TECHNICAL FIELD This disclosure relates generally to tilting assemblies for cantilevered umbrellas, and more particularly, tilting assemblies for cantilevered umbrellas utilizing worm gears.
BACKGROUND Cantilevered umbrellas provide shade from the sun. Traditional cantilevered umbrellas have a dome-shaped canopy that is suspended from a cantilevered arm. The canopy is typically opened using a crank mechanism. Because of this, traditional cantilevered umbrellas can be cumbersome to operate and position to ensure that the shade provided is maximized.
SUMMARY Cantilevered umbrellas are disclosed herein. In one aspect of the present disclosure, a cantilevered umbrella is disclosed that includes a mast, a cantilevered arm defining a longitudinal axis and being rotationally fixed in relation to the mast, a canopy that is supported by the cantilevered arm and movable between collapsed and expanded positions, and a tilting assembly that is operatively connected to the canopy to tilt the canopy along a tilt axis that extends in generally parallel relation to the longitudinal axis of the cantilevered arm.
In certain embodiments, the tilting assembly may include a gear assembly with first and second gear members. In certain embodiments, the first gear member may define a worm and the second gear member may define an output shaft and a plurality of teeth that are in engagement with the worm such that rotation of the first gear member causes corresponding rotation of the second gear member. In certain embodiments, the first gear member may define a first axis of rotation and the second gear member may define a second axis of rotation, wherein the first axis of rotation subtends an acute angle (e.g., approximately 45°) with a reference axis that intersects the first axis of rotation and extends in parallel relation to the second axis of rotation. In certain embodiments, the tilting assembly may further include a drive member that extends axially through the cantilevered arm. In certain embodiments, the drive member may be positioned about the first gear member such that axial movement of the drive member causes rotation of the first gear member and the second gear member. In certain embodiments, the drive member may include a cogged belt defining a first belt portion and a second belt portion. In certain embodiments, the first and second belt portions may be connected by at least one cable. In certain embodiments, the tilting assembly may further include a knuckle assembly that is positioned adjacent an end of the cantilevered arm and is operatively connected to the canopy. In certain embodiments, the knuckle assembly may include a stationary housing and a movable housing that is in mechanical cooperation with the gear assembly such that actuation of the gear assembly causes displacement of the movable housing to thereby tilt the canopy. For example, in certain embodiments, the output shaft of the second gear member may be connected to the movable housing such that actuation of the gear assembly causes rotation of the output shaft and displacement of the movable housing. It is envisioned that the cantilevered umbrella described above may include any combination of the features and the elements described in this paragraph.
In another aspect of the present disclosure, a cantilevered umbrella is disclosed that includes a cantilevered arm; a canopy that is supported by the cantilevered arm; and a tilting assembly that is operatively connected to the canopy to tilt the canopy. The tilting assembly includes a worm gear assembly that is operatively connected to the canopy such that actuation of the worm gear assembly causes tilting of the canopy.
In certain embodiments, the tilting assembly may further include a drive member that extends axially through the cantilevered arm. In certain embodiments, the worm gear assembly may include a first gear member that defines a worm and a second gear member that defines an output shaft and a plurality of teeth that are in engagement with the worm such that rotation of the first gear member by the drive member causes corresponding rotation of the second gear member. In certain embodiments, the drive member may be positioned about the first gear member such that axial movement of the drive member causes rotation of the first gear member. In certain embodiments, the first gear member may define a first axis of rotation, and the second gear member may define a second axis of rotation, wherein the first axis of rotation subtends an acute angle (e.g., approximately 45°) with a reference axis that intersects the first axis of rotation and extends in parallel relation to the second axis of rotation. In certain embodiments, the drive member may include a cogged belt defining a first belt portion and a second belt portion. In certain embodiments, the first and second belt portions may be connected by at least one cable. In certain embodiments, the tilting assembly may further include a knuckle assembly that is positioned adjacent an end of the cantilevered arm and is operatively connected to the canopy. In certain embodiments, the output shaft may be in mechanical cooperation with the knuckle assembly such that rotation of the output shaft (of the second gear member) is transmitted to the knuckle assembly to thereby tilt the canopy. For example, in certain embodiments, the knuckle assembly may include a stationary housing and a movable housing that is in mechanical cooperation with the worm gear assembly (e.g., the movable housing may be in mechanical cooperation with the output shaft of the second gear member) such that actuation of the worm gear assembly causes displacement of the movable housing to thereby tilt the canopy. It is envisioned that the cantilevered umbrella described above may include any combination of the features and the elements described in this paragraph.
In another aspect of the present disclosure, a method of tilting a canopy of a cantilevered umbrella is disclosed that includes rotating a first gear member of a tilting assembly to thereby cause corresponding rotation of a second gear member operatively connected to the canopy to thereby tilt the canopy.
In certain embodiments, rotating the first gear member may include rotating a worm of the first gear member in engagement with teeth of the second gear member. In certain embodiments, rotation of the second gear member may cause displacement of a movable housing portion operatively connected to the second gear member and the canopy such that displacement of the movable housing portion causes the canopy to tilt. It is envisioned that the method described above may include any combination of the features and the elements described in this paragraph.
In another aspect of the present disclosure, a cantilevered umbrella is disclosed that includes a cantilevered arm defining a longitudinal axis; a canopy that is supported by the cantilevered arm; and a gear assembly that is operatively connected to the canopy to tilt the canopy along a tilt axis that extends in generally parallel relation to the longitudinal axis of the cantilevered arm. The gear assembly includes a first gear member and a second gear member that is in mechanical engagement with the first gear member such that, upon actuation of the gear assembly, rotation of the first gear member causes corresponding rotation of the second gear member.
