Abstract:
An awning assembly and method of construction that includes a first main member rotatably coupled to a vertical track at a first end of the first main member; a second main member pivotally coupled to and at a second end of the first main member; a first supplemental member rotatably and slidably connected to the vertical track at a first end of the first supplemental member; a second supplemental member having a first end pivotally coupled to and at a second end of the first supplemental member. The second supplemental member has a second end pivotally coupled to the second main member. The first main member includes first, second, and third cross-sections spaced the second cross-section comprising slot that allows for the passage of the first supplemental member through the first main member, wherein the first cross-section differs from the second cross-section.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority under 35 U.S.C. §119(c) to currently pending U.S. Provisional Patent Application Ser. No. 62/312,575 filed Mar. 24, 2016 entitled AWNING CANOPY ASSEMBLY. The above-identified application is incorporated herein by reference in its entirety for all purposes: 
     
    
     FIELD OF THIS DISCLOSURE 
       [0002]    The present disclosure relates to an awning canopy assembly, and more particular, an awning assembly that is more compact in size than awnings having a similar strength when in an extended position. 
       BACKGROUND 
       [0003]    An awning is a welcome addition to a house, recreational vehicle, or other dwelling. The awning typically provides increased enjoyment of an outdoor area surrounding the dwelling. The awning can cast a shaded area that creates an escape from direct sunlight, thereby providing a space in which an occupant of the dwelling may relax. The shaded area created by the awning contributes to the relaxation of the occupant in that there is a perceived decrease in temperature and, thus, generally becomes more comfortable. The awning as well advantageously protects occupants underneath from precipitation. 
         [0004]    Known awning structures generally consist of a base that is permanently affixed to the dwelling, and a canopy that is removably attached to the base. Conventional awning structures are discussed in detail further in U.S. Pat. No. 6,971,433 assigned to Carefree/Scott Fetzer Company. U.S. Pat. No. 6,971,433 is incorporated herein by reference in its entirety for all purposes. 
       SUMMARY 
       [0005]    One aspect of the present disclosure comprises an awning assembly that includes a vertical track at a first end of the first main member; a second main member pivotally coupled to and at a second end of the first main member; a first supplemental member rotatably and slidably connected to the vertical track at a first end of the first supplemental member; a second supplemental member having a first end pivotally coupled to and at a second end of the first supplemental member. The second supplemental member has a second end pivotally coupled to the second main member. The first main member includes first and second cross-sections spaced by a slot that allows for the passage of the first supplemental member through the first main member, wherein the first cross-section differs from the second cross-section. The first main member comprising first, second, and third cross-sections, the second cross-section comprising a slot that spaces the first and third cross-sections, the slot allowing for the passage of said first supplemental member through said first main member, wherein said first cross-section differs from said second cross-section. 
         [0006]    Another aspect of the present disclosure comprises a method of constructing an awning assembly, the method comprising rotatably coupling a first main member to a vertical track at a first end of said first main member, pivotally coupling a second main member to and at a second end of the first main member, rotatably and slidably connecting a first supplemental member to said vertical track at a first end of said first supplemental member, said first supplemental member is pivotally connected to said first main member by a hinge pin, and pivotally coupling a first end of a second supplemental member having to and at a second end of the first supplemental member, the second supplemental member having a second end pivotally coupled to said second main member. The method further comprising providing said first main member with a first cross-section comprising a C-shaped channel, a second cross-section comprising a slot, and a third-cross-section comprising a second C-shaped channel, the slot spacing the first cross-section and third cross-section and allowing for the passage of said first supplemental member through said first main member. 
