Fastener for assembling truss bars in a collapsible canopy frame

A collapsible canopy frame is provided that includes a first truss bar having a surface that defines an opening; a second truss bar having a surface that defines an opening that is aligned with the first truss bar opening; and a connector assembly that pivotally connects the first truss bar to the second truss bar. The connector assembly includes a locking plate at a second end of the connector assembly having a base that defines first and second surfaces with an opening extending therebetween, wherein the first base surface abuts the second truss bar; and a fastener having a main body that extends through each of the first and second truss bar openings and the locking plate base opening. The fastener also includes spaced apart first and second arms each having a shoulder that laterally extends from the main body to abut the second base surface of the locking plate to pivotally connect the first truss bar to the second truss bar.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority to and the benefit of Korean Utility Model Application No. 20-2003-0019414 filed on Jun. 19, 2003 in the Korean Intellectual Property Office, now registered as Utility Model Registration No. 2003-25662-0000 on Aug. 26, 2003, the entire content of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a fastener for assembling truss bars in a collapsible canopy frame and to a method of assembling truss bars in a collapsible canopy frame.

BACKGROUND

Conventional collapsible canopy frames typically include multiple side poles disposed in a predetermined configuration. Typically each pair of adjacent side poles is connected and supported by an edge scissor assembly. Each edge scissor assembly is movable between an extended position and a retracted position, such that the collapsible canopy frame as a whole is movable between an extended position (where the collapsible canopy frame forms a stable structure for supporting a canopy covering) and a retracted position (where the collapsible canopy frame is collapsed for ease of transport.)

For additional support, many collapsible canopy frames include inner scissor assemblies that connect the edge scissor assemblies to a center pole. Typically, each edge scissor assembly and each inner scissor assembly includes one or more scissor units. Each scissor unit includes two pivotally connected truss bars. Typically, these truss bars are pivotally connected by the use of nut and bolt combinations. For example, such a coupling is typically formed by aligning respective holes in the truss bars; inserting a bolt through the respective holes; and threadingly connecting a nut to the bolt until a desired tightness is achieved.

However, this process is undesirably time consuming. In addition, it is often difficult for the assembler to determine how tightly the nut is to be fitted to the bolt often relying on his personal experience and judgment. Accordingly, a need exists for an improved fastener for pivotally connecting truss bars in a collapsible canopy frame and to a method of assembling truss bars in a collapsible canopy frame.

SUMMARY

In an exemplary embodiment of the present invention, a collapsible canopy frame is provided that includes a first truss bar having a surface that defines an opening; a second truss bar having a surface that defines an opening that is aligned with the first truss bar opening; and a connector assembly that pivotally connects the first truss bar to the second truss bar. The connector assembly includes a locking plate at a second end of the connector assembly having a base that defines first and second surfaces with an opening extending therebetween, wherein the first base surface abuts the second truss bar; and a fastener having a main body that extends through each of the first and second truss bar openings and the locking plate base opening. The fastener also includes spaced apart first and second arms each having a shoulder that laterally extends from the main body to abut the second base surface of the locking plate to pivotally connect the first truss bar to the second truss bar.

In another exemplary embodiment of the present invention, the above described assembly further includes an end plate at a first end of the connector assembly having a base that is connected to the fastener and laterally extends from the fastener to abut the first truss bar and each arm further includes an angled portion extending from a tip of a corresponding one of the arms to an edge of a corresponding one of the shoulders to form a ramp.

In yet another exemplary embodiment of the present invention, a method of pivotally connecting a first truss bar to a second truss bar in a collapsible canopy frame is provided that includes forming an opening in a first truss bar; forming an opening in a second truss bar that is aligned with the opening in the first truss bar; and providing a connector assembly that pivotally connects the first truss bar to the second truss bar. The connector assembly includes an end plate having a base at a first end of the connector; a fastener extending from the base of the end plate and including a main body and spaced apart first and second arms each having a shoulder that laterally extends from the main body; and a locking plate at a second end of the connector assembly having a base that defines first and second surfaces having an opening extending therebetween. The method further includes inserting the fastener arms into and through each of the first and second truss bar openings and the locking plate base opening, such that the end plate base abuts the first truss bar, the locking plate base first surface abuts the second truss bar, and the fastener shoulders abut the locking plate base second surface to pivotally connect the first truss bar to the second truss bar.

