WIND-RESISTANT RETRACTABLE AWNING

Abstract

A retractable awning including a fabric awning, a roller tube defining a linear track for securing the fabric awning to the roller tube, first and second extension arms coupled to opposing ends of the roller tube through spherical plain bearings, and first and second brace arms slidably coupled along the length of the respective first and second extension arms.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. application Ser. No. 61/601,288 filed Feb. 21, 2012, the contents of which are incorporated herein by reference.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention relates generally to the field of retractable awnings, and more particularly, to a retractable awning configured to withstand high winds that is easily and readily installable, repairable and operated by the consumer.

Retractable awnings are well known for providing shade and protection from the elements as needed on recreational vehicles, trailers, mobile homes and other structures. While numerous types of retractable awnings are known, conventional designs are prone to tearing, breaking and otherwise failing under high wind loading. Damaged awnings require repair or replacement, thereby increasing the frustration and cost of ownership to the consumer. Failure of the awning under high wind loading may also damage the supporting structure, further increasing frustration and costs.

Conventional awnings can also be complex, cumbersome, and difficult to install and operate. Some awnings also require parts to be stored when not in use, which is particularly disadvantageous for recreational vehicles and trailers where storage space is limited.

Accordingly, what is needed is a retractable awning capable of withstanding high wind loading without failure that also overcomes other disadvantages of conventional awning designs.

BRIEF SUMMARY OF THE INVENTION

It is an object of the present invention to provide a retractable awning configured to withstand high winds.

It is a further object of the invention to provide an awning assembly configured to be easily and readily installed, repaired and operated by the consumer.

It is a further object of the invention to provide an awning assembly manually movable between stowed and deployed positions without having to remove and separately stow parts.

It is a further object of the invention to provide an awning assembly including a support frame configured to flex and twist under high force winds to reduce stresses and strain on the fabric awning, frame members, bearings and mounting brackets.

To achieve the foregoing and other objects and advantages, in one embodiment a retractable awning assembly is provided herein generally including a fabric awning, a roller tube defining a linear track along the length thereof for attaching a first end of the fabric awning to the roller tube, first and second extension arms coupled to opposing ends of the roller tube through spherical plain bearings, and first and second brace arms slidably coupled along the length of the respective first and second extension arms.

The first and second extension arms may each include a hook near the roller tube for capturing a pin of a wall bracket when the retractable awning is in the stowed configuration. The pin may extend between legs of a U-shaped wall bracket.

The spherical plain bearings may each include an inner ring having a spherical convex outside surface and an outer ring having a correspondingly spherical but concave inside surface, wherein the rings cooperate to permit tilting movement between the first and second extension arms and the roller tube under high wind loading. The inner rings may be attached to the roller tube and the outer rings may be attached to the extension arms.

The roller tube may be made up of a plurality of shorter hollow segments interconnected through solid aluminum bars positioned at the segment joints. This arrangement provides, for example, for compactness in shipping and strength after assembly. The aluminum bars and hollow segments overlap and pins may be received in corresponding openings through the hollow segments and the aluminum bars for securing the components together.

The other end of the awning is configured for being attached to a supporting wall, and when attached to the supporting wall, may be positioned vertically above attachment points of the first and second brace arms and the supporting wall.

The awning may further include eyelets or like structure for attaching tie-downs thereto.

The fabric awning may be constructed of air-permeable fabric, and may further include a waterproof coating.

Frame members of the extension arms, roller tube and brace arms may include telescoping parts for length adjustment, compactness in shipping, and ease of assembly.

Ends of the first and second extension arms and the first and second brace arms may be pivotally attached to the support wall such the extension and brace arms can be rotated vertically against the support wall when the awning is in the stowed configuration, and rotated to an angle relative to the supporting wall when the awning is in the deployed configuration. The support wall may be the wall of a recreational vehicle, trailer, mobile home, building, etc.

The roller tube may terminate at one or more ends in a hexagon-shaped head or other head shape for engaging with a crank handle for rotating the roller tube to wind the fabric awning on the roller tube.

