Abstract:
A structural system and methodology for erecting a shading structure. The system and methodology provides for a rapid and fool proof installation of the shading element over a canopy structure. The shading element is coupled into a locking mechanism on a perimeter beam which rotates to increase effective the effective surface area of the canopy structure thereby providing the correct amount of tension to the shading element, thereby completing the installation process.

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates generally to mechanical structures and associated methodology for providing shade and ultraviolet (UV) protection in various outdoor environments play areas, auto parking, sports fields, theme parks, country clubs and the like. 
     2. Description of the Related Art 
     Shade structures are well-known in the art and provide shade—hail, snow, water, heat and UV protection in numerous applications: automobile dealerships, auto parking facilities, water parks, playgrounds, swimming pool areas, tennis courts, outdoor eating areas, amusement parks, and the like. Providing shade has become increasingly significant throughout the United States and abroad because of ever changing and indeterminate weather conditions and the increasing awareness of skin cancer caused by the harmful UV rays from sunlight. Conventional shade structures typically comprise a mechanical support structure made of reinforced steel, and a covering made of high density polyethylene cloth having UV additives. The support structure is designed to handle loading due to wind, snow, hail and other elements in accordance with the local building codes. The structures are often designed in different configurations depending on the desired application. Thus, for example, a dome structure may be used with the roofs on surrounding buildings are curved or there are curved lines present in the design of the building. A hip structure is commonly used to enhance the roofline of surrounding buildings. A pyramid structure is often used when the desired shade area is square. 
     Another common structure is a cantilever. In this structure as illustrated generally in FIG. 1, each of a set of central support posts  100   a-n  are provided with a pair of outwardly-extending trusses  102   a-b.  Each truss  102  is generally triangular in shape and includes a plurality of cross support beams  104  in a known configuration. The shade  106  extends from an apex  108  outward to an edge  110  of each truss  102 . In the prior art, the shade  106  typically includes a cable or rope  112  inside an outside pocket  114 . During installation, the shade is positioned over the trusses and pulled taut, and the cable is then secured to an outer perimeter beam  116  in each truss section using a fastener or other mechanical locking means. 
     With this design, however, it is often difficult to position the shade in an attractive and secure manner along the outer perimeter beam in each truss section. If the shade is not secured properly, it may be damaged during subsequent use and thus compromise the aesthetic appearance and physical integrity of the structure. 
     The present invention addresses this problem. 
     BRIEF SUMMARY OF THE INVENTION 
     It is the object of the present invention to provide a rapid and “fool proof” method for installing the shading element or fabric over the canopy structure. 
     The perimeter beam connecting each truss section is adapted to swivel or pivot between a first and second position. In the first, installation position, an end of a shading element is loosely positioned within a locking device of the perimeter beam. Thereafter, the beam is rotated outwards and downwards into the second, locking position pulling the shade fabric taut. In this position, the shade fabric extends around an outer periphery of the beam and is locked within the locking structure. This configuration provides secure tensioning of the shade fabric that is aesthetically pleasing. In particular, the edge of the shade is secured and hidden within the locking structure of the perimeter beam when viewed from the outside edge of the structure. 
     Additionally, a methodology is provided for installing a shading element the comprises the steps of placing the fabric on a canopy structure, spreading the fabric out over the top of the structure and positioning it in approximate final position, inserting the edge of the shading element into a locking channel in a pivoting perimeter beam, and pivoting the beam around a pivot point to a locking position, thereby pulling the fabric taunt and completing the installation process all in one motion. 
     The foregoing has outlined some of the more pertinent objects and features of the present invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention as will be described. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the following Detailed Description of the Preferred Embodiment. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention and the advantages thereof, reference should be made to the following Detailed Description taken in connection with the accompanying drawings in which: 
     FIG. 1 is a perspective view of a prior art cantilever shade structure; 
     FIG. 2 is an elevation view of an outer portion of an individual truss illustrating the perimeter beam in cross-section in a first, installation position; 
     FIG. 2A is a close-up view of the perimeter beam illustrating how the shade fabric end is retained in a locking mechanism of the beam; 
     FIG. 3 is an elevation view of the perimeter beam after it has been swiveled into its second, locking position tension and secure the shade; 
     FIG. 4 is an illustration methodology for the present invention in block diagram form; and 
     FIGS. 5A-5E are close-up views of various perimeter beams illustrating how the shade fabric end is retained in various different locking mechanisms of the design. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIGS. 2,  2 A and  3  illustrate the invention in use in a cantilever shade structure. This is not a limitation of the invention, however, as the invention may be used in any structure (regardless of configuration) having a perimeter beam that may be positioned as is now described. 