DETAILED DESCRIPTION

As shown inFIGS. 1-6, the present invention is directed to a fastener for pivotally connecting truss bars in a collapsible canopy frame and to a method of assembling truss bars in a collapsible canopy frame.

FIG. 1shows a collapsible canopy frame10according to an exemplary embodiment of the present invention. As shown, the collapsible canopy frame10includes four side poles12arranged in a generally rectangular or square configuration. In other embodiments, however, the collapsible canopy frame10may include any appropriate number of side poles12arranged in any appropriate configuration, such as pentagonal, hexagonal or octagonal, among other appropriate configurations.

Each pair of adjacent side poles12is connected to and supported by an edge scissor assembly14. In the depicted embodiment, each edge scissor assembly14includes two scissor units16. However, in other embodiments, each edge scissor assembly14may include any appropriate number of scissor units16. Each scissor unit16includes two pivotally connected truss bars18that move about a pivot in a scissor-like manner between an expanded position and a retracted position.

An upper end of each edge scissor assembly14is pivotally connected to a corresponding one of the side poles12through a side pole upper mounting bracket20, and a lower end of each edge scissor assembly14is pivotally connected to a corresponding one of the side poles12through a side pole lower mounting bracket22. In one embodiment, each upper mounting bracket20is fixedly mounted at a top end of a corresponding one of the side poles12and each lower mounting bracket22is disposed in surrounding relation to a corresponding one of the side poles12and is slidably mounted thereon.

Adjacent scissor units16in each edge scissor assembly14are also pivotally coupled to each other. For example, in one embodiment the upper ends of adjacent scissor units16in each edge scissor assembly14are pivotally coupled to an edge scissor assembly upper mounting bracket24and the lower ends of adjacent scissor units16in each edge scissor assembly14are pivotally coupled to an edge scissor assembly lower mounting bracket26.

In one embodiment, such as that shown inFIG. 1, each edge scissor assembly14is coupled to and supports a center pole28through an inner scissor assembly30. The center pole28is disposed generally at the center of the collapsible canopy frame10and has a head member32, such as a convex shaped head member, which supports a canopy cover (not shown).

In the depicted embodiment, each inner scissor assembly30includes one scissor unit16′. However, in other embodiments, each inner scissor assembly30may include any appropriate number of scissor units16′. As with the edge scissor assembly14, each scissor unit16′ in each inner scissor assembly30includes two pivotally connected truss bars18′ that move about a pivot in a scissor-like manner between an expanded position and a retracted position.

Each inner scissor assembly30is pivotally coupled to a corresponding one of the edge scissor assemblies14through the upper and lower mounting brackets24and26. For example, in one embodiment the upper ends of each inner scissor assembly30are pivotally coupled to the edge scissor assembly upper mounting bracket24and the lower ends of each inner scissor assembly30are pivotally coupled to the edge scissor assembly lower mounting bracket26.

Each inner scissor assembly30is also pivotally mounted to the center pole28. In one embodiment, each inner scissor assembly30is pivotally mounted to the center pole28through upper and lower center pole mounting brackets34and36. As shown in the embodiment ofFIG. 1, an upper end of each inner scissor assembly30is pivotally mounted to the upper center pole mounting bracket34and a lower end of each inner scissor assembly30is pivotally mounted to the lower center pole mounting bracket36. In one embodiment, the lower center pole mounting bracket36is fixedly mounted at a bottom end of the center pole28and the upper center pole mounting bracket34is disposed in surrounding relation to the center pole28and is slidably mounted thereon.