Additional features, aspects and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present invention are better understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

FIG. 1 is an exploded view of major frame components of the retractable awning according to an embodiment of the present invention;

FIG. 2 is a side elevation view showing the awning assembly in a deployed configuration;

FIG. 3 is a side elevation view of a trailer having a wall that may serve as the supporting wall of the retractable awning of the present invention;

FIG. 4 is a detailed perspective view of a hook on an extension arm for capturing a pin of a wall bracket to hold the awning in a stowed configuration;

FIG. 5 is an exploded perspective view showing the installation of a wall bracket to a supporting wall;

FIGS. 6a, 6b and 6c illustrate assembly steps of a roller tube of the present invention;

FIG. 7 is a sectional view through a supporting wall showing the attachment of the fabric awning to the supporting wall;

FIG. 8 is a detailed view of a spherical plain bearing at the end of an extension arm; and

FIG. 9 is a cross-sectional view through one end of the roller tube at the location of the spherical plain bearing.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which exemplary embodiments of the invention are shown. However, the invention may be embodied in many different forms and should not be construed as limited to the representative embodiments set forth herein. The exemplary embodiments are provided so that this disclosure will be both thorough and complete, and will fully convey the scope of the invention and enable one of ordinary skill in the art to make, use and practice the invention. Like reference numbers refer to like elements throughout the various drawings.

Referring to the drawings, provided herein is an embodiment of a wind-resistant retractable awning, shown generally at reference numeral 10. The retractable awning generally includes a fabric awning 12, an adjustable and flexible supportive frame, and a plurality of brackets and bearings for making flexible frame connections and attachments to a supporting wall 14. The supporting wall 14 may be an exterior wall of a trailer, recreational vehicle, mobile home, building or any other structure that could benefit from the retractable awning 10. A trailer is shown in FIG. 3 as one example of a conveyance including a supporting wall to which the retractable awning can be attached. The manner by which the frame member interconnections are made, brackets are installed and fabric awning is attached provide for easy and ready installation, operation and repair by the consumer. The retractable awning 10 may be installed as original equipment or as a kit for retrofit applications. The awning is configured to move between a stowed configuration and a deployed configuration, and movement may be manual or automated.

Referring to FIGS. 1 and 2, the retractable awning 10 generally includes a fabric awning 12, a roller tube 24 upon which the fabric awning 12 is wound, first and second extension arms 16, 18 that serve as the main awning support members, and first and second brace arms 20, 22. The first extension arm 16 and first brace arm 20 are slidably coupled and support one end of the roller tube 24, while the second extension arm 18 and second brace arm 22 are slidably coupled and the support the other end of the roller tube 24. The first and second sets of arms thus form spaced arms that cooperatively support the roller tube 24 in a generally horizontal position in both the deployed and stowed configurations.

Each of the first and second extension arms 16, 18 may include telescoping members that can be locked at various lengths as known in the art of telescoping parts. The length of the first and second extension arms 16, 18 can be shortened, for example, when the awning is in the stowed configuration or partially deployed, and lengthened when the awning is fully deployed. The length of the first and second extension arms 16, 18 can also be adjusted to change the pitch of the fabric awning 12. One end of each of the first and second extension arms 16, 18 is coupled to the roller tube 24, while the other end of each of the extension arms is pivotally attached to the supporting wall 14, both of which are described in detail below. Each of the first and second extension arms 16, 18 thus include an attached end and a movable end, the moveable end being movable between a position generally against the supporting wall to a position at an angle with respect to the supporting wall 14.

The first and second brace arms 20, 22 are slidably coupled to the respective first and second extension arms 16, 18 along the length thereof. The brace arms 20, 22 are pivotally attached to the supporting wall 14 at one end and engage mid-span along the length of the extension arms 16, 18 through a sleeve that surrounds the extension arms. In this configuration, the coupled ends of the brace arms are able to slide along the length of their respective extension arm while maintaining engagement therewith as the awning moves between the stowed and deployed configurations. The brace arms 20, 22 can be locked along the length of the extension arms by any suitable locking means. The first and second brace arms 20, 22 are pivotally attached to the supporting wall 14 at a position vertically spaced above the attachment points of the first and second extension arms 16, 18 and the supporting wall 14. As shown in FIG. 2, the end of the brace arm 20 coupled to the extension arm 16 includes a pivoting connection that allows the brace and extension arms to fold generally parallel when the awning is stowed against the supporting wall 14.

The fabric awning 12 is attached at one end to the roller tube 24 and at the other end to the supporting wall 14. The fabric awning 12 can be constructed from any material known in the art of awnings. In a preferred embodiment, the fabric awning 12 is constructed of air-permeable material. The fabric awning 12 can optionally include a waterproof coating. The fabric awning 12 can have any width or length depending on the application. The dimensions of the fabric awning 12 partly dictate the length of the supporting frame members. As shown in FIG. 2, the fabric awning 12 is attached to the supporting wall 14 at a position vertically above the attachment points of the first and second brace members 20, 22 and the supporting wall. In this arrangement, the frame members are positioned beneath the fabric awning 12 and are protected from the elements. This arrangement is also advantageous in that the weight of the underlying frame members helps deploy the awning and provides weight to resistant upward lifting forces from the wind.

