Abstract:
A structure that is foldable and expandable to support a canopy when a covering is placed on top of the framework includes a plurality of upright supports and a plurality of edge scissor assemblies that interconnect adjacent ones of the upright supports. Mounting brackets are disposed on the upright supports and also between scissor assemblies to fasten outer, end portions of the edge scissor assemblies together or to the upright supports. The mounting brackets each have a plurality of unique single side wall sockets each including a means for limiting torsional twisting of the scissor assemblies fastened in the socket. The limiting means comprises a complementary groove or rib for matingly engaging, in a complementary fashion, a complementary rib or groove, respectively, formed on the end of the scissor member received in the socket and secured therein with a pivot pin. The mounting brackets on each upright support may be relatively movable to allow expansion and contraction of the framework while limiting the side to side stresses on the scissor members pivotally held within the mounting brackets.

Description:
BACKGROUND 
       [0001]    1. Field 
         [0002]    The present disclosure generally relates to the attachment of pivoting structural members in an integrated collapsible canopy system. Specifically, the present disclosure relates to a structural device, in the form of non-compressible mounting brackets each forming a plurality of sockets for use in a collapsible canopy framework, wherein each socket captures an end portion of a scissor assembly member. 
         [0003]    2. General Background 
         [0004]    There is a need recognized when collapsible canopy products are manufactured to simplify the mounting bracketing of the scissor bar elements, one to another into scissor units and the resulting scissor units into interconnected scissor or truss assemblies, and in the connection of such truss assemblies in a pivotal expandable/collapsible manner to respective corner and intermediate supports. There is a need for interconnections which would be more resistive to shear and bending moments. The mounting brackets in the following description are structured to provide free pivots while at the same time resisting lateral and torsional deflection of the scissor assembly components. 
       SUMMARY 
       [0005]    A collapsible frame adapted to support a flexible fabric canopy or tent in an extended configuration and a collapsed configuration in accordance with the present disclosure has a plurality of upright support members oriented alongside one another in the collapsed state and movable outwardly apart from one another toward the expanded state. A plurality of edge scissor link assemblies each interconnect adjacent support members, each edge scissor link assembly comprising one or more pairs of scissor link members. 
         [0006]    A unique mounting bracket connects one or more scissor link members to one of either one of the upright support members or another edge scissor link assembly. The mounting bracket is a solid body having a plurality of sockets therein each shaped to receive and pivotally hold one end of one of the link members therein. Each socket has an inner face, a horizontal wall, and only a single vertical side wall merging substantially at a right angle with the horizontal wall and the inner face of the socket. A pivot fastener extends through the one end of the link member and into the single side wall to hold the member in the socket and permit rotation of the link member about an axis of the pivot fastener. The mounting bracket further includes means formed between the horizontal wall of the socket and the end of the link member in the socket for limiting the effect of twisting side stresses applied to the scissor link member in the socket when the frame is fully expanded to support the canopy or tent cover. 
         [0007]    The means for limiting preferably is formed within the socket by a groove formed in the horizontal wall extending parallel to the vertical wall and mates with a complementary shaped rib formed on the end of the scissor member engaged with the groove in the socket when the pivot fastener fastens the link member to the vertical wall in the socket. 
         [0008]    Alternatively, the means for limiting may preferably be a rib formed in the horizontal wall extending into the socket parallel to the vertical wall and a complementary shaped groove formed on the end of the scissor member engaged with the rib in the socket when the pivot fastener fastens the link member to the vertical wall in the socket. 
         [0009]    The framework structure includes several different configurations of the mounting bracket of the present disclosure that have two, three, or four or more sockets formed therein, each of which includes the means for limiting the effect of twist or side stresses to which the scissor member in the socket may be subjected to. For example, a mounting bracket at one of the corners of the framework may have two sockets at right angles. A mounting bracket placed in the center of the framework for supporting the central portion of the canopy roof will have four sockets at right angles from each other. If the canopy or tent framework has roof members extending from the corners, then the corner mounting brackets each may include a socket oriented between the right angle sockets. 