In certain embodiments, the first gear member may define a worm and the second gear member may define a plurality of teeth that are in engagement with the worm. In certain embodiments, the first gear member may define a first axis of rotation and the second gear member may define a second axis of rotation that is different from the first axis of rotation. In certain embodiments, the first axis of rotation may subtend an acute angle with a reference axis that intersects the first axis of rotation and extends in parallel relation to the second axis of rotation. In certain embodiments, the acute angle may lie substantially within a range of approximately 30° to approximately 60°. For example, in certain embodiments, the acute angle may be approximately 45°. In certain embodiments, the cantilevered umbrella may further include a drive member that extends axially through the cantilevered arm. In certain embodiments, the drive member may be in mechanical cooperation with the gear assembly such that axial movement of the drive member causes actuation of the gear assembly. In certain embodiments, the drive member may be positioned about the first gear member such that axial movement of the drive member causes rotation of the first gear member. In certain embodiments, the cantilevered umbrella may further include a knuckle assembly that is positioned adjacent to an end of the cantilevered arm and is operatively connected to the canopy. In certain embodiments, the knuckle assembly may include a stationary housing and a movable housing that is rotatable in relation to the stationary housing. In certain embodiments, the movable housing may be in mechanical cooperation with the gear assembly such that actuation of the gear assembly causes rotation of the movable housing to thereby tilt the canopy. In certain embodiments, the second gear member may include an output shaft that is connected to the movable housing such that actuation of the gear assembly causes rotation of the output shaft to thereby rotate the movable housing. In certain embodiments, the cantilevered umbrella may further include a mast. In certain embodiments, the cantilevered arm may be rotationally fixed in relation to the mast. In certain embodiments, the canopy may be movable between a collapsed position and an expanded position. It is envisioned that the cantilevered umbrella described above may include any combination of the features and the elements described in this paragraph.
BRIEF DESCRIPTION OF THE DRAWINGS The invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. Throughout the present disclosure, the term “proximal,” and variations thereof, should be understood as referring to components that are closer to the mast of the disclosed umbrella and the term “distal,” and variations thereof, should be understood as referring to components that are further from the mast of the disclosed umbrella. Additionally, it is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.
FIG. 1 is a perspective view of a cantilevered umbrella in an open position.
FIG. 2 is a schematic drawing of an upper portion of the cantilevered umbrella.
FIG. 3 is a schematic drawing of a first embodiment of the cantilevered umbrella.
FIG. 4 is a schematic drawing of an over-center spring assembly of the cantilevered umbrella in a first position.
FIG. 5 is a schematic drawing of an over-center spring assembly of the cantilevered umbrella in a second position.
FIG. 6 is a schematic drawing of a second embodiment of the cantilevered umbrella.
FIG. 7 is a perspective view of a handle of the cantilevered umbrella.
FIG. 8 is a perspective, cross-sectional view of a first embodiment of a tilting assembly of the cantilevered umbrella.
FIG. 9 is a perspective view of the cantilevered umbrella rotated in the open position.
FIG. 10 is a perspective, cross-sectional view of a second embodiment of the tilting assembly of the cantilevered umbrella.
FIG. 11 is a schematic drawing of the cantilevered umbrella in a collapsed position.
FIG. 12 is a perspective view of the cantilevered umbrella including an alternate embodiment of a tilting assembly.
FIG. 13 is a perspective view of the cantilevered umbrella with a tilted canopy.
FIG. 14 is a perspective view of a cantilevered arm of the umbrella assembly illustrating the titling assembly seen in FIG. 12.
FIG. 15 is a partial, side, perspective view of a collar supporting the cantilevered arm and a handle assembly of the tilting assembly.
FIG. 16 is a top, perspective view of the collar seen in FIG. 15.
FIG. 17 is a rear, perspective view of the collar seen in FIG. 15.
FIG. 18 is an exploded view of the cantilevered arm and the tilting assembly seen in FIG. 12.
FIG. 19 is a partial, rear view of the cantilevered arm and the tilting assembly with parts separated.
FIG. 20 is a top, perspective view illustrating a driver and a drive member of the tilting assembly.
FIGS. 21 and 22 are end, perspective views illustrating a knuckle assembly and a worm gear assembly of the tilting assembly with parts separated.
FIG. 23 is a side, perspective view of the worm gear assembly seen in FIGS. 21 and 22.
FIG. 24 is an end, perspective view illustrating the knuckle assembly and the worm gear assembly with parts separated.
FIG. 25 is a partial, cross-sectional view of the cantilevered umbrella and the tilting assembly.
FIG. 26 is a side, perspective view of a tension adjustment mechanism.
FIG. 27 is a partial, side view of the cantilevered arm illustrating access to the tension adjustment mechanism seen in FIG. 26.
DETAILED DESCRIPTION The disclosure herein is directed to a cantilevered umbrella 10 that uses a constant force spring 103, instead of a crank, to assist with the operation of the cantilevered umbrella 10. The constant force spring 103 can reduce the force necessary to open the cantilevered umbrella 10 to an open position while also counter balancing the weight of a cantilevered arm 40 and a canopy 60. An over-center spring assembly 150 can be provided that assists with extending the canopy 60 and holding the canopy 60 in the open position.
As illustrated in FIG. 1, the cantilevered umbrella 10 can be comprised of a base 20, a mast 30, the cantilevered arm 40, a support arm 50, and the canopy 60. The base 20 supports the cantilevered umbrella 10 and can have any configuration. In the illustrated, non-limiting example, the base 20 is hollow and has a pentagonal configuration with a collar 21 that surrounds the mast 30 where the mast 30 extends from the base 20. Examples of other configurations include triangular, rectangular, and hexagonal, among others. Alternatively, the base 20 could be solid or substantially solid. If the base 20 is hollow, the base 20 can include an opening or door (not shown) that allows a user to fill the base 20 with sand or a similar type of material to provide additional weight to counter balance the cantilevered umbrella 10.
The mast 30 can have an elongated configuration with an internal cavity 31 (shown in FIG. 2) that houses a carriage 102, the over-center spring assembly 150, and the constant force spring 103. A rail 32 can be formed on an outer surface 33 of the mast 30 to guide a guide 101 that is attached to the carriage 102. To reduce frictional loads acting on the carriage 102, the guide 101 can include ball bearings (not shown). The rail 32 can include a slot 36 (shown in FIG. 7) that extends the length of the rail 32 either in the center or on the side of the rail 32. In the illustrated, non-limiting example, the slot 36 is on the center of the rail 32, and the rail 32 extends approximately 75 percent of the length of the mast 30 from the collar 21 of the base 20. It is anticipated that the rail 32 could be shorter or longer, such as the entire length of the mast 30. The mast 30 may have a substantially tapered upper end 34 and an extension 35 that is closer to the upper end 34 than the base 20. The extension 35 can house a portion of the over-center spring assembly 150 (shown in FIG. 2).
