56. A cord 64 is attached to the base 62 and routed through the gap 60 to carry power generated by the photovoltaic panel 14.

From the foregoing, it will be appreciated that the pocket 12 conveniently allows a photovoltaic panel 14 to be quickly and easily mounted to a shade assembly 10, and subsequently removed and replaced. Thus, repair or replacement of one or more photovoltaic panels 14 can be accomplished while leaving the shade assembly 10 in place. Similarly, the photovoltaic panels 14 can be readily removed and retained to accommodate repair or replacement of the shade assembly 10. In addition to holding the photovoltaic panels 14 to the shade assembly 10, the pockets 12 provide protection to the photovoltaic panels 14 from environmental forces like wind and rain, and aid in the routing of the cord 64.

Though not necessarily limited to such, the shade assembly 10 and pockets 12 are advantageously used in connection with lightweight, flexible, nano-enabled photovoltaic materials, such as Power Plastic® photovoltaic panels produced by Konarka Technologies, Inc.

Referring to FIG. 3, exemplary dimensions for the depicted pocket 12 embodiment include an overall length (from left to right, in FIG. 3) of 1320 mm and width (from top to bottom, in FIG. 3) of 354 mm. First and second welds 50, 54 extend inwards 10 mm from the sides of the respective first and second parts 40, 42. The length of the first part 50 is 1320 mm, with a length of 1220 mm to the first opening 52 and a flap length of 100 mm. The length of the second part is preferably 50 mm, with 50 mm between the first and second openings 52, 56. The gap 60 is 20 mm wide. Preferably, the first and second parts 40, 42 are connected to the panel 26(28) such that, when the shade assembly 10 is in place, the first part 40 is an upper part, and the second part 42 is a lower part (see FIG. 2). However, the present invention is not necessarily limited to such dimensions, nor to a shade assembly having an umbrella configuration, or to the quantities, shapes and sizes of segments or panels shown herein.

As discussed above, the first and second parts 40, 42 and the panels 26(28) preferably have interfacing plastic surfaces and are connected by plastic welding. Although not necessarily limited to such materials, it is preferred that the panels 26(28) be formed from a polyvinylchloride—(PVC) coated polyester fabric or a polytetrafluoroethylene—(PTFE) coated fiberglass fabric, which has been treated for flame retardancy. The first and second parts 40, 42 are preferably formed from a clear ethylene tetrafluoroethylene (ETFE) film.

Preferably, a computer controlled plotter/cutter machine with an air vacuum table bed is used for plotting and cutting of the EFTE film to specified dimensions. Advantageously, the cut EFTE film components are initially stitched to the underlying fabric panels. For this purpose, an industrial grade sewing machine can be employed, preferably with at least a single needle and a high-speed, oil bath-type chain stitch with walking foot operation. Industrial sewing machines sold under the brands Singer™, Juki™ and Pfaff™ have been found suitable. Tenara™-brand thread, produced by the W.L. Gore Company, has been found suitable for its resistance to ultraviolet (UV) light degradation.

Where PVC-coated polyester fabrics are to be used, a high frequency (HF) electronic welding machine is preferred for welding the EFTE film components to the fabric. An HF welding machine having at least a 10 kilowatt welding capacity, with a oil cooled/water cooled welding electrode holder, and an individual air pressure regulator valve for graduated control of downward welding bar pressure, has been found suitable. Exemplary machine settings include 50-75 pounds per square inch (psi) downward welding bar pressure, a power setting of 30-60 milliamps, a weld time of 6-10 seconds, and a cooling time of 3-6 seconds between welds.

Where PTFE-coated fiberglass fabrics are to be used, a direct heat PTFE welding machine is preferred for welding the EFTE film components to the fabric. A direct heat welding machine with a minimum electrode thrust capacity of 4 kilonewtons (Kn) and 1.5 meter length has been found suitable. A catalyst including a copolymer of hexafluoropropylene and tetrafluoroethylene is advantageously employed in the welding process. A weld time of approximately three minutes has been found to ensure a sufficient weld.