When the collapsible canopy frame10according to the present invention is constructed as described above, the collapsible canopy frame10is moveable between an expanded position (forming a stable portable structure as shown inFIG. 1), and a retracted position (forming a compacted structure for ease of transport as shown inFIG. 2.) In one embodiment, the connection of each edge scissor assembly14to corresponding ones of the side pole upper and lower mounting brackets20and22; the connection of each scissor unit16in each edge scissor assembly14to corresponding ones of the edge scissor assembly upper and lower mounting brackets24and26; the connection of the inner scissor assembly30to corresponding ones of the edge scissor assembly upper and lower mounting brackets24and26; and the connection of the inner scissor assembly30to the upper and lower center pole mounting brackets34and36are accomplished by use of any one of the embodiments of the fastener as described in U.S. patent application Ser. No. 10/847,831, entitled “Fastener for Assembling Connecting Parts of a Collapsible Canopy Frame” filed on May 18, 2004, which is herein incorporated by reference.

FIG. 3shows an exploded view of a connector assembly40for pivotally connecting a first truss bar42to a second truss bar44. It is to be understood that the first and second truss bars42and44may be used as the truss bars18for any or all of the scissor units16in each edge scissor assembly14, and that the first and second truss bars42and44may be used as the truss bars18′ for any or all of the scissor units16′ in each inner scissor assembly30.

As shown inFIG. 3, the first truss bar42includes an outwardly facing surface46, an inwardly facing surface48and side surfaces50extending therebetween. An opening58extends through the outwardly facing surface46and the inwardly facing surface48. Similarly, the second truss bar44includes an outwardly facing surface52, an inwardly facing surface54and side surfaces56extending therebetween. An opening59extends through the outwardly facing surface52and the inwardly facing surface54.

In the depicted embodiment ofFIG. 3the first and second truss bars42and44are substantially rectangular in cross section, however in other embodiments the cross section of the first and second truss bars42and44may have other appropriate configurations.

The connector assembly40includes a fastener end60and a locking end62. The fastener end60of the connector assembly40includes an end plate64having a fastener66extending therefrom. In the depicted embodiment ofFIG. 3, the cover plate64is substantially U-shaped in cross section having a base surface68and opposing side arms70extending from the base surface68. The fastener66includes a body portion72extending from the base surface68of the end plate64and a head portion74extending from the body portion72. In the depicted embodiment ofFIG. 3, the body portion72is generally cylindrical in shape and is concentric with the head portion74, which is also generally cylindrical in shape. However, in other embodiments, the body portion72and the head portion74may have other appropriate shapes. As shown, the body portion74of the fastener66has a substantially smooth outer perimeter.

In one embodiment, the fastener66is a separate component part mounted to the end plate64. In another embodiment, the fastener66and the end plate64are integrally formed, such as by a molding process or a molding process.

As shown inFIG. 4, the head portion74of the fastener66includes a first arm76and a second arm78. The first and second arms76and78are separated by a longitudinally extending channel80. For example, inFIG. 4the channel80extends along a longitudinal axis of the fastener66to separate the ends of the first and second arms76and78. The channel80allows the first and second arms76and78to be bent inwardly towards each other when an external force is applied thereto. As such, in one embodiment, the fastener66is composed of a material that is flexible enough to allow the first and second arms76and78to bend inwardly towards each other when an external force is applied thereto, but resilient enough and including a sufficient shape memory to return the first and second arms76and78to their original positions when the external force is released. In an exemplary embodiment, the fastener66is composed of a polymeric material, such as a plastic material. However in other embodiments, the fastener66may be composed of other suitable materials having the above described properties, for example a metal material or a composite material.