         [0007]    Yet another aspect of the present disclosure comprises an awning assembly comprising at least one support structure coupled to a canopy. The at least one support structure having a first main member rotatably coupled to a vertical track at a first end of said first main member, wherein the vertical track is couplable to a support surface. The at least one support structure further having a second main member pivotally coupled to a second end of the first main member at a first end of the second main member, and coupled to the canopy at a second end of the second main member. The at least one support structure additionally having a first supplemental member comprising a first end rotatably and slidably connected to said vertical track, and a second supplemental member having a first end pivotally coupled to a second end of the first supplemental member, the second supplemental member having a second end pivotally coupled to said second main member. The first main member comprising a first cross-section, comprising a first C-shaped channel, and a second cross-section, comprising a slot formed through a C-shaped channel, and a third cross-section comprising a second C-shaped channel, the slot allowing for the passage of said first supplemental member through said first main member, wherein said first supplemental member is pivotally connected to said first main member by a hinge pin. The at least one support structure also having a gas spring, wherein said gas spring includes a first end and a second end, the first end being pivotally connected to said vertical track and said second end being connected to said hinge pin. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0008]    The foregoing and other features and advantages of the present disclosure will become apparent to one skilled in the art to which the present disclosure relates upon consideration of the following description of the disclosure with reference to the accompanying drawings, wherein like reference numerals, unless otherwise described refer to like parts throughout the drawings and in which: 
           [0009]      FIG. 1  is a side elevation view of an awning canopy assembly in a retracted position in accordance with one example embodiment of the present disclosure; 
           [0010]      FIG. 2  is a left side elevation view of an awning canopy assembly in a partially expanded or partially open position in accordance with one example embodiment of the present disclosure; 
           [0011]      FIG. 3  is a perspective view of an awning canopy assembly in an open or expanded position in accordance with one example embodiment of the present disclosure; 
           [0012]      FIG. 4  is a perspective view of an awning canopy assembly support system constructed in accordance with one example embodiment of the present disclosure; 
           [0013]      FIG. 5  is a second perspective view of an awning canopy assembly support system in accordance with another example embodiment of the present disclosure; 
           [0014]      FIG. 5A  is a cross-sectional view along a first main member of  FIG. 5  along section lines  5 A- 5 A; 
           [0015]      FIG. 5B  is a cross-sectional view along a first main member of  FIG. 5  along section lines  5 B- 5 B; 
           [0016]      FIG. 5C  is a perspective view of a first main member constructed in accordance with one example embodiment of the present disclosure; 
           [0017]      FIG. 5D  is a cross-sectional view along a first main member of  FIG. 5  along section lines  5 D- 5 D; and 
           [0018]      FIG. 6  is a side elevation view of  FIG. 4 . 
       
    
    
       [0019]    Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure. 
         [0020]    The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. 
       DETAILED DESCRIPTION 
       [0021]    Referring now to the figures generally wherein like numbered features shown therein refer to like elements having similar characteristics and operational properties throughout unless otherwise noted. The present disclosure relates to an awning canopy apparatus, and more particularly, an awning assembly that is more compact in size yet provides sufficient strength to the overall system when in an extended position over conventional awning structures. 
         [0022]    Now referring to  FIGS. 1-5 , an awning assembly  20  is illustrated. The awning assembly  20  includes a flexible awning canopy  26  that is mounted to a vertical support surface  24 , which might be for example, the side wall of a recreational vehicle, mobile home, a recreational vehicle slide-out, or more permanent building structure. The flexible awning canopy  26  includes an inner or proximal edge  28  secured to a support rail  22  and an outer edge  30  secured to a roll bar  32 , which can be motor, manual, or spring driven by one or more motors  34 , gears, or springs that are operatively connected to, and maintained by, a support system  36  in the form of a pair of scissor-type arms  38 . 
         [0023]    in the illustrated example embodiment of  FIG. 1 , the motors  34  are hidden or enclosed to be protected from the elements in respective housings or covers  35 , The covers  35  are typically made from plastic or metal, In the illustrated example embodiment, the scissor-type arms  38  are constructed of metal, such as aluminum, but could be made of other materials of similar weight and strength. 
         [0024]    The support system  36  shown in further detail in  FIGS. 4-8  includes one of two scissors-type arms  38  (that support the awning assembly  20  only one of the two arms being shown in  FIGS. 4-8 ) mounted on a vertical track  40  that during use would attach to the support surface  24 . In the illustrated example embodiment, the vertical track  40  is coupled to a base portion  53 . The support system  36  is shown extended in  FIGS. 3 and 5  with the awning assembly  20  in the extended position. While the assembly  20  is fully retracted, as illustrated in  FIG. 1 , it will be appreciated that the support system  36  is vertically disposed and in close adjacent relationship with the track  40  during use. In the illustrated example embodiment of  FIG. 1 , a second main member  52  and the base portion  53  are aligned to form a substantially uniform appearance of the arms  38  when the support system is in a first closed position. 
         [0025]    As will be appreciated, and as shown in the illustrated example embodiment of  FIG. 1 , as the motors  34  are driven in a first or second direction, represented by arrows C and D, respectively, the awning canopy  26  is rolled onto or unrolled from the roll bar  32  causing the awning  20  to retract or extend, respectively. The awning  20  retracts or extends in cooperation with gas springs  42  associated with the respective support arms  38 . Responsive to the roll bar  32  being rotated in the first direction C to retract the awning assembly  20  by wrapping the awning canopy  26  about the roll bar, the support arms  38  are forced to retract in direction A against the bias of the gas springs  42  until the awning is in the fully retracted first position illustrated in  FIG. 1 . 