     FIG. 2 illustrates a cross-section of a cantilevered shade structure (not shown) consisting of a cantilevered truss section  201 . Truss section  201  further comprises of a top truss arm  202 , a bottom truss arm  208  joined together at edge  210 . Cross support beam  204  may be added to provide additional structural support to the truss section  201 . An outer perimeter beam  216  is mechanically attached to edge  210  such that beam  216  may swivel or pivot around a fixed point  224 . Beam  216  spans the distance between two separate truss section edges, thereby connecting them. 
     Various mechanical attachment methods may be utilized as the mechanical pivot point, such as a nut and bolt configuration, a fixed pin configuration or other such means known in the mechanical arts. A shading element such as fabric  206  is placed on top of upper truss arm  202  to provide the shading portion of the structure. 
     While not meant to be limiting, canopy structure and the truss structure  201  shown in FIGS. 2 and 3 are typically steel structures designed to meet or exceed the requirements of the 1997 Uniform Building Code. All steel tubing is typically triple coated for rust protection using the in-line zinc electroplating process. Tubing is internally coated with zinc and organic coating to prevent corrosion. 
     While not meant to be limiting, the shading element or fabric  206  typically consists of a high-density polyethylene fabric or some similar material with ultra violet additives. This provides the fabric with a high strength, low shrinkage factor that can withstand wide temperature ranges. Additional properties of the fabric are that it is flexible, abrasion resistant and possesses ultra violet radiation immunity when properly treated. Its properties make it resistant to cleaning agents, acid rain, mildew, rot, chlorine, saltwater, and industrial pollutants. It is constructed using a monofliament and tape construction and Rachel knitted to ensure the fabric will not unravel if cut. Typically, all corners of fabric  206  are strengthened with non-tear vinyl material and a protective webbing is sewn into all areas where steel cable  212  or an alternative rigid material enter and exits the cloth pockets. The rigid material runs the length of the edge of fabric  206   
     Although not meant to be limiting, steel cable or wire rope  212  is typically ¼ inch nominal diameter, 7 strand, 19 wires per strand, with a nominal tensile strength of 9,000 pounds. Cable  212  is typically secured with approved fittings and hardware. 
     FIG. 2A illustrates a detailed cross-sectional view of one end of beam  216  in the installation position. In FIG. 2A, fabric  206  is shown with a rigid member, such as steel cable or wire rope  212 , placed into an outside pocket  214  along one end of fabric  206 . Other such rigid members may be used instead, such as a plastic member, or a metal strip. These can be attached, inserted or sewn into the fabric in the outside pocket  214 . Beam  216  further comprises of a fabric-locking mechanism  230  that accepts pocket  214  with cable  212  and restrains it as beam  216  is rotated or pivoted outward and downward into the locked position. 
     In FIG. 2A, fabric-locking mechanism  230  is comprised of two tubular structures, upper tube  220  and lower tube  222 . Tubes  220  and  222  are attached to beam  216  and are parallel to each other and extend the length of beam  216 . A gap between tubes  220  and  222  is determined by the thickness of the edge of fabric  206  that contains pocket  214  with cable  212  so that as beam  216  is pivoted outward and downward, pocket  214  with cable  212  is “caught” within the locking mechanism&#39;s  230  gap and locked into it. 
     Fabric locking mechanism  230  may be designed differently to facilitate the invention and the present discussion is not meant to be limiting. FIGS. 5A-D illustrate different examples of potential locking mechanisms  230 . FIG. 5A shows “lip” structure  520  whereby the cable is positioned below lip  530  and as beam is rotated into position lip  520  secures pocket  214 . FIG. 5B shows clamping structure  505  that secures the fabric to beam  216 . FIG. 5C shows male/female coupling means  510 , whereby fabric pocket  214  is inserted into the receiving portion  512  of beam  216 . FIG. 5D shows movable and adjustable locking means  525 , whereby as beam  216  is rotated an inner portion covers and secures pocket  214  with the portion of beam  216 . 