The above described embodiment and method of making are provided for illustrative and exemplary purposes; the present invention is not necessarily limited thereto. Rather, those skilled in the art will appreciate that various modifications, as well as adaptations for particular circumstances, are possible within the scope of the invention as herein shown and described and of the appended claims.

Claims

1. A shade assembly adapted to hold a photovoltaic panel thereon, the shade assembly comprising:

a shade panel;

a first pocket part formed of a substantially clear plastic connected to the shade panel along a plurality of first pocket edges thereof, a first pocket opening being defined between the shade panel and the first pocket part dimensioned to accommodate insertion of a first end of the photovoltaic panel therein;

a second pocket part connected to the shade panel along a plurality of second pocket edges thereof, a second pocket opening being defined between the shade panel and the second pocket part dimensioned to accommodate insertion of a second end of the photovoltaic panel therein, the first and second pocket part openings being substantially opposed; and

a closure flap extending between the first and second pocket parts and operable to cover the first and second pocket openings.

2. The assembly of claim 1, wherein the closure flap is integral with the first pocket part.

3. The assembly of claim 2, wherein the shade assembly is oriented such that the first pocket part is an upper part.

4. The assembly of claim 3, wherein the closure flap substantially overlies the second pocket part when closed.

5. The assembly of claim 3, wherein the a cord gap is defined between the second part and the shade panel along a lower edge of the second part, the cord gap being dimensioned to route a cord for connection to the second end of the photovoltaic panel therethrough.

6. The assembly of claim 1, wherein the first and second pocket part openings are spaced apart.

7. The assembly of claim 1, wherein the first pocket part is substantially longer than the second pocket part.

8. A method of using the shade assembly of claim 1, the method comprising:

inserting the first end of the photovoltaic panel under the first pocket part through the first pocket opening;

flexing the photovoltaic panel;

inserting the second end of the photovoltaic panel under the second pocket part through the second pocket opening;

closing the closure flap to cover the first and second openings.

9. The method of claim 8, wherein the closure flap is integral with the first pocket part, the shade assembly is oriented such that the first pocket part is an upper part, the closure flap substantially overlies the second pocket part when closed, and a cord gap is defined between the second part and the shade panel along a lower edge of the second part, the method further comprising:

routing a cord through the cord gap being and connecting the cord to the second end of the photovoltaic panel.

10. A shade assembly adapted to hold a photovoltaic panel thereon, the shade assembly comprising:

at least one shade panel; and

a pocket attached to the shade panel and including: a first part having a closure flap at a first end thereof; and a second part underlying the flexible closure flap;

wherein the pocket is dimensioned to accommodate the photovoltaic panel therein and at least one of the first and second part are formed from a substantially transparent polymer material.

11. The assembly of claim 10, wherein the at least one shade panel is a fabric panel.

12. The assembly of claim 11, wherein the at least one shade panel is formed of least one of a polyvinylchloride-coated fabric and a polytetrafluoroethylene-coated fiberglass fabric.

13. The assembly of claim 10, wherein at least one of the first and second parts is formed of a plastic material.

14. The assembly of claim 13, wherein at least one of the first and second parts is thermally welded to the shade panel.

15. The assembly of claim 13, wherein at least one of the first and second parts is formed of an ethylene tetrafluoroethylene film.

16. The assembly of claim 10, wherein the first part has four edges, first part connections to the shade panel being formed only along three edges thereof such that a first opening is defined between the first part and the shade panel under the closure flap.

17. The assembly of claim 16, wherein the closure flap is flexible the connections between the shade panel and the first part do not extend under any edges of the closure flap.

18. The assembly of claim 16, wherein the second part has four edges, second part connections to the shade panel being formed only along three edges thereof such that a second opening, substantially opposed to the first opening, is defined between the second part and the shade panel under the closure flap.

19. The assembly of claim 10, wherein the second part has four edges, second part connections to the shade panel being formed only along three edges thereof such that a second opening is defined between the second part and the shade panel under the closure flap.

20. The assembly of claim 19, wherein a gap is formed in the second part connection to the shade panel opposite the second opening, adapted to accommodate a cord of the photovoltaic panel therethrough.