         [0026]    To open the awning assembly  20 , the roll bar  32  is rotated as shown in  FIG. 2  in the second direction D to extend the awning in direction B by unwrapping the awning canopy  26  from the roll bar. The support arms  38  are assisted in extending by the bias of the gas springs  42  until fully extended to the second position illustrated in  FIGS. 3 and 5 . 
         [0027]    It would be appreciated by one having ordinary skill in the art that additional example embodiments of the awning assembly  20  are contemplated. In one such example embodiment, the awning assembly  20  has support arms  38  that retract up and/or rotate inwards such as towards the roll bar  32  indicated by arrows E in  FIG. 1  by a fixture assembly (not shown). Stated another way, the support system  36  when in the contracted position (see  FIG. 1 ) can rotate such that the support system  36  that includes the vertical tracks  40  are parallel with the roll bar  32 . 
         [0028]    As shown in the example embodiments of  FIGS. 4-8 , the support system  36  of the awning canopy assembly  20  is illustrated. In one example embodiment, the support system  36  comprises a first support of a first side of the awning  20 , wherein a mirror image of the support system  36  comprises a second support of a second side of the awning. The support system  36  comprises first and second main members  50 ,  52  and first and second supplemental members  54 ,  56 , respectively. Each of the members  50 - 56  in the illustrated example embodiment are formed from metal, plastic, or the like. In one example embodiment, the members  50 - 56  are formed from extruded aluminum channeling. 
         [0029]    The first member  50  is rotatably attached to the vertical track  40  by fixed pin  58  that passes through both the first member and track at a first end  72  of the first member. At a second end  74  of the first main member  50 , a rotating pin  60  couples the first main member to the second main member  52 , such that the two main members have relative rotation about the pin  60  as the awning assembly  20  moves between the fully retracted first position illustrated in  FIG. 1  to the fully extended the second position illustrated in  FIGS. 3 and 5 . A slideable pin  62  allows for translation of the first supplemental member  54  about and within the vertical track  40  in the directions of arrows F in  FIG. 4 . The slideable pin  62  further allows for rotational pivoting of the first supplemental member  54  at a first end  76 . At a second end  78  of the first supplemental member  54  a rotating pin  64  couples the first supplemental member to the second supplemental member  56 , such that the two supplemental members have relative rotation about the pin  64  as the awning assembly  20  moves between the first and second positions. The opposite end of the second supplemental member  56  is rotatably coupled to a rotatable pin  70  that is fixedly attached to the second main member  52 . 
         [0030]    Located substantially about the medial point along the first main member  50  and the first supplemental member  54  is a hinge pin  68  (extending across stiffening flanges  85  and  86  of the main member, see  FIG. 5A ) that allows for relative rotation of the first members  50 ,  54  during the opening and closing of the awning canopy assembly  20 . In one example embodiment, the first supplemental member  54  comprises a first section  54   a  and a second section  54   b,  wherein the first section is between the hinge pin  68  and the first end  76  of the first supplemental member and the second section is between the hinge pin and the second end  78  of the first supplemental member. Near or above the hinge pin  68 , a slot  80  is formed within a lateral flange  89  of the first main member  50  that is no greater than twice the width of first supplemental member  54 . In one example embodiment, the width w is two inches (2″), so the slot  80  is approximately three and one-half inches (3.5″), not exceeding four (4″). The slot  80  allows for the second end  78  of the first supplemental member  54  to pass through the first main member  50  and pivot about the hinge pin  68 . The slot  80  defines an opening in the lateral flange  89  as illustrated in  FIGS. 5 and 5A . In one example embodiment, the slot  80  is formed between the first and second stiffening flanges  85  and  86 , wherein the lateral flange  89  is removed by the formation of the slot. 
         [0031]    In one example embodiment, toward the first end  72  of the first main member  50  away from the slot  80 , the cross-section of the first main member comprises a first C-shaped channel  82  as illustrated in  FIG. 5  and in the section view of  FIG. 5D  taken along section lines  5 D- 5 D in  FIG. 5 . In this example embodiment, toward the second end  74  of the first main member  50  away from the slot  80 , the cross-section of the first main member comprises a second C-shaped extrusion  84  as illustrated in  FIG. 5  and in the section view of  FIG. 5B  along section lines  5 B- 5 B in  FIG. 5 , In another example embodiment, the first main member  50  comprises the first C-shaped channel  82  between the first end  72  and the slot  80  and the second C-shaped channel  84  between the slot  80  and the second end  74 . In the illustrated example embodiment, portions  89   a,    89   b  (shown in dashed lines) of the lateral wall  89  are residually present in the slot  80  (see  FIG. 5A ). In one example embodiment, the lateral flange  89  interacts with a sidewall of the first supplemental member  54  when in the retracted position, such that a portion of the first supplemental member  54  is housed within the second C-shaped channel  84 . 