Referring to FIGS. 4 and 5, a hook 30 may be provided near the roller tube ends of each of the first and second extension arms 16, 18 for capturing a pin 32 of a bracket 26 attached to the supporting wall 14. The hook 30 captures the pin 32 when the first and second arms are stowed against the supporting wall 14. The extension arms are released from their respective pins 32 by moving the hooks 30 vertically upward above the pins such that the pins are free from capture and clear of the hooks and the extension arms can be pulled away from the supporting wall.

The pins 32 bridge the gap between legs of a U-shaped bracket 26 configured to be attached to the supporting wall 14. A plurality of brackets 26 may be used for pivotally attaching ends of the first and second extension arms 16, 18 to the supporting wall 14, pivotally attaching ends of the first and second brace arms 20, 22 to the supporting wall, and presenting pins 32 for capture by the hooks. In one example, the retractable awning may utilize six brackets for installation.

Each bracket 26 includes a U-shaped member 34 positioned on the outside of the supporting wall 14, a backing plate 36 positioned on the inside of the supporting wall, a pin 32, and one or more fasteners 38 for securing the U-shaped member and the plate together through the wall. As shown, the fasteners 38 may be externally threaded bolts and internally threaded nuts. The use of two spaced fasteners prevents the bracket from rotating relative to the supporting wall. Other bracket configurations are envisioned and may be utilized based on the type and construction of the supporting wall 14.

Referring to FIGS. 6a-6c, the roller tube 24 includes a plurality of hollow segments 42 interconnected through internal solid aluminum bars 44 positioned at the joints between hollow segments. The solid aluminum bars 44 are lightweight and provide strength to the hollow segments 42 at the joints. Pins 46 are installed through aligned openings in the hollow segments 42 and the aluminum bars 44 to prevent the segments from being pulled apart or rotated when the roller tube is assembled. The hollow segments 42 collectively define an elongate linear track 48 for attaching one end of the fabric awning to the roller tube 24. To assemble the roller tube 24, the hollow segments 42 are first slid over the ends of the aluminum bar 44 as shown in FIG. 6a, the hollow segments 42 are then moved in the direction toward each other as shown in FIG. 6b, and finally the pins 46 are inserted through the openings when the openings through the components are aligned as shown in FIG. 6c. The pins 46 may also be received through openings or grommets in the fabric awning 12 to hold the fabric awning in the track 48.

Referring to FIG. 7, the fabric awning 12 is mounted to the supporting wall 14 using a track 40 secured over the awning fabric to hold the fabric between the track and the supporting wall. The fabric awning 12 and track 40 are preferably mounted above the molding where the wall and roof of the structure meet for aesthetics, pitch and drainage.

Referring to FIGS. 8 and 9, the first and second extension arms 16, 18 are coupled to their respective ends of the roller tube 24 through roller heads 28 housing spherical plain bearings 50 that permit tilting movement between the extension arms and the roller tube. This movement between components is critical for accommodating high wind loading without damage to the awning. The spherical plain bearings 50, sliding coupling movement of the brace arms and extension arms, and pivotal attachment of the arms to the supporting wall cooperatively allow the awning frame to flex and tilt under high wind loading. The awning, for example, is configured withstand winds in excess of 60 mph when deployed. Each roller head 28 may further include an eyelet 60 or like structure for attaching a tie-down thereto for staking the awning to the ground or strapping to other structure.

Referring specifically to FIG. 9, a cross-sectional view through one end of the roller tube 24 and roller head 28 shows the position, functionality and benefit of the spherical plain bearing 50. The spherical plain bearings 50 allow the roller tube to rotate within and relative to the roller heads 28 to wind and unwind the fabric awning. Rolling assistance may be provided by conventional methods know in the art of awnings and shades. The spherical plain bearings 50 also permit tilting between the roller tube 24 and extension arms 16, 18 such that the awning can flex, twist and tilt in high winds to relieve stresses on the frame components.

Each spherical plain bearing 50 includes an inner ring 52 secured around the roller tube 24 and an outer ring 54 secured within the roller head 28. The inner ring 52 defines a spherical convex outside surface and the outer ring 54 defines a corresponding spherical but concave inside surface. The complimentary spherical shapes allow for freedom of movement between the rings in various directions. For example, tilting movement of the roller tube 24 is shown by the directional arrows in FIG. 9.

The roller tube 24 may terminate at one or more of its ends in a hex-head or other shaped head for engaging with a crank handle for turning the roller tube to wind and unwind the fabric awning 12.

The extension arms 16, 18, brace arms 20, 22 and roller tube segments 42 may be constructed from metal such as aluminum for lightweight, strength and resistance to corrosion.