As shown in FIG. 2, a first end 51 of the support arm 50 is pivotally connected to the upper end 34 of the mast 30 through the use of a conventional fastener (not shown) that is capable of pivotal attachment. The support arm 50 can have an arcuate configuration with a circular cross-sectional configuration. The first end 51 and a second end 52 of the support arm 50 can have a substantially rectangular cross-sectional configuration with rounded ends and an aperture 53 extending therethrough. The support arm 50 can be solid or hollow. The second end 52 of the support arm 50 is pivotally connected to a flange 54 integrally formed on a sleeve 55 that surrounds an outer surface 43 of the cantilevered arm 40. The flange 54 can have rounded ends and an aperture (not shown) extending therethrough to accept a conventional fastener that pivotally attaches the second end 52 of the support arm 50 to the flange 54. A bore 56 can extend longitudinally through the sleeve 55 and have a large enough diameter that the cantilevered arm 40 can extend through the bore 56 and rotate within the sleeve 55, which allows the cantilevered arm 40 to be rotatably connected to the support arm 50.
The cantilevered arm 40 can be straight or have a slight bend as it extends longitudinally from a first end 41 to a second end 42. The first end 41 of the cantilevered arm 40 can include a knuckle 44 that is pivotally connected to the guide 101. The second end 42 of the cantilevered arm 40 can include an extension 45 that is pivotally connected to the canopy 60 (shown in FIG. 1). The cantilevered arm 40, including the knuckle 44 and the extension 45, has a hollow portion 46 that allows a canopy cable 65 to pass freely through the cantilevered arm 40 to the mast 30.
As illustrated in FIG. 3, the canopy 60 can be comprised of a plurality of upper ribs 61, a plurality of lower ribs 62, a lower cap 63, an upper cap 64, the canopy cable 65, a center support 66, and a covering 68. Other canopy 60 configurations are possible. In the illustrated, non-limiting example, the upper ribs 61 are longer than the lower ribs 62, and the same number of upper ribs 61 and lower ribs 62 are provided. The upper ribs 61 and the lower ribs 62 can have any cross-sectional configuration, such as substantially circular or substantially rectangular. One end of each upper rib 61 can be pivotally connected to the upper cap 64, while the other end of each upper rib 61 can be free. One end of each lower rib 62 can be pivotally connected to a corresponding upper rib 61, and the other end of each lower rib 62 can be pivotally connected to the lower cap 63. The lower cap 63 is attached to one end of the center support 66, and the upper cap 64 is attached to the other end of the center support 66. The center support 66 can have any cross-sectional configuration, such as substantially circular or substantially rectangular. The center support 66 can be telescopic and have a hollow portion 67 that allows the canopy cable 65 to pass from the lower cap 63, where one end of the canopy cable 65 is attached, to the hollow portion 46 of the cantilevered arm 40. The covering 68, made from any suitable material such as cloth or plastic, is attached to or suspended from the upper ribs 61 to provide shade coverage or some rain protection.
The canopy 60 is moveable between the open position and a collapsed position. In the open position, shown in FIG. 1, the upper ribs 61 are extended generally horizontal, and the center support 66 is in its shortest length if the center support 66 is telescoping. In the collapsed position, shown in FIG. 11, the upper ribs 61 are extended generally vertical, and the center support 66 is in its longest length if the center support 66 is telescoping. Pulling and loosening the canopy cable 65 moves the canopy 60 between the open position and the collapsed position.
As shown in FIG. 3, the canopy cable 65 extends through the mast 30, the cantilevered arm 40, and the center support 66. One end of the canopy cable 65 is connected to a point 74 within the internal cavity 31 of the mast 30 near the base 20, and the other end is connected to the lower cap 63 of the canopy 60. To assist with the transition of the canopy cable 65 between the canopy 60 and the cantilevered arm 40, a first pulley 71 can be included within the hollow portion 46 of the extension 45. A second pulley 72 can be included in the knuckle 44 of the cantilevered arm 40. From the second pulley 72, the canopy cable 65 enters the mast 30 via the slot 36 on the rail 32 of the mast 30. A third pulley 73 can be included on the carriage 102 inside the internal cavity 31 of the mast 30 to assist with the transition of the canopy cable 65 from the cantilevered arm 40 into the mast 30.
The constant force spring 103 counterbalances the weight of the cantilevered arm 40 and the canopy 60. One end of the constant force spring 103 is attached or connected to a second end 104 of the carriage 102, and the other end of the constant force spring 103 is attached or connected to the mast 30 within the internal cavity 31. In the illustrated, non-limiting example, the other end of constant force spring 103 is attached or connected near the upper end 34 of the mast 30 within the internal cavity 31. Because the carriage 102 is moveable within the internal cavity 31 of the mast 30, the constant force spring 103 uncoils or extends as the carriage 102 is lowered and recoils or retracts as the carriage 102 is raised within the internal cavity 31 of the mast 30. Lowering of the carriage 102 results in the canopy 60 being moved to the collapsed position, and raising of the carriage 102 results in the canopy 60 being moved to the open position. Because the cantilevered arm 40 is pivotally connected to the guide 101 on the carriage 102, the lowering of the carriage 102 moves the cantilevered arm 40 to a vertical position, and the raising of the carriage 102 moves the cantilevered arm to a horizontal position.
The over-center spring assembly 150 with a gas spring 151 and a forked lever arm 152 can be provided within the internal cavity 31 of the mast 30. In the illustrated, non-limiting example, the over-center spring assembly 150 is provided within the extension 35 of the mast 30, best seen in FIG. 2. One end of the gas spring 151 can be attached to the mast 30 above the constant force spring 103, and the other end of the gas spring 151 is pivotally connected to the forked lever arm 152 below the constant force spring 103. The forked lever arm 152 has a recess 153 and an aperture 154 that allows the forked lever arm 152 to be pivotally connected to the gas spring 151. The recess 153 on the forked lever arm 152 is sized so that it can be engaged by a roller 105 extending from the second end 104 of the carriage 102 as the carriage 102 is raised within the internal cavity 31 of the mast 30.
To assist with opening the canopy 60 and holding the canopy 60 in the open position, the over-center spring assembly 150 is moveable between a first position, shown in FIG. 4, and a second position, shown in FIG. 5. In the first position, the gas spring 151 holds the forked lever arm 152 so that the recess 153 of the forked lever arm 152 is angled slightly downward and is able to accept the roller 105 on the carriage 102. In the second position, the gas spring 151 holds the forked lever arm 152 so that the recess 153 of the forked lever arm 152 is angled substantially horizontal to retain the roller 105 on the carriage 102.
Because of the line of rotation of the forked lever arm 152 and the gas spring 151, the forked lever arm 152 will mechanically want to rest in either the first position or the second position. For example, if the forked lever arm 152 is in the first position and is moved away from the first position by the roller 105 on the carriage 102, the forked lever arm 152 will be forced back into the first position by the gas spring 151 unless enough force is applied by the roller 105 of the carriage 102 to move the forked lever arm 152 at least halfway toward the second position. Once enough force has been applied by the roller 105 of the carriage 102 to move the forked lever arm 152 past the halfway point, the force of the gas spring 151 will assist in moving the forked lever arm 152 into the second position. The same scenario is true for moving from the second position into the first position.
In a second embodiment of the cantilevered umbrella (10), the over-center spring assembly 150 is omitted, which is illustrated in FIG. 6. The constant force spring 103 is replaced with a gas spring 112 that is connected to the mast 30 and the carriage 102. For all other intents and purposes, the first and second embodiments of the cantilevered umbrella (10) are the same and interchangeable. In other words, the gas spring 112 could be used with the over-center spring assembly 150 as described in relation to the first embodiment, and the over-center spring assembly 150 could be omitted when the constant force spring 103 is used instead of the gas spring 112. Any reference to the constant force spring 103 in this disclosure applies to the gas spring 112 as well.
To allow pivotal rotation of the cantilevered arm 40 and the canopy 60, a tilting assembly is provided within the knuckle 44 of the cantilevered arm 40 that is activated by a handle 106 with a lever 107. As seen in FIGS. 7-8, the handle 106 extends longitudinally along the mast 30 and can be provided with a plurality of apertures 108, 109 that can be used as handgrips. In the illustrated, non-limiting example, there are two substantially similar apertures 108 along the right and left sides of the handle 106, which allow the handle 106 to be operated from either side of the cantilevered umbrella 10. A third aperture 109 is along the bottom of the handle 106. The handle 106 can have an arcuate cross-sectional configuration that bends slightly around the mast 30. The underside of the handle 106 can also include a protrusion or similar feature (not shown) that allows the handle 106 to be secured to the carriage 102 with a conventional fastener (now shown), such as a bolt. The lever 107 extends from an upper region of the handle 106 and has a flange 110 extending substantially perpendicular to the handle 106. A free end of the flange 110 has an aperture 111 extending therethrough.
According to a first embodiment 80 of the tilting assembly, the lever 107 is pivotally connected to a plunger 81 through the use of a conventional fastener (not shown). The plunger 81 is elongated and extends through the hollow portion 46 of the knuckle 44. The plunger 81 has a hollow portion to allow passage of the canopy cable 65 (not shown in FIGS. 7-8) and includes a first shoulder 82 that is complementary to a first shoulder 49 formed in the knuckle 44. When the handle 106 is substantially vertical, a slight gap is formed between the first shoulder 82 of the plunger 81 and the first shoulder 49 of the knuckle 44. The end opposite the lever 107 provides a face plate 83 with a contoured surface 84. The face plate 83 surrounds the plunger 81 and forms a second shoulder 88 for a first spring 89 that surrounds the plunger 81. The other end of the first spring 89 engages a second shoulder 59 formed in the knuckle 44. An outer circumference of the face plate 83 extends toward the mast 30, and the contoured surface 84 is provided on the end of the face plate 83 that faces the mast 30.
A joint 85 is connected to the cantilevered arm 40 such that rotation of the joint translates into rotation of the cantilevered arm 40 and the canopy 60. The joint 85 having a substantially tubular configuration is housed within the knuckle 44 adjacent to a second spring 90. The joint 85 includes an internal face plate 86 having a contoured surface 87 that faces away from the mast 30. The contoured surface 87 of the joint 85 is engageable with the contoured surface 84 of the plunger 81. When the handle 106 is substantially vertical, a slight gap is formed between the contoured surface 87 of the joint 85 and the contoured surface 84 of the plunger 81.
The first embodiment 80 of the tilting assembly rotates the cantilevered umbrella 10, as shown in FIG. 9, by pivoting the bottom of the handle 106 away from the mast 30. As a result, the lever 107 on the handle 106 pulls the plunger 81 toward the mast 30 so that the contoured surface 84 of the plunger 81 engages the contoured surface 87 of the joint 85. With the contoured surfaces 84, 87 engaged, the cantilevered arm 40 will rotate along with the handle 106. Once the desired rotation of the cantilevered arm 40 and the canopy 60 is achieved, the handle 106 is returned and secured to the substantially vertical position along the mast 30. The first spring 89 will push the face plate 83 of the plunger 81 away from the face plate 86 of the joint 85. The cantilevered arm 40 and the canopy 60 will remain in the desired position.
The tilting assembly is simplified in a second embodiment 180, which is shown in FIG. 10. The second embodiment 180 of the tilting assembly includes a plunger 181 with a contoured surface 182, a spring 183, and a contoured surface 184 on the cantilevered arm 40. Similar to the plunger 81 of the first embodiment 80, the plunger 181 of the second embodiment 180 is pivotally connected to the lever 107, is disposed within the knuckle 44, and has a hollow portion 185 that allows the canopy cable 65 to pass through the plunger 181. The spring 183 surrounds the plunger 181 and engages a shoulder 186 formed in the knuckle 44 and a shoulder 187 formed on the plunger 181. The contoured surface 182 on the plunger 181 faces away from the mast 30. The contoured surface 184 on the cantilevered arm 40 faces toward the mast 30.