         [0032]      FIG. 5C  illustrates the first main member  50  and how the stiffening flanges  85  and  86  of the C-shaped channel  82  are continuously extruded into the second C-shaped channel  84 , forming stiffening flanges or walls that link the first and second C-shaped channels  82 ,  84 . Additionally,  FIG. 5C  illustrates how the lateral flange  89  is continuous, absent the slot  80 , between the first C-shaped channel  82  and the second C-shaped channel  84 , integrally connecting the stiffening flanges  85 ,  86  together. The first C-shaped channel  82  includes first and second stiffening flanges  85  and  86  that are spaced and supported by the lateral flange  89 . The slot  80  includes a pocket  90  that nest the second end  78  of the first supplemental member  54  when the support system  36  is in the fully retracted first position, such that no portion of the second end extends beyond the stiffening flanges  85  or  86 . In one example embodiment, the nesting of the second end  78  within the slot  80  is such that it forms a press-fit connection when in the fully retracted first position. 
         [0033]    The second C-shaped channel  84  nest the first end  76  of the first supplemental member  54  when the support system  36  is in the fully retracted first position, such that no portion of the first end extends beyond the stiffening flanges  85  or  86 . In one example embodiment, the nesting of the first end  76  within the second C-shaped channel  84  is such that it forms a press-fit connection when in the fully retracted first position. 
         [0034]    The first and second supplemental members  54 ,  56 , respectively are box-shaped channels made from metal, such as aluminum or steel. Similarly all of the pins, such as rotating pins, fixed pins, hinge pins, and sliding pins are made from metal, such as aluminum or steel and attached to the members by cotter pins or other conventional fastening means as would be appreciated by one of ordinary skill in the art. It would be appreciated by one having ordinary skill in the art that attachment means other than pins are contemplated. 
         [0035]    Illustrated in  FIGS. 4 and 6 , but omitted from  FIG. 5  as part of the support system  36  is gas spring  42 . The gas spring  42  is rotatably connected to the vertical track  40  by a fixed pin  92  at a first end  94  of the gas spring. The vas spring  42  is also rotatably connected to the hinge pin  68  at a second end  96  of the gas spring. The gas spring  42  acts as an assist to more readily move the awning assembly  20  between the fully retracted first position (see  FIG. 1 ) to the fully expanded second position (see  FIG. 3 ). 
         [0036]    When rotated to the first contracted or closed position as indicated by arrow F, the gas spring  42  resides in a first portion  101  of a pocket  98  formed by a U-shaped channel  100  in the vertical track  40 . Similarly, in one example embodiment, when rotated to this first contracted or closed position as indicated by arrow F, the first end  76  of the first supplemental member  54  resides in at least partially in a different or second portion  99  of the pocket  98  formed by the channel  100  in the vertical track  40 , wherein the first end  76  also at least partially resides with the second C-shaped channel  84 . When the awning assembly  20  is advanced to the first closed or contracted position of  FIG. 1 , the second supplemental member  56  is received within a U-shaped channel  102  formed within the second main member  52  (see  FIG. 5 ). In one example embodiment, when the awning assembly  20  is in the first closed position, the gas spring  42  is at a first angle  69  relative to the first portion  54   a  of the first supplemental member  54  in the U-shaped channel  102 . The first angle is between about 180° to about 140°. 
         [0037]    Because the gas spring  42  and first end  76  of the first. supplemental member  54  are connected at the same rotational point, namely the hinge pin  68 , both the gas spring and first end  76  form a compact fit within the U-shaped channel  100  and the second C-shaped channel  84 , respectively, when in the first closed position. This compact fit advantageously reduces bulky awning assemblies when in the first closed position, thus reducing breakage during transport. While the first C-shaped channel  82  and second C-shaped channel  84  that form the majority of the first main member  50 , provides superior strength to the support system  36  over conventional awning assemblies. In addition, such construction of the support system  36  requires fewer parts for assembly over conventional awnings. Finally, the single pieces construction of the first main member  50  provides smoother opening and closing of the awning assembly  20  over conventional awning that include two piece construction that could lead to racking and require great loads on the motor during operation. 
         [0038]    The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The disclosure is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. 
         [0039]    Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed. 
         [0040]    The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.