The retractable awning 10 may include additional components, for example, hook-and-loop fasteners and other fasteners for maintain the fabric awning 12 in the wound configuration. In an alternative embodiment, the roller tube segments 42 may have a large hex fitting at one end, and the other end of one half may be hollow and the other end of the other half may have a solid, grooved or round bar with holes. To assemble the roller tube 24, the solid bar of the second half may be inserted into the hollow end of the first half. The two halves may then be pushed completely together, lining up the awning fabric track of both bars and the two holes in the first half with the holes in the grooved bar of the second half. Once the bars are together, roll pins may be driven into the holes to secure the two halves together. Screws may be advanced into the roll pins to further secure them in place.

To deploy the awning, at least one of the first and second extension arms 16, 18 are first raised to release the pin(s) 32 from its respective hook(s). Once released, the roller tube 24 is gently pivoted away from the supporting wall 14 to unwind the fabric awning 12. To stow the awning, a crank handle is engaged with the end of the roller tube 24, the roller tube is rotated to wind the fabric awning 12 for stowing.

The foregoing description provides embodiments of the invention by way of example only. It is envisioned that other embodiments may perform similar functions and/or achieve similar results. Any and all such equivalent embodiments and examples are within the spirit and scope of the present invention.

Claims

1. A retractable awning, comprising:

a fabric awning;

a roller tube defining a linear track along the length thereof for attaching a first end of the fabric awning to the roller tube;

first and second extension arms coupled to opposing ends of the roller tube through spherical plain bearings; and

first and second brace arms slidably coupled along the length of the respective first and second extension arms.

2. The retractable awning of claim 1, wherein the first and second extension arms each include a hook for capturing a pin of a wall bracket when the retractable awning is stowed.

3. The retractable awning of claim 2, wherein the pin extends between legs of a U-shaped bracket attached to a supporting wall.

4. The retractable awning of claim 1, wherein the spherical plain bearings each include an inner ring having a spherical convex outside surface and an outer ring having a correspondingly spherical but concave inside surface that cooperate to allow tilting movement between the first and second extension arms and the roller tube under high wind loading.

5. The retractable awning of claim 4, wherein the inner rings of the spherical plain bearings are attached to the roller tube and the outer rings are attached to the first and second extension arms.

6. The retractable awning of claim 1, wherein the roller tube comprises a plurality of hollow segments joined through solid aluminum bars positioned within the hollow segments at joints between the hollow segments.

7. The retractable awning of claim 6, wherein pins are received in corresponding openings through the hollow segments and the aluminum bars for securing the hollow segments to the aluminum bars.

8. The retractable awning of claim 1, wherein a second end of the awning is configured for being attached to a supporting wall.

9. The retractable awning of claim 8, wherein the second end of the awning, when attached to the supporting wall, is positioned vertically above attachment points of the first and second brace arms and the supporting wall.

10. The retractable awning of claim 1, further comprising eyelets on the first and second extension arms for attaching tie-downs thereto.

11. The retractable awning of claim 1, wherein the fabric awning is constructed of air-permeable fabric.

12. The retractable awning of claim 1, wherein the fabric awning includes a waterproof coating.

13. The retractable awning of claim 1, wherein the first and second extension arms include telescoping segments.

14. The retractable awning of claim 1, wherein ends of the first and second extension arms and first and second brace arms are configured for pivotal attachment to a support wall.

15. The retractable awning of claim 1, wherein the roller tube terminates at one end in a hexagon-shaped head for engaging with a crank handle for rotating the roller tube to wind the fabric awning.

16. A retractable awning, comprising:

an fabric awning;

a roller tube attached to a first end of the fabric awning and upon which the fabric awning is wound when the awning is stowed and unwound from when the awning is deployed;

first and second spaced extension arms coupled to opposing ends of the roller tube through spherical plain bearings and supporting the roller tube in a generally horizontal position; and

first and second brace arms slidably coupled along the length of the respective first and second extension arms, the first and second brace arms being substantially shorter than the first and second extension arms.

17. The retractable awning of claim 16, wherein the first and second extension arms each include a hook for capturing a pin of a bracket secured to a supporting wall.

18. The retractable awning of claim 16, wherein the spherical plain bearings each include an inner ring having a spherical convex outside surface and an outer ring having a correspondingly spherical but concave inside surface that cooperate to allow tilting movement between the first and second extension arms and the roller tube under high wind loading.

19. The retractable awning of claim 16, wherein the roller tube comprises a plurality of hollow segments joined through solid aluminum bars positioned within the hollow segments at joints between the hollow segments.

20. The retractable awning of claim 16, wherein a second end of the awning is configured for being attached to a supporting wall, and when attached to the supporting wall is positioned vertically above attachment points of the first and second brace arms and the supporting wall.