     When beam  216  is in the installation position as shown in FIGS. 2 and 2A, fabric  206  with cable  214  may be inserted between tubes  220  and  222  or inserted into any of the other locking mechanisms as above described. 
     FIG. 2A further illustrates beam  216  comprising of a second hole  226  for a second attaching means that is used to secure beam  216  to end  210  when beam  216  is in the locked position. In FIGS. 2 and 2A, beam  216  is shown in the installation position, and thus hole  226  is devoid of an attaching means such as a nut and bolt. When the present invention is pivoted into the “locked” position, as described below in FIG. 3, a nut and bolt or similar mechanical securing device will be inserted through hole  226  such that the lower portion of beam  216  is attached or locked to lower truss arm  208  at edge  210 . 
     FIG. 3 illustrates the present invention in the “locked” position. In FIG. 3, beam  216  has been rotated outward and downward about pivot hole  224  until hole  226  is lined up with hole  228 , providing a passage through which an attachment means may be inserted through both holes. By inserting the attachment means such as a nut and bolt configuration through holes  226  and  228  and tightened the nut and bolt configuration, beam  216  is secured to edge  210  such that no further pivoting may occur. Additionally, the attachment means in pivot hole  224  is tightened or secured such that beam  216  is rigidly attached to edge  210  through both points  224  and  228 . When beam  216  is in the “locked”, fabric  206  is pulled taunt. Cable  212  is “locked” into position between locking mechanism  230  by the tension on fabric  206 , the tension being provided by the fabric being presented on increased surface area of beam  216  upon the rotation of beam  216  around pivot  224  and “locked” into position. 
     FIG. 4 illustrates in block the present inventive methodology  400  from the installation position to locking position. In step  402 , a canopy structure is assembled to receive fabric  206 . Beam  216  is placed in the “installation position” in step  405 . In step  410 , fabric  206  is positioned on top of the upper truss in the approximate layout designed for the canopy-shading portion. Once approximately positioned, fabric  206  is elongated and loosely positioned over the upper truss arm  202  in step  415  to cover the desired portion of upper truss arm  202 . In this step, fabric  206  is not pulled taunt. 
     Once the fabric covers the desired portion of upper truss arm  202 , the end of fabric  206  with pocket  214  and cable  212  is inserted into locking mechanism  230 , which in the present example comprises of placing pocket  214  in between tubes  220  and  222 , coupling the length of the edge of fabric  206  with beam  216  in step  425 . Once successfully inserted in between the locking tubes, beam  216  is rotated outward and downward around pivot point  224  in step  430 . 
     While in rotation, the end of fabric  206  with cable  212  remains in between locking mechanism  230 . The rotation of beam  216  wraps the end portion of fabric  206  around the outer portion of beam  216  increasing the effective surface area that fabric  206  covers. As step  430  occurs, beam  206  begins to pull fabric  206  taunt, and pocket  214  with cable  212  is locked into place by locking mechanism  230  through the tension produced on fabric  206  caused by the increased surface area that fabric  206  is exposed to. 
     Once upper hole  226  is aligned with hole  228  on edge  210 , beam  216  is in the “locked” position. An attachment means such as a nut and bolt is inserted through holes  226  and  228  to secure beam  216  in the locked position in step  435 . Finally, once beam  216  is locked into place, pivot bolt  224  is secured and any extraneous wire  212  may be removed to ensure a smooth and ascetically pleasing appearance in step  440 . 
     The present invention provides numerous advantages. Assembling the structure with the present invention provides a system and methodology for ensuring a uniform and consistent position for the shading fabric over the canopy structure. Using the present invention, the canopy is tightened to the correct specifications the first time, providing a uniform, taunt, secure fit over the length of the canopy structure. The uniform fit ensures an ascetically pleasing appearance for the structure, proper shading protection, and structural support due to decreased wind resistance. 
     It should be appreciated by those skilled in the art that the specific embodiments disclosed above may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.