         [0010]    The framework structure can be folded and stored in a collapsed state and erected in an expanded state on a support surface in order to support a canopy covering above the support surface. In the collapsed state, the support members are oriented alongside one another but are movable outwardly apart from one another towards the expanded state. 
         [0011]    A preferred embodiment of the framework structure includes a plurality of edge scissor assemblies that form truss members for the expandable framework with there being an edge scissor assembly interconnecting adjacent ones of the support members. Each edge scissor assembly may be made of two or more pairs of scissor members linked together. In addition, mounting brackets in accordance with the present disclosure connecting the scissor member pairs together. In addition, a fixed and slidable pair of mounting brackets are disposed on the upright support members to fasten the edge scissor assemblies to the upright support members. 
         [0012]    The mounting brackets each have sockets that include a track or means for engaging the end of the scissor member of the scissor assembly received within a respective one of the sockets. A fastening pivot pin pivotally secures each outer end portion of each edge scissor assembly in its respective socket. 
         [0013]    The mounting brackets on the upright support member are relatively movable with respect to one another so that the edge scissor assemblies are operative to open and close whereby the framework structure may move between the expanded and contracted states. One mounting bracket is stationary while the other is slidable. The sockets and the mounting brackets thus provide pivotal connections for the scissor bars or members which form the scissor pairs which in turn comprise the scissor assemblies. 
         [0014]    The roof support assembly of the framework may be extendible roof members pivotally attached to the stationary mounting brackets in sockets at upper ends of the upright support members with these roof members projecting radially inwardly to form one or more apices to support the canopy covering. Alternately, the roof support members may extend radially inwardly from the slide mounting brackets to form such apex. 
         [0015]    These and other objects of the present disclosure will become more readily appreciated and understood from a consideration of the following detailed description of an exemplary embodiment when taken together with the accompanying drawings. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a perspective view of an exemplary canopy framework structure of the present disclosure; 
           [0017]      FIG. 2  is a perspective view of a corner mounting bracket at an upper end portion of a corner support member; 
           [0018]      FIG. 3  is a perspective view of an exemplary slide mounting bracket of the present disclosure for use on a corner support member; 
           [0019]      FIG. 4  is a perspective bottom view of a floating apex mounting bracket as shown in the exemplary embodiment of the present disclosure in  FIG. 1 ; 
           [0020]      FIG. 5  is a perspective bottom view of the lower floating mounting bracket shown in  FIG. 1 ; 
           [0021]      FIG. 6  is a perspective view of an exemplary floating mounting bracket of the present disclosure used to connect adjacent scissor units; 
           [0022]      FIG. 7  is a partial vertical sectional view through an assembled scissor member and socket of an exemplary mounting bracket of the disclosure such as in  FIG. 3 . 
           [0023]      FIG. 8  is a perspective view of an alternative embodiment of the slide mounting bracket shown in  FIG. 3  illustrating an alternative groove and rib arrangement in accordance with the disclosure. 
           [0024]      FIG. 9  is a bottom perspective view of the top corner mounting bracket shown in  FIG. 2 . 
           [0025]      FIG. 10  is a separate perspective view of an exemplary scissor bar member showing the end cap structure that matingly fits within one of the sockets in the mounting brackets shown in  FIG. 9 . 
           [0026]      FIG. 11  is a sectional end view of an alternative embodiment of a socket as in  FIG. 7 . 
           [0027]      FIG. 12  is a sectional end view of a different embodiment of a unit of  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    The present disclosure specifically concerns novel mounting brackets which may be used to interconnect the framework forming elements, such as the upright corner and intermediate leg support members, scissor assemblies and roof support structures in a collapsible canopy framework structure.  FIG. 1  shows a perspective view of a framework structure  11  used to support a fabric canopy  12 . In  FIG. 1  a framework structure  11  is shown in an expanded state and supports a covering fabric  12  (shown in partial phantom view) to produce a canopy unit  10 . Framework structure  11  is formed by four upright corner support members  14  each of which comprises a pair of telescoping pole structures such as square tubular upper leg section  15  into which square tubular lower leg section  16  is slidable received. Each upright support member  14  has a lower end  17  which engages or rests on a support surface, such as the ground, and an upper end  18  opposite the lower end  17 . 