As shown inFIG. 4, the fastener arms76and78combine to form a generally cylindrical main body77. As is also shown, the first arm76includes a first ramp82and the second arm78includes a second ramp84. Each ramp82and84extends radially outwardly from the end of the fastener66toward the end plate64and connects with the main body77of the fastener arms76and78to form first and second shoulders86and88. Although the main body77of the fastener arms76and78has been described as generally cylindrical in shape, the main body77of the fastener arms76and78may have any appropriate configuration as long as the first and second shoulders82and84laterally extend from the main body77.

Referring back toFIG. 3, the locking end62of the connector assembly40includes a locking plate90having a substantially U-shaped cross section with a base surface92and opposing side arms94extending from the base surface92. An opening96extends through the base surface92. A wall98extends from the base surface92in the opposite direction from the side arms94. The wall98encircles the locking plate opening96. Although the wall98is shown as having a circular shape, in other embodiments the wall98may have any appropriate shape, as long as is at least partially encircles the locking plate opening96.

As shown inFIG. 3, when it is desired to assemble the first truss bar42to the second truss bar44, the fastener66is inserted into and through the first truss bar opening58; the second truss bar opening59; and the locking plate opening96. The first and second truss bar openings58and59are each larger than the combined lateral dimension of the ramps82and84of the fastener arms76and78.

However, the locking plate opening96is smaller than the combined lateral dimension of the ramps82and84of the fastener arms76and78, yet larger than the main body77of the fastener arms76and78. As such, when the fastener66is inserted into the locking plate opening96, a circular sidewall that defines the locking plate opening96applies a compression force against the ramps82and84of the fastener arms76and78causing the arms76and78to bend inwardly toward each other. When the shoulders86and88of the fastener arms76and78have traversed the locking plate opening96, the resiliency of the fastener arms76and78allows the fastener arms76and78to move outwardly away from each other, such that the shoulders86and88of the fastener arms76and78abut the base surface92of the locking end62to lock the fastener66to the second truss bar44, thus pivotally mounting the first truss bar42to the second truss bar44.

When the fastener66is so positioned, the ramps82and84of the fastener arms82and84are positioned adjacent to the locking plate wall98. The locking plate wall98, thus prevents inadvertent removal of the fastener66from the first and second truss bars42and44. However, the locking plate wall98is sufficiently spaced from the ramps82and84of the fastener arms76and78to allow a tool or a person's fingers to extend between the locking plate wall98and the ramps82and84of the fastener arms76and78to apply a compression force against the ramps82and84, causing the fastener arms76and78to bend inwardly towards each other, allowing the fastener66to be removed from the first and second truss bars42and44.

As shown in most clearly inFIGS. 3 and 5, at the fastener end60of the connector assembly40, the lateral dimension of the end plate64is larger than the lateral dimension (or the end cross-section) of the fastener66. This makes the fastener end60of the connector assembly40much easier to manipulate by a user's hand since the lateral dimension of the fastener end60of the connector assembly40would other wise be relatively small, making the fastener66easy to drop.

Also, as shown most clearly inFIG. 5, when the fastener end60of the connector assembly40is attached to the locking end62of the connector assembly40to pivotally connect the first truss bar42to the second truss bar44, the side arms70of the end plate64of the connector assembly40extend adjacent to the sides surfaces50of the first truss bar42, and the side arms94of the locking plate90of the connector assembly40extend adjacent to the sides surfaces56of the second truss bar44. This prevents rotational movements of the fastener66with respect to the first truss bar42and the locking plate with respect to the second truss bar44, thus preventing a relative movement between the fastener66and the locking plate90, which increases the stability of the connection of the fastener66to the locking plate90.

A washer100having an opening102extending therethrough is optionally placed between the inwardly facing surface48of the first truss bar42and the outwardly facing surface52of the second truss bar44. The washer100helps reduce wear on the first and second truss bars42and44. In such a case, the fastener66extends through the washer opening102to hold the washer100between the first and second truss bars42and44.

It will be appreciated by those of ordinary skill in the art that the invention can be embodied in other specific forms without departing from the spirit or essential character thereof. The present invention is therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.