Similar to the first embodiment 80 of the tilting assembly, the cantilevered umbrella 10 is rotated by pivoting the bottom of the handle 106 away from the mast 30. As a result, the lever 107 on the handle 106 pulls the plunger 181 away from the mast 30 so that the contoured surface 182 of the plunger 181 is pulled away from the contoured surface 184 of the cantilevered arm. With the contoured surfaces 182, 184 disengaged, the cantilevered arm 40 is free to rotate with the handle 106. Once the desired rotation of the cantilevered arm 40 and the canopy 60 is achieved, the handle 106 is returned and secured to the substantially vertical position along the mast 30. The spring 183 will push the contoured surface 182 of the plunger 181 toward the contoured surface 184 of the cantilevered arm 40.
To open the cantilevered umbrella 10 from the collapsed position shown in FIG. 11, the handle 106 is pushed toward the upper end 34 of the mast 30 with the guide 101 guided along the rail 32 on the mast 30. Because of the constant force spring 103 and the over-center spring assembly 150, the carriage 102 raises within the internal cavity 31 of the mast 30 in an essentially effortless operation. As the carriage 102 rises, the constant force spring 103 recoils, the cantilevered arm 40 moves to the substantially horizontal position, and the lower cap 63 of the canopy 60 is brought closer to the upper cap 64 by the canopy cable 65, which opens the canopy 60. As the carriage 102 approaches the over-center spring assembly 150, the roller 105 on the carriage 102 will engage the recess 153 on the forked lever arm 152 without input from the user. The forked lever arm 152 is pushed upward by the roller 105 on the carriage 102. Once the forked lever arm 152 is pushed at least halfway from the first position to the second position, the over-center spring assembly will provide additional force to fully extend the canopy 60 and hold the canopy 60 in the open position. Once fully extended, the cantilevered umbrella 10 can be rotated as previously described depending the embodiment of the tilting assembly that is present.
To return the cantilevered umbrella 10 to the collapsed position, the handle 106 is pushed toward the base 20 with the guide 101 guided along the rail 32 on the mast 30. As the carriage 102 lowers within the internal cavity 31 of the mast 30, the constant force spring 103 uncoils, the cantilevered arm 40 moves to the substantially vertical position, and the lower cap 63 of the canopy 60 is moved away from the upper cap 64 by the canopy cable 65, which collapses or closes the canopy 60. When the roller 105 on the carriage 102 disengages the recess 153 on the forked lever arm 152, the over-center spring assembly 150 holds the forked lever arm 152 is the second position, which allows the forked lever arm 152 to be ready to accept the roller 105 on the carriage 102 the next time the cantilevered umbrella 10 is moved to the open position.
With reference now to FIGS. 12-27, another embodiment of the tilting assembly will be discussed, which is identified by the reference character 200. The tilting assembly 200 allows for movement (e.g., pivoting or rotation) of the canopy 60 about a tilt axis T that extends in generally parallel relation to a longitudinal axis X defined by the cantilevered arm 40. More specifically, the tilting assembly 200 allows for movement of the canopy 60 in the directions identified by arrows 1 and 2 (FIG. 12) through a range of motion that lies substantially within the range of approximately 60° to 120°, although movement through a larger or smaller range of motion would not be beyond the scope of the present disclosure. In contrast to the preceding embodiments, during tilting of the canopy 60, the cantilevered arm 40 remains rotationally stationary.
The tilting assembly 200 includes a handle assembly 300 (FIG. 13), a drive guard 400 (FIGS. 14, 18, 19), a drive mechanism 500 (FIG. 18), and a knuckle assembly 600 (FIGS. 14, 18, 21). The handle assembly 300 is connected to the mast 30 via a movable collar 302 (FIGS. 12, 13, 15-17). More specifically, the collar 302 includes a (first) yoke 304 and a guide member 306 (e.g., a rib 308) that extends inwardly towards the mast 30. The guide member 306 is configured for positioning within a channel 310 (FIG. 12) defined by the mast 30 such that the collar 302 is slidably repositionable along the mast 30 during height adjustment of the canopy 60.
The handle assembly 300 includes a ratchet handle 312 (FIGS. 13-15, 18, 19) supporting a (second) yoke 314 (FIG. 19) that receives a driver 316 configured as a cog 318 (e.g., a gear, sprocket, or the like). The cog 318 defines a plurality of outwardly-extending projections 320 (e.g., teeth 322) (FIG. 20), and is secured within the yoke 314 by a pin 324. More specifically, the pin 324 extends through the yoke 314 and the driver 316 such that movement of the ratchet handle 312 towards and away from the mast 30 (FIG. 12) causes incremental rotation of the driver 316 about an axis of rotation R1 (FIG. 19) defined by the pin 324.
The ratchet handle 312 includes an internal ratchet mechanism (not shown) and a repositionable selector 326 (FIGS. 14, 15, 18, 19) that allows for variation in operability of the handle assembly 300. More specifically, when the selector 326 is in a first position, movement of the ratchet handle 312 towards the mast 30 will cause rotation of the cog 318 in a first direction (e.g., clockwise), and movement of the ratchet handle 312 away from the mast 30 will have no bearing upon the rotational position of the cog 318 (i.e., the cog 318 will remain rotationally stationary). When the selector 326 is in a second position, however, operability is reversed. More specifically, when the selector 326 is in the second position, movement of the ratchet handle 312 towards the mast 30 will have no bearing on the rotational position of the cog 318, and movement of the ratchet handle 312 away from the mast 30 will cause rotation of the cog 318 in a second, opposing direction (e.g., counterclockwise). Although shown as a rotatable knob 328 located adjacent an end 330 of the ratchet handle 312, it should be appreciated that the particular configuration and/or location of the selector 326 may be varied in alternate embodiments of the disclosure. For example, the selector 326 may instead include a slidable switch (not shown) or other such mechanism.
With reference now to FIGS. 14, 18, and 19, the drive guard 400 includes a first housing 402 and a second housing 404. The housings 402, 404 are positioned about the handle assembly 300 and the drive mechanism 500 (e.g., to protect the internal components from damage, debris, dust, water, etc.) and are connectable via one or more fasteners 406 (e.g., removable screws 408). The drive guard 400 is configured for receipt and support by the (first) yoke 304 (FIGS. 13, 15) defined by the collar 302. More specifically, in the illustrated embodiment, the pin 324 extends through the yoke 304, into corresponding openings 410, 412 defined by the housings 402, 404 of the drive guard 400, through the (second) yoke 314 supported by the ratchet handle 312, and through the driver 316 such that the yoke 314 is nested within the yoke 304.
With reference now to FIGS. 18-25, the drive mechanism 500 will be discussed. The drive mechanism 500 includes a drive member 502 and a worm gear assembly 504 in mechanical cooperation with the drive member 502. The drive member 502 extends longitudinally through the cantilevered arm 40 and, in the illustrated embodiment, is configured as a belt 506 that defines a plurality of inwardly extending projections 508 (e.g., teeth 510). The projections 508 defined by the drive member 502 are configured in correspondence with the projections 320 (FIG. 20) defined by the driver 316 such that rotational movement of the driver 316 is translated into longitudinal movement of the drive member 502. In one embodiment, it is envisioned that the belt 506 may include discrete first and second (e.g., proximal and distal) belt portions 506A, 506B, respectively, as seen in FIGS. 18 and 22, for example. The first (proximal) belt portion 506A defines opposing ends 512A, 514A and engages the driver 316, and the second (distal) belt portion 506B defines opposing ends 512B, 514B and engages the worm gear assembly 504 such that longitudinal movement of the drive member 502 (via rotation of the driver 316) causes actuation of the worm gear assembly 504.
As seen in FIG. 18, the ends 512A, 514A of the belt portion 506A are connected to the ends 512B, 514B of the belt portion 506B by a pair of cables 516A, 516B (or other such suitable members). It should be appreciated, however, that the configuration and/or components of the drive member 502 may be varied in alternate embodiments of the disclosure. For example, the belt 506 may be unitary in construction and may include opposing ends 512, 514 that are connected by a single cable 516, and may be utilized in connection with embodiments of the disclosure in which the cantilevered arm 40 includes minimal (if any) curvature. Alternatively, the drive member 502 may be devoid of the aforementioned belt 506 and may instead include one or more flexible members (e.g., cables 516) that are in engagement with the driver 316 and the worm gear assembly 504. Such implementations of the drive member 502 may be utilized, for example, in connection with embodiments of the disclosure in which the cantilevered arm 40 includes a more pronounced curvature. In such embodiments, it is envisioned that the flexible member(s) (e.g., the cables 516) may be connected to the driver 316 and the worm gear assembly 504 in any manner suitable for the intended purpose of translating longitudinal movement of the drive member 502 (via rotation of the driver 316) into actuation of the worm gear assembly 504. For example, the cables 516 may be wrapped around the driver 316 and the worm gear assembly 504, or the cables 516 may be secured to the driver 316 and the worm gear assembly 504 using a mechanical connection (e.g., a clip, weld, fastener, etc.).
To facilitate adjustment in the tension of the cables 516, in certain embodiments, the tilting assembly 200 may include a tension adjustment mechanism 518 (FIGS. 18, 26, 27). For example, the tension adjustment mechanism 518 may include a pair of connectors 520, 522 that are secured to ends 524, 526 of the cable(s) 516, a threaded member 528 that extends from the connector 520 so as to support a pair of rotatable nuts 530, 532, and a biasing member 534 that extends between the threaded member 528 and the connector 522. To adjust tension in the drive member 502 (e.g., tension in the cable(s) 516), the distance between the nuts 530, 532 can be varied to thereby vary the length of the biasing member 534 and, thus, the overall length of the drive member 502. More specifically, by decreasing the length of the biasing member 534 (e.g., through the application of force applied by rotation of the nut 532 in one direction), the overall length of the drive member 502 can be decreased and tension in the cable(s) 516 can be increased, and by increasing the length of the biasing member 534 (e.g., through the removal of force by rotation of the nut 532 in the opposite direction), the overall length of the drive member 502 can be increased and tension in the cable(s) 516 can be decreased. As seen in FIGS. 26 and 27, in one embodiment, it is envisioned that the tension adjustment mechanism 518 may be accessed via an opening 536 formed in the cantilevered arm 40.
With reference to FIGS. 18 and 21-25 in particular, the worm gear assembly 504 will be discussed. The worm gear assembly includes respective first and second gears 538, 540 that are in mechanical cooperation with the drive member 502 such that longitudinal movement of the drive member 502 actuates the worm gear assembly 504.
The first gear 538 includes a worm 542 defining a plurality of outwardly-extending projections 544 (e.g., teeth 546) (FIG. 23) that are arranged so as to define a helical thread 548, one or more bearings 550 (FIG. 23), and a head portion 552 defining a plurality of outwardly-extending projections 554 (e.g., teeth 556). The drive member 502 is positioned about the head portion 552 of the first gear 538 such that the projections 554 on the head portion 552 engage the projections 508 that extend inwardly from the drive member 502, whereby longitudinal movement of the drive member 502 is translated into rotational movement of the first gear 538 about an axis of rotation R2. To maintain consistent engagement between the first gear 538 and the drive member 502, and inhibit (if not entirely prevent) unintended movement of the drive member 502 along the axis R2, the head portion 552 may include retainers 558, 560 that are positionable on opposing sides of the drive member 502. For example, as seen in the illustrated embodiment, the retainers 558, 560 may be configured as annular discs 562, 564 that define a receiving space 566 (FIG. 23) therebetween that is configured to accommodate the drive member 502.