         [0029]    A stationary mounting bracket  60  in an exemplary embodiment of the framework  11  of the present disclosure is disposed at each upper end  18 . A sliding mounting bracket  62  is slidably received on upper leg section  15  so that each slide mounting bracket  62  may move from a position remote from a respective stationary mounting bracket  15  to a location proximate stationary mounting bracket  60  in the fully expanded state as shown in  FIG. 1 . When located proximate to stationary mounting bracket  60 , each mounting bracket  62  may be latched into position by a suitable latch structure. This can be a spring mounting bracketed button latch  13   a  in the floating mounting bracket  62  and is engagement when exposed so that it enters into holes  13   b  in the respective walls of support  15 . Each upright support member  14  is interconnected to an adjacent upright corner support member by a scissor assembly  19  which has opposite outer upper and lower ends captured in sockets formed in mounting brackets  60  and  62 . In an additional aspect, visible in  FIG. 3 , the spring-loaded pull-out pin  13   a  is pulled by means of the pull ring  13   c . A spring biases the pins  13   a  towards insertion into the apertures  13   b.    
         [0030]    In  FIG. 1 , the peripheral edge scissor assemblies  19  each comprise a set of two pairs of scissor member bars  40  and  42 . It should be understood that additional pairs of scissor members  40  and  42  may be utilized in forming larger canopy or tent framework structures. Each of scissor bars  40  and  42  is preferably hollow, extruded aluminum tubular material having a rectangular cross section and substantially similar to one another. Each bar may also have internal strengthening ribs to provide enhanced rigidity. Alternately, scissor bars  40  and  42  may be made of any suitable construction material such as steel, plastic, fiberglass and the like. For example, the scissor bars  40  and  42  have a hollow interior  70  formed by sidewalls  72  and  74 . The sidewalls define a vertical dimension of height “h” for the scissor bar such as scissor bars while sidewalls  76  and  78  define a horizontal dimension or width “w.” 
         [0031]    The scissor bars  40  and  42  are connected at common central pivot joint  43 . A pivot fastener structure is provided. The pivot fastener structure includes a pair of cooperative mating pivot fastener structures that define a pivot axle that is a non-compressive element formed by a pair of cooperative axle pins such as female pin and male pin. The male pin has an elongated shaft terminating in a threaded end of reduced cross-section which, in turn, may be threadably received in threaded bore of shaft on the female pin. When joined, the shoulder on the shaft abuts the rim on the shaft so that the respective heads of female and male axle pins have a minimum distance of separation defined by the lengths of shafts. The minimum distance for the spacing between heads is at least the combined cross-sectional widths of scissor bars  40  and  42 . Further, the heads are preferably separated a minimum distance to accommodate a spacer washer. The heads are tapered, and countersunk washers are preferably provided for mounting bracketing on the outermost sides of scissor bars  40  and  42 . 
         [0032]    Mounting brackets  20  connect the scissor units  40  and  42 , as shown in  FIG. 1 , one to another, in end-to-end relation in the form of either single or multiple scissor unit trusses to their respective upright supports  14 . Each of the mounting brackets  20  has sockets  120  as described below with reference to the corner mounting brackets  60  and  62 . One of these mounting brackets  20  is shown upside down in  FIG. 6 . In the embodiment of the framework  11  shown in  FIG. 1 , the mounting brackets  20  also have sockets  120  connecting ends of a scissor unit pair  40  and  42  between the edge scissor assembly  19  and the roof support mounting brackets  66  and  67  respectively. The roof support mounting brackets  66  and  67  are similar in structure to the corner mounting brackets  62  and  60  respectively, except that each of brackets  66  and  67  has four sockets as is shown in  FIGS. 4 and 5 . 
