FLEXIBLE FRAME WITH ARTICULATING JOINTS

A collapsible frame for supporting a fabric structure includes frame members which themselves can be plastically deformed as well as folded around one or more hinges. The ductile frame members can be deformed plastically to hold the fabric structure in a predetermined orientation. When not in use, the frame can be folded around the hinges disposed between the individual frame members. Folding the frame around the hinges significantly reduces the possibility of the ductile frame members work-hardening and experiencing a metal fatigue failure.

BACKGROUND OF THE INVENTION

This invention relates generally to outdoor equipment and, in particular fabric structures supported by rigid frames

It is well-known in the art to provide outdoor equipment consisting of a lightweight fabric structure supported by a collapsible resilient frame. For example, U.S. Pat. No. 5,163,461 to Ivanovich et al. discloses a self-erecting shelter consisting of a fabric material stretched over an armature made of a highly resilient material, such as spring steel. The shelter can be collapsed by coiling the armature into a flattened package. Because the spring steel armature is highly elastic, the armature does not plastically deform and therefore springs back into shape to form the structure when released.

It is also well-known in the art to provide outdoor equipment consisting of a lightweight fabric structure supported by a hinged, rigid or semi-rigid frame, for example, U.S. Pat. No. 5,842,495 to Egnew et al. discloses a portable shelter consisting of a fabric material stretched over a series of rigid bows that are hinged at a common anchor point so that the bows can be collapsed one on top of the other. The bows are also hinged at a center point so each bow can be folded in half to further reduce the size of the folded assembly. What the prior art lacks, however, and what the present invention provides is a fabric structure that is supported by a collapsible frame in which the frame members themselves can be plastically deformed as well as folded around one or more hinges.

SUMMARY OF THE INVENTION

The present invention comprises a fabric structure that is supported by a collapsible frame in which the frame members themselves can be plastically deformed as well as folded around one or more hinges. According to an illustrative embodiment, the fabric structure comprises a slouch hat with a flexible frame attached to the perimeter of the brim. The ductile frame members can be deformed plastically to hold one side of the brim in a particular orientation when the hat is in use. When not in use, the hat can be folded around the hinges disposed between the individual frame members. Folding the frame around the hinges significantly reduces the possibility of the ductile frame members work-hardening and experiencing a metal fatigue failure.

DETAILED DESCRIPTION

The drawing figures are intended to illustrate the general manner of construction and are not necessarily to scale. In the detailed description and in the drawing figures, specific illustrative examples are shown and herein described in detail. It should be understood, however, that the drawing figures and detailed description are not intended to limit the invention to the particular form disclosed, but are merely illustrative and intended to teach one of ordinary skill how to make and/or use the invention claimed herein and for setting forth the best mode for carrying out the invention.

With reference to the figures and, in particularFIGS. 1 and 3, a fabric structure, which in the illustrative embodiment comprises a cloth slouch hat10having a brim12, is supported by a flexible frame14. In the illustrative embodiment, flexible frame14consists of four elongated frame members16A,16B,16C, and16D, which are connected together by four articulating joints18A,18B,18C, and18D. Flexible frame14is attached to brim12by means of clips20attached directly to elongated frame members16A,16B,16C, and16D, as well as by clip members22which are integral to articulating joints18A,18B,18C, and18D. Although in the illustrative embodiment flexible frame14is attached to brim12using clips, other temporary or permanent means, such as clips, pins, clamps or magnets may be utilized without departing from the scope of the invention.

In the illustrative embodiment, elongated frame members16A,16B,16C, and16D, have a core28made of 0.035 inch diameter ductile aluminum alloy such as ER4043, having a yield strength of 10,000 psi and an ultimate tensile strength of 30,000 psi. Although aluminum alloy is used in the illustrative embodiment, any suitable material having a high degree of plasticity such as low carbon steel may be utilized without departing from the scope of the invention. The high degree of plasticity is desirable so that the elongated frame members16A,16B,16C, and16D, can be deformed such as at bend24and at bend26and thereafter will substantially retain the shape, for example to hold one side of brim12in an upright folded position. In the illustrative embodiment, elongated frame members16A,16B,16C, and16D further have a flexible sheath30comprising 0.160 to 0.180 inch (4.0 to 4.5 mm) diameter hollow core vinyl screen spline. The purpose of the flexible sheath is to increase the effective diameter of four elongated frame members16A,16B,16C, and16D. thereby making it easier to manipulate the four elongated frame members16A,16B,16C, and16D by hand. The increased effective diameter also increases the bend radius of bend24and bend26, thereby making it less likely core28will work harden with repeated bending and fail from metal fatigue.

Although it would be possible to fold hat10relatively flat for storage simply by bending the four elongated frame members16A,16B,16C, and16D as noted above, such repeated bending would eventually lead to work hardening and metal fatigue failure of elongated frame members16A,16B,16C, and16D. Accordingly, articulating joints18A,18B,18C, and18D are provided. With additional reference toFIG. 2, articulating joint18A is composed of a first clevis portion32, a second clevis portion34and a connecting link36. First clevis portion32is attached (e.g. by adhesive) to an end portion38of frame member16A. Second clevis portion34is attached (e.g. by adhesive) to an end portion40of frame member16B. Connecting link36is rotatably attached to first clevis portion32and second clevis portion34about pivot axes42and44. The center distance between axes42and44is greater than the width of first clevis portion32and second clevis portion34. This enables articulating joint18A to assume a “Z” shape as shown inFIG. 2B, or to rotate through 180° as shown inFIG. 2C. The structure and operation of articulating joints18B,18C, and18D are substantially the same as articulating joint18A and therefore will not be discussed in detail herein. As shown inFIG. 3, by appropriate rotation of articulating joints18A,18B,18C, and18D, the fabric structure10can be folded flat without substantial bending of elongated frame members16A,16B,16C, and16D

According to an alternative embodiment, a fabric structure110is supported by a flexible frame114. In the alternative embodiment, flexible frame114consists of four elongated frame members116A,116B,116C, and116D, which are connected together by four articulating joints118A,118B,118C, and118D, however, flexible frame114is contained within a pocket inside of the brim112of fabric structure110. This obviates the need for clips, pins, clamps magnets or other temporary means of attachment.

Although certain illustrative embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the invention. For example, although in illustrative embodiment the fabric structure was made of cloth, any flexible material such as leather, rubber or plastic could be used without departing from the invention and therefore as used herein, the word “fabric” is defined to mean any flexible material capable of being supported by a frame. Moreover, although in the illustrative embodiment the fabric structure comprises a slouch hat, other structures including shirt collars, covered hammocks, tents, umbrellas, inflatable boats, vests, face masks, inflatable pool toys, and car sun shades may be supported by a flexible frame incorporating features of the present invention. Accordingly, it is intended that the invention should be limited only to the extent required by the appended claims and the rules and principles of applicable law. Additionally, as used herein, references to direction such as “up” or “down” as well as recited materials or methods of attachment are intended to be exemplary and are not considered as limiting the invention and, unless otherwise specifically defined, the terms “generally,” “substantially,” or “approximately” when used with mathematical concepts or measurements mean within ±10 degrees of angle or within 10 percent of the measurement, whichever is greater. As used herein, a step of “providing” a structural element recited in a method claim means and includes obtaining, fabricating, purchasing, acquiring or otherwise gaining access to the structural element for performing the steps of the method. As used herein, the claim terms are to be given their broadest reasonable meaning unless a clear disavowal of that meaning appears in the record in substantially the following form (“As used herein the term ______ is defined to mean ______”)