The second gear 540 includes one or more bearings 568, an output shaft 570 defining an engagement structure 572 (e.g., a keyway 574) (FIG. 23), and a plurality of outwardly-extending projections 576 (e.g., teeth 578). The projections 576 are configured in correspondence with the helical thread 548 defined by the worm 542 on the first gear 538 such that rotation of the first gear 538 causes corresponding rotation of the second gear 540 about an axis of rotation R3. In certain embodiments, such as that shown throughout the figures, it is envisioned that the second gear 540 may define a guide channel 580 (FIG. 23) that extends longitudinally therethrough and is configured to receive the canopy cable 65 such that the canopy cable 65 passes through the second gear 540 and exits the output shaft 570 as it is routed through the worm gear assembly 504 to the knuckle assembly 600 and the canopy 60. To facilitate routing of the canopy cable 65 through the cantilevered arm 40, it is envisioned that one or more rollers 582 may be provided in any suitable location. For example, as illustrated throughout the figures, the rollers 582 may be provided and secured within the cantilevered arm 40, the drive guard 400, the knuckle assembly 600, etc.
It is envisioned that the configurations of the gears 538, 540 may be varied in alternate embodiments of the disclosure to achieve any suitable or desired ratio for the worm gear assembly 504 (i.e., the ratio between the number of projections 544 defined by the worm 542 and the number of projections 576 defined by the second gear 540). For example, the gears 538, 540 may be configured such that the ratio of the worm gear assembly 504 is above a certain threshold (e.g., 4:1) to facilitate self-locking of the worm gear assembly 504 and inhibit (if not entirely prevent) unintended movement of the drive member 502 and/or the gears 538, 540 to preserve the tilt of the canopy 60.
As seen in FIG. 23, the first and second gears 538, 540 are offset such that the respective axes of rotation R2, R3 extend in non-intersecting relation, which allows the tilt axis T (FIG. 12) to extend in generally parallel relation to a longitudinal axis X defined by the cantilevered arm 40. More specifically, the gears 538, 540 are oriented such that the axis of rotation R2 subtends an angle a with a reference axis R that intersects the axis R2 and is parallel to the axis of rotation R3. In the illustrated embodiment, the angle a lies substantially within the range of approximately 30° to 60°. For example, the angle may be approximately 45°, as seen in FIG. 23. It should be appreciated, however, that the orientation of the gears 538, 540 may be varied in alternate embodiments of the disclosure and that larger and smaller values for the angle a would not be beyond the scope of the present disclosure.
With reference now to FIGS. 18, 21, 22, 24, and 25, the knuckle assembly 600 will be discussed. The knuckle assembly 600 is supported adjacent a distal end 602 of the cantilevered arm 40 and includes a first housing 604, a second housing 606 that is positioned distally of the first housing 604 (i.e., further from the mast 30 (FIG. 12)), and a third housing 608 that is positioned distally of the second housing 606. The knuckle assembly 600 operatively connects the canopy 60 (FIG. 25) to the worm gear assembly 504 to facilitate tilting of the canopy 60 in the manner described herein, and may include (e.g., may be formed from) any suitable material or combination of materials (e.g., plastics, polymers, metallic materials, etc.).
The first housing 604 is fixedly secured to the distal end 602 of the cantilevered arm 40 (e.g., using an adhesive, one or more fasteners, etc.), and defines an internal channel 610 (FIGS. 21, 22) that accommodates the drive member 502 such that the drive member 502 extends longitudinally through the first housing 604. The first housing 604 also defines a (first) support 612 (e.g., a cradle 614) that is configured to accommodate the first gear 538 and a (second) support 616 (e.g., a barrel 618) that is configured to accommodate the second gear 540. In the particular embodiment seen in FIG. 22, for example, the cradle 614 is configured as an arcuate brace 620, and the barrel 618 defines a longitudinal opening 622 that receives the second gear 540. The supports 612, 616 define respective bearing surfaces 624, 626 that are configured for engagement with the bearings 550, 568 (FIG. 23) respectively included on the gears 538, 540 to facilitate rotation of the gears 538, 540 in relation to the knuckle assembly 600.
The second housing 606 is connected to the first housing 604 such that the respective first and second housings 604, 606 are each fixed in relation to the cantilevered arm 40 and remain stationary during use of the tilting assembly 200. The second housing 606 includes a (generally) planar proximal end face 628 (FIG. 22) and a pair of (generally) planar distal end faces 630A, 630B, respectively, that are longitudinally separated so as to define a recessed portion 632 (e.g., a cutout 634) that is configured to receive the third housing 608 and accommodate movement thereof, as described in further detail below. The second housing 606 further includes an opening 636 that is configured to receive the output shaft 570 of the second gear 540 such that the output shaft 570 extends distally beyond the second housing 606, as seen in FIG. 25, for example. It is envisioned that the respective first and second housings 604, 606 may be fixedly (e.g., monolithically or integrally) formed, or, alternatively, that the housings 604, 606 may be configured and dimensioned for releasable connection (e.g., to facilitate inspection, repair, and/or replacement of the worm gear assembly 504, the drive member 502, etc.). As seen in FIGS. 22 and 24, for example, the second housing 606 may be connected to the first housing 604 via one or more removable fasteners 638 (e.g., screws 640).
The third housing 608 defines proximal and distal end faces 642, 644, respectively, each of which may be (generally) planar in configuration. As seen in FIG. 25, in certain embodiments, it is envisioned that the respective second and third housings 606, 608 may be configured such that the distal end face 630A defined by the second housing 606 and the distal end face 644 defined by the third housing 608 are generally coplanar. The third housing 608 includes a yoke 646 (FIGS. 22, 24) that is configured to facilitate pivotal connection of the third housing 608 to the canopy 60, as discussed in connection with the preceding embodiments, as well as an opening 648 (FIG. 22). The opening 648 is configured to receive the output shaft 570 of the second gear 540 to facilitate mechanical connection of the output shaft 570 to the third housing 608 such that, upon actuation of the worm gear assembly 504, rotation of the second gear 540 and the output shaft 570 is transmitted to the third housing 608 to cause corresponding movement of the third housing 608 and tilting of the canopy 60. It is envisioned that the output shaft 570 and the third housing 608 may be connected in any manner suitable for the intended purpose of facilitating rotation in unison. For example, the third housing 608 may include an engagement structure 650 (e.g., a keyway 652) that corresponds in configuration to the engagement structure 572 (e.g., the keyway 574) defined by the output shaft 570 such that the output shaft 570 engages the third housing 608 in mating relation. Additionally, or alternatively, the output shaft 570 and the third housing 608 may be connected through the use of one or more fasteners 654 (FIG. 24), such as clips, pins, screws, dowels, etc. For example, the third housing 608 may include one or more transverse openings 656 (FIG. 24) to facilitate insertion of the fastener(s) 654 and engagement with the output shaft 570 through the third housing 608. As such, embodiments are envisioned in which the output shaft 570 may extend distally beyond the third housing 608, as are embodiments in which the output shaft 570 may terminate proximally of the distal end face 644 of the third housing 608.
In certain embodiments of the disclosure, such as that seen in FIG. 24, it is envisioned that the second housing 606 and the third housing 608 may include corresponding guide surfaces 658, 660. For example, the guide surfaces 658, 660 may include corresponding respective chamfered surfaces 662, 664 and arcuate profiles such that the guide surfaces 658, 660 are engageable in mating relation to facilitate controlled relative movement of the third housing 608 in relation to the second housing 606 during tilting of the canopy 60 (FIG. 25).
With reference now to FIGS. 12-25, use and operation of the tilting assembly 200 will be discussed to vary the position of the canopy 60. Initially, the position of the selector 326 (FIGS. 14, 15, 18, 19) is chosen depending upon the direction of tilt desired. For example, in the illustrated embodiment, when in the first position, actuation of the ratchet handle 312 (i.e., pumping towards and away from the mast 30) will cause tilting of the canopy 60 in the direction indicated by arrow 1 (FIG. 12), whereas in the second position, actuation of the ratchet handle 312 will cause the canopy to tilt in the direction indicated by arrow 2. More specifically, movement of the ratchet handle 312 will cause the cog 318 (FIG. 19) to rotate (e.g., clockwise from the perspective shown in FIG. 19), which causes corresponding incremental movement (e.g., advancement) of the drive member 502 through the cantilevered arm 40. Via engagement with the projections 554 (FIG. 23) on the head portion 552 of the first gear 538, longitudinal advancement of the drive member 502 is translated into rotational movement of the first gear 538 in the direction indicated by arrow 3 (FIG. 21), which causes corresponding rotation of the second gear 540 in the direction indicated by arrow 5 via engagement of the worm 542 with the projections 576 on the second gear 540. Due to the secured engagement between the output shaft 570 of the second gear 540 and the third housing 608 of the knuckle assembly 600, rotation of the second gear 540 causes corresponding rotation of the third housing 608 (e.g., relative to the second housing 606) to thereby tilt the canopy 60 in the direction indicated by arrow 1 (FIG. 12).
To tilt the canopy 60 in the opposite direction, indicated by arrow 2 (FIG. 12), the position of the selector 326 (FIGS. 14, 18) can be reversed such that actuation of the ratchet handle 312 causes rotation of the cog 318 in the opposite direction (e.g., counterclockwise from the perspective shown in FIG. 19) to thereby cause opposing longitudinal movement (e.g., retraction) of the drive member 502. As the drive member 502 is retracted within the cantilevered arm 40, the first gear 538 is rotated in the direction indicated by arrow 4 (FIG. 21), which causes corresponding rotation of the second gear 540 in the direction indicated by arrow 6. Rotation of the second gear 540, and the resultant rotation of the output shaft 570, is transmitted to the third housing 608 of the knuckle assembly 600 to thereby rotate the third housing 608 and tilt the canopy 60 in the direction indicated by arrow 2 (FIG. 12).
Persons skilled in the art will understand that the various embodiments of the disclosure described herein, and shown in the accompanying figures, constitute non-limiting examples, and that additional components and features may be added to any of the embodiments discussed hereinabove without departing from the scope of the present disclosure. Additionally, persons skilled in the art will understand that the elements and features shown or described in connection with one embodiment may be combined with those of another embodiment without departing from the scope of the present disclosure to achieve any desired result, and will appreciate further features and advantages of the presently disclosed subject matter based on the description provided. Variations, combinations, and/or modifications to any of the embodiments and/or features of the embodiments described herein that are within the abilities of a person having ordinary skill in the art are also within the scope of the disclosure, as are alternative embodiments that may result from combining, integrating, and/or omitting features from any of the disclosed embodiments.
Use of the term “optionally” with respect to any element of a claim means that the element may be included or omitted, with both alternatives being within the scope of the claim. Additionally, use of broader terms such as “comprises,” “includes,” and “having” should be understood to provide support for narrower terms such as “consisting of,” “consisting essentially of,” and “comprised substantially of.” Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims that follow, and includes all equivalents of the subject matter of the claims.
In the preceding description, reference may be made to the spatial relationship between the various structures illustrated in the accompanying drawings, and to the spatial orientation of the structures. However, as will be recognized by those skilled in the art after a complete reading of this disclosure, the structures described herein may be positioned and oriented in any manner suitable for their intended purpose. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” “inner,” “outer,” “left,” “right,” “upward,” “downward,” “inward,” “outward,” etc., should be understood to describe a relative relationship between the structures and/or a spatial orientation of the structures. Those skilled in the art will also recognize that the use of such terms may be provided in the context of the illustrations provided by the corresponding figure(s).
Additionally, terms such as “approximately,” “generally,” “substantially,” and the like should be understood to allow for variations in any numerical range or concept with which they are associated. For example, it is intended that the use of terms such as “approximately” and “generally” should be understood to encompass variations on the order of 25%, or to allow for manufacturing tolerances and/or deviations in design.
Although terms such as “first,” “second,” etc., may be used herein to describe various steps, elements, components, regions, and/or sections, these steps, elements, components, regions, and/or sections should not be limited by use of these terms in that these terms are used to distinguish one step, element, component, region, or section from another. Thus, unless expressly stated otherwise, a first step, element, component, region, or section could be termed a second step, element, component, region, or section without departing from the scope of the present disclosure.
Each and every claim is incorporated as further disclosure into the specification, and represents embodiments of the present disclosure. Also, the phrases “at least one of A, B, and C” and “A and/or B and/or C” should each be interpreted to include only A, only B, only C, or any combination of A, B, and C