         [0033]    A separate perspective upper view of a corner mounting bracket  60  is shown in  FIG. 2  and a bottom view of this mounting bracket  60  is shown in  FIG. 9 . The stationary mounting bracket  60  is a solid body that has a central portion  112  having a cavity  114  formed therein. Cavity  114  is sized to matingly receive an upper end portion of an upright support member, such as a corner support member  14 . A pair of flanges or lobes  116  and  118  extend outwardly from the central section  112  at right angles to one another to form the corner configuration. Each of lobes  116  and  118  forms a portion of a socket  120 . Each socket  120  is defined by a single vertical sidewall  122 , which extends at right angles from both central portion  112  and the horizontal wall or flange  116 . Thus the socket  120  has only one vertical sidewall  122 , a horizontal wall  116  and an inner surface formed by the exterior of the central portion  112 . Note that the corner mounting brackets  60  and  62  only have two sockets  120 . In contrast, roof support mounting brackets  66  and  67  each have four sockets  120  as shown in  FIGS. 4 and 5 . 
         [0034]    Mounting brackets  20  each has three sockets  120  as shown in  FIG. 1  and  FIG. 6 . Each socket  120  includes a groove  302  extending parallel to the vertical side wall  122  of the socket  120 , and, as shown in both  FIGS. 6 and 8 , the horizontal wall  164  merges via a curved surface  308  into the central section of the bracket  60 ,  62  or  20  having a radius of curvature complementary to the radius of curvature of the end cap  44  on the scissor members  40  or  42 . 
         [0035]    A transverse pivot pin  140  pivotally fastens each end cap  44  of one of the scissor bar members  40  or  42  into the socket  120  through bore  45  in the end cap  44 . Each pivot pin  140  is preferably threaded into and fixed into the vertical wall  122  of the socket  120 . The end portions of the respective scissor bar members  40  and  42  are sized for close fitted mated engagement in the sockets  120  for relatively free pivotal motion therein. Due to this close fitted construction, each sidewall  122  forms a planar contact surface with its respective scissor bar  40  and  42  and, thus, resists lateral and torsional deflections of their respective scissor bars  40  and  42  along the planar contact surface of vertical wall  122 . 
         [0036]    However, stresses and torsional loads that are applied off axis to the pivot pin  140  are not restrained by the vertical wall  122 . Accordingly a unique means for limiting torsional loads and side stresses is incorporated into each of the sockets  120  in each of the mounting brackets  60 ,  62 ,  66 ,  67 , and  20 . These features are clearly shown in detail in  FIGS. 3 through 12 . Basically, each socket  120  includes a complementary set of ribs and grooves formed between the end cap  44  of the bar members  40  or  42  and the horizontal walls  116  and  118 . These complementary rib/groove formations interact when the pivot pin  140  secures the end cap of the members  40  or  42  securely in the socket  120  to prevent side loading and side stresses from unduly twisting the pivot pin  140 , providing a secure rotatable yet rigid joint structure without the need for an opposite side wall parallel to the single side wall  122  of the socket  120 . 
         [0037]    One exemplary arrangement of the stress limiting means incorporated into each of the sockets  120  in the mounting bracket of the present disclosure is shown with reference to the lower sliding bracket  62  shown in  FIG. 3  and in cross sectional view in  FIG. 7 . The structure for supporting the scissor member  40  in the socket  120  includes a raised rib  300  formed on the end cap  44  around the curved portion of the end cap  44 . This protruding raised rib  300  engages a complementarily shaped groove  302  best seen in  FIG. 7 . As the scissor member  40  is rotated about the pivot pin  140  the end cap  44 , the rib  300  rides within the groove  302  and hence the scissor member  40  (or  42 ) is prevented from twisting out of parallel alignment with the sidewall  122  by the interaction between the complementary structures. The rib  300  need only extend partially around the end cap  44  and need not extend completely around as is shown in  FIG. 3 . Similarly the groove  302  need not extend as far up the inner wall as shown. Since the torsional loading is primarily experienced only when the frame work  11  is fully extended as in  FIG. 1 , the complementary rib/groove arrangement need only engage in the fully extended position as shown in  FIG. 3 . 
         [0038]    As illustrated in  FIG. 11 , a different configuration is shown where the rib  310  is illustrated as having a triangular cross section, which fits into a V shaped groove  312  in the flange or base  164  of the socket  120 . In  FIG. 12 , a different configuration is shown where the end cap  304  is shown with a trapezoidal cross sectional groove  313  for mating with the trapezoidal raised rib  314  in the flange or base  164  of the socket  120 . 
         [0039]    In different configurations of the sockets  120  there can be different shapes of the interacting rib and groove arrangement than that illustrated. In  FIG. 8 , for example, the mounting bracket  62  is configured with a raised rib  302  in the flange  164  extending parallel to the vertical wall  170  or  316  which engages a complementary groove  314  formed in the end cap  44  or  304 . Otherwise the mounting bracket  62  shown in  FIG. 8  is identical to the bracket shown in  FIG. 3 . 
         [0040]    At the front edge of the flange or base  164  forming the horizontal wall of each of the sockets  120  there is a transverse rib  318  which protrudes from the flange  164  and engages a mating transverse groove  320  in the end cap  44 . These rib/groove combinations operate to stabilize the mounting or mooring of the scissor elements  40  and  42  within the mounting bracket sockets  120 . 
         [0041]    Exemplary corner slide mounting brackets  62  are shown in perspective views in  FIGS. 3 and 8 . Each has a central section  152  defining a square shaped passageway  154  extending therethrough. An upper leg section of an upright support member  14  may be telescopically received through passageway  154  so that slide mounting bracket  62  may readily slide thereon. A pair of lobes  156  and  158  project outwardly from the central section  152  at right angles to one another to form the horizontal walls of sockets  120 . Each of lobes  156  and  158  has a vertical wall  170  extending upward from the horizontal wall  164  formed by the lobe  156  or  158 . The vertical wall  170  merges into the central section  152 . The merger between the central section  152  and the horizontal wall  164  of each of the lobes  156  and  158  is preferably curved complementary to the radius of the end cap  44  of the scissor member  40  (or  42 ). The vertical wall  170  is provided with a countersunk threaded bore  166  to receive and hold a pivot fastener  140  therein to secure the scissor member in the socket  120  as shown in  FIG. 3 . 
         [0042]      FIGS. 4 and 5  show perspective views of roof support mounting brackets  66  and  67  respectively. The upper mounting bracket  66  has a central section  232  through which extends a passageway  234  sized to accommodate a roof apex spring loading elements such as a support post  100  shown in phantom lines. Central section  232  has a plurality of lobes  238  that project horizontally outwardly from central section  232  at right degree angles with respect to one another. Each lobe  238  forms the horizontal wall of a socket  240  that is also defined by a vertical side wall  241  that merges from the lobe  238  into the central section  232 . Countersunk bores  246  are again provided in the vertical side wall  241  to receive a fastening pin  140  forming a pivotal axle for scissor bar elements, such as scissor bar elements  40  and  42  which may be matingly received in each of sockets  240 . 
         [0043]    Lower central mounting bracket  67 , shown in  FIG. 5 , includes a central section  252  provided with a passageway  254  extending therethrough. A plurality of lobes  258  project outwardly from central section  252  and each forms a socket  260  that has a single vertical wall rising from the lobe  258  and merging with the central section  252 , which is also the same general construction described with respect to stationary mounting bracket  60 , slide mounting bracket  62 . Each of the sockets  260  has a groove  302  (or rib as in  FIG. 8 ) configured to mate with a complementary rib (or groove) in the end cap  44  or  304  on the scissor member  40  or  42  as above described. 
         [0044]    The central mounting brackets  66  and  67  are substantially identical to the other mounting brackets described above. The central mounting brackets may be of a different configuration but will necessarily have at least one socket  240  for each roof member to be terminated thereto. 
         [0045]    While the mounting bracket apparatus has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. For example, other configurations of the canopy are envisioned. Another embodiment may include only three upright corner support members or five or six corner support members. In such configurations, the angles between sockets  120  or  240  may be other than 90 degrees. However, the internal structure of each socket will be substantially the same, defined by a single vertical wall and a horizontal wall both merging into an inner surface of the central section of the mounting bracket. Each socket will also have a groove or rib extending along the horizontal wall, spaced from and parallel to the vertical wall for receiving a complementary rib or groove formed in the end portion of the support member that is carried within the socket. This disclosure is intended to cover various modifications and similar arrangements that will be readily apparent to those skilled in the art and are included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures.