Awning assembly including drop-down shade

The primary roller of an awning assembly has an internal cavity, an opening between the internal cavity and the exterior of the primary roller and a first arresting element. A first awning material is adapted to be unwound from the primary roller when the primary roller rotates in a first direction and wound onto the primary roller when the primary roller rotates in a second direction. A secondary roller is mounted for rotation within the internal cavity of the primary roller. One end of a second awning material attached to the secondary roller extends through the opening in the primary roller. A second arresting element is attached to the one end of the second awning material and is adapted to engage the first arresting element of the primary roller, whereby rotation of the secondary roller in the second direction causes the primary roller to rotate in the second direction together with the secondary roller.

BACKGROUND OF THE INVENTION

The present invention in general concerns awning assemblies, and, in particular, the invention concerns awning assemblies that include both a main awning component and an auxiliary awning component such as a drop-down shade or flyer.

Awning assemblies that are applied to various structures such as store-fronts and recreational vehicles, for example, often include both a main awning section that can be supported at and deployed from the structures as well as a secondary awning section, in the nature of a drop-down shade or flyer, that can be deployed from the end of the main awning section that is furthest removed from the structures when the main awning section is deployed. The secondary awning section, particularly where it can be deployed over a range of lengths, can provide additional protection from the sun and elements such as wind and rain.

Often times, the awing assemblies are contained in housings that are mounted at the structures. Typically the awning fabric of the main awning section is wound and unwound on a roller for storage in such a housing and deployment, respectively. In many cases the main awning section is supported in a deployed state by folding support arms that are secured at the structures and at the rollers on which the awning fabric of the main awning section is wound and unwound. The main awning section can also be supported when it is deployed by supports that rest on the ground.

A variety of constructions can be provided for deployment of the secondary awning sections that are associated with the main awning sections. In some instances provisions are made so that the secondary awning sections can be extended from the main awning sections over a range of lengths and thereby provide a selective degree of protection from the sun, wind, rain and the like.

SUMMARY OF THE INVENTION

According to one aspect of the invention, there is provided an awning assembly that is adapted to be mounted at a structure. The awning assembly comprises a primary roller with a first awning material and a secondary roller with a second awing material. The primary roller has an internal cavity within at least a portion of the primary roller, an opening between the internal cavity and the exterior of the primary roller and a first arresting element. The primary roller is adapted to rotate around its longitudinal axis in a first direction and in a second direction opposite to the first direction. The first awning material has a first end and a second end. The first awning material is attached adjacent its first end to the primary roller and is adapted to be secured adjacent its second end at the structure. The first awning material also is adapted to be unwound from the primary roller when the primary roller is rotated in the first direction and wound onto the primary roller when the primary roller is rotated in the second direction. The secondary roller is mounted within the internal cavity of the primary roller substantially coaxially with the primary roller for rotation within the internal cavity around the longitudinal axis of the second roller in the first direction independently of the primary roller and in the second direction selectively independently of the primary roller and together with the primary roller. The second awning material has a first end and a second end. The second awning material is attached adjacent its first end to the secondary roller and the second end of the second awning material extends through the opening in the primary roller between the internal cavity and the exterior of the primary roller. The second awning material is adapted to be unwound from the secondary roller when the secondary roller is rotated in the first direction and wound onto the secondary roller when the secondary roller is rotated in the second direction. A second arresting element is attached adjacent the second end of the second awning material and is adapted to engage the first arresting element of the primary roller, whereby, upon engagement of the first and second arresting elements, rotation of the secondary roller in the second direction causes the primary roller to rotate in the second direction together with the secondary roller.

According to another aspect, the opening in the primary roller extends along a substantial portion of the length of the primary roller and is substantially parallel to the longitudinal axis of rotation of the primary roller.

According to a further aspect, the first arresting element is located at the opening in the primary roller.

According to still another aspect, the first arresting element comprises a shoulder that projects inwardly of the exterior of the primary roller towards the exterior of the secondary roller to form an arresting space between the shoulder and an outermost wrap of the second awning material when the second awning material is wound onto the secondary roller to the maximum extent of the second awning material.

According to yet another aspect, the second arresting element is larger than the arresting space between the shoulder of the first arresting element and the outermost wrap of the second awning material when the second awning material is wound onto the secondary roller to the maximum extent of the second awning material.

According to another aspect, the second arresting element is a cylindrical rod that extends along a substantial portion of the second awning material.

According to a further aspect, the first roller comprises a cylindrical shell. Additionally, the second roller can comprise a cylindrical shell. Where the primary roller comprises a cylindrical shell, the shoulder of the primary roller can comprise a portion of the primary roller cylindrical shell that is turned inwardly toward the exterior of the secondary roller.

DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

FIG. 1of the drawings illustrates an awning assembly, indicated generally at10, in accordance with an embodiment of the present invention. The awning assembly is shown as attached at a first end12to a bracket14and at a second end16to a bracket18. The brackets14and18can each be connected to ends of folding extension arms (not shown) that are secured at a structure such as a store front, residence, recreational vehicle or the like, for example, for the purpose of supporting the awning assembly, particularly when the awning assembly is deployed. The manner in which the folding extension arms are operatively connected to the awning assembly and the structure and are unfolded as the awning assembly is deployed, so as to support the awning assembly, is known to those having ordinary skill in the art and is not described in detail here. It will also be understood by those skilled in the art that a housing with a frontal opening adequate to accommodate the awning assembly10and the folding extension arms can be secured to the structure to provide a storage area for the awning assembly and the extension arms when the awning assembly is not deployed.

The awning assembly can also be supported when it is deployed by alternative supporting structures such as support posts for example that can be secured at one of their ends to the ends of the awning assembly in place of the folding extension arms and the brackets14and18. As will be understood by those skilled in the art, the other ends of the support posts can rest on the ground or be secured to the structure at which the awning assembly is mounted.

The awning assembly of the invention in general has application wherever awning assemblies can be used. Thus, as indicated above, the awning assembly of the invention can be applied to stationary structures such as residences, where it may be used to provide shade or protection from the elements over an outdoor patio for example. The awning assembly of the invention can also be applied to mobile structures such as recreational vehicles for example. The recreational vehicles can comprise mobile homes, motor homes, travel trailers, fifth wheelers, recreational vans and the like. It will therefore be understood that the awning assembly of the present invention is adapted to be employed with a variety of structures.

Referring toFIGS. 1 and 2, it can be seen that the awning assembly comprises a primary roller20, a first awning material30, a secondary roller40and a second awning material50. The primary roller20has an internal cavity within at least a portion of the primary roller. In the embodiment shown in the drawings, the primary roller comprises a cylindrical shell that can be made of a hard plastic or a metal for example so that the primary roller's internal cavity extends the full length of the primary roller.

The primary roller20is adapted to rotate around its longitudinal axis that extends from the first end12to the second end16of the primary roller. As further described below, the primary roller is adapted to rotate around its longitudinal axis in a first direction when the awning assembly is deployed from the structure at which it is mounted and in a second direction opposite to the first direction when the awning assembly is returned to the structure at which it is mounted. The primary roller20includes an opening between the internal cavity and the exterior of the primary roller. The opening in the primary roller20can extend along a substantial portion of the length of the primary roller and can be substantially parallel to the longitudinal axis of rotation of the primary roller. In the embodiment of the invention illustrated in the drawings, as best shown inFIG. 2, the opening22between the internal cavity21and the exterior of the primary roller20extends the entire length of the primary roller, is parallel to the longitudinal axis of rotation of the primary roller and is created by not having the cylindrical shell completely closed.

The first awning material30, which can comprise any type of awning fabric or the like, has a first end31and a second end32. The first awning material is attached adjacent its first end31to the primary roller20and is adapted to be secured adjacent its second end32at the structure at which the awning assembly is mounted. As best seen inFIGS. 2 through 5, for attaching the first awning material to the primary roller20, cylindrical recesses24and25are provided in the exterior of the primary roller from the first end12to the second end16of the primary roller and hold in place dowel-like elements34and35, respectively, that are attached to the first awning material30adjacent the first end31of the first awning material.

The first awning material30is adapted to be unwound from the primary roller20when the primary roller is rotated in the first direction as indicated by the directional arrow60inFIG. 3, such as would be the case when the awning assembly is deployed from the structure at which it is mounted, and wound onto the primary roller20when the primary roller is rotated in the second direction as indicated by the directional arrow61inFIG. 5such as when the awning assembly after having been deployed is returned to the structure.

The secondary roller40is mounted within the internal cavity21of the primary roller20substantially coaxially with the primary roller and has a first end41and a second end42. The secondary roller can comprise a cylindrical shell made of a hard plastic or a relatively rigid metal for example. The secondary roller40is mounted for rotation within the internal cavity around the longitudinal axis of the secondary roller that extends from the first end41to the second end42of the secondary roller such that rotation of the secondary roller40in the first direction60results in rotation of the secondary roller40independently of the primary roller20and rotation of the secondary roller in the second direction61selectively results in the rotation of the secondary roller40independently of the primary roller20or in the rotation of the secondary roller together with the rotation of the primary roller. Further details concerning the mounting of the secondary roller within the cavity of the primary roller and the operational relationship between the primary and secondary rollers are set forth below.

The secondary awning material50also can comprise any type of awning fabric or material. The secondary awning material has a first end51and a second end52. The second awning material is attached adjacent its first end51to the secondary roller40. As can be seen inFIGS. 2 through 5, in the illustrated embodiment, a cylindrical recess53extends along the length of the secondary roller from the first end41to the second end42of the secondary roller. A dowel-like element54is attached adjacent the first end51of the second awning material50and is held in place in the cylindrical recess53. The second end52of the second awning material50extends through the opening22in the primary roller20between the internal cavity21and the exterior of the primary roller. As further described below, the second awning material50is adapted to be unwound from the secondary roller50when the secondary roller is rotated in the first direction60and wound onto the secondary roller when the secondary roller is rotated in the second direction61.

The primary roller20and the second awning material50include a first arresting element and a second arresting element, respectively, whereby, upon engagement of the first and second arresting elements, rotation of the secondary roller40in the second direction61causes the primary roller20to rotate in the second direction along with the secondary roller40. In the embodiment of the invention shown in the drawings, the first arresting element26on the primary roller20is located at the opening22in the primary roller. As best seen inFIG. 4, the first arresting element comprises a shoulder26that projects inwardly of the exterior of the primary roller20towards the exterior of the secondary roller40to form an arresting space63between the shoulder26and an outermost wrap of the second awning material50when the second awning material is wound onto the secondary roller40to the maximum extent of the second awning material. In the embodiment shown in the drawings, the shoulder26of the primary roller comprises a portion of the primary roller cylindrical shell that is turned inwardly toward the exterior of the secondary roller40.

The second arresting element included with the second awning material50is larger than the arresting space63between the shoulder of the first arresting element26and the outermost wrap of the second awning material50when the second awning material is rolled onto the secondary roller40to the maximum extent of the second awning material. In the embodiment shown in the drawings, the second arresting element comprises a cylindrical rod55that extends along a substantial portion of the second awning material and can extend along the entire width of the second awning material as best seen inFIG. 2.

The first and second arresting elements can be other than as described above and illustrated in the drawings. Other types of arrangements where the secondary roller seizes the primary roller so as to rotate the primary roller can be used. For example, the awning material50can be provided at its second end52with hooks that hook onto the primary roller.

Based on the foregoing description, further details can now be presented with reference to the operational features of the embodiment of the invention as shown inFIGS. 3,4and5of the drawings.FIGS. 3,4and5are end views of the awning assembly shown with various elements removed so as to better illustrate the operational relationships among the primary and secondary rollers, the first and second awning materials and the first and second arresting elements.

FIG. 3illustrates the condition of the awning assembly after it has been deployed from the structure at which it is mounted and the second awning material, in the nature of a drop-shade or flyer for example, also has been deployed a selected extent.FIG. 4illustrates the condition of the awning assembly when the awning assembly is to be returned to the structure at which it is mounted and drop shade or flyer has been wound on the secondary roller until the first and second arresting elements are in engagement.FIG. 5of the drawings illustrates the condition after the first awning material has been wound on the primary roller and the awning assembly has been returned to the structure at which it is mounted.

As will be understood, after the awning assembly has been deployed as illustrated inFIG. 3, the first awning material30will have been unwound from the primary roller20by the rotation of the primary roller in the direction shown by the directional arrow60. Once the primary roller reaches a deployed condition, the second awning material50will be unwound to a desired degree from the secondary roller40by the rotation of the secondary roller in the direction shown by the directional arrow60. At such time as it is desired to return the awning assembly to the structure at which it is mounted, the second awning material50is wound onto the secondary roller40by the rotation of the secondary roller in the direction shown by the directional arrow61. As the second awning material50is wound on the secondary roller40and the wraps of the second awning material accumulate on the secondary roller, the space63between the shoulder26of the primary roller20and the outermost wrap becomes smaller. Finally, as the dowel55on the second awning material50reaches the shoulder26on the primary roller, the space63is so small as to prevent the dowel55from passing through the space. As a result, continued rotation of the secondary roller40in the direction shown by the directional arrow61will cause the primary roller20to rotate in the same direction. The first awning material30will thereby be wound onto the primary roller20until the first awning material and the second awning material are completely wound on their respective rollers as illustrated inFIG. 5and the awning assembly is returned to the structure at which it is mounted.

It will be understood by those having ordinary skill in the art, that the awning assembly described above can be provided with a variety of means for unwinding and winding of the awning assembly. For example, an electric motor as described in greater detail below can be employed. By way of further example, a mechanical cranking arrangement can be used to wind and unwind the awning assembly.

Referring now in particular toFIG. 2for one example of the manner in which an electric motor can be incorporated into the awning assembly, reference is first had to the primary roller20of the awning assembly. As previously described, the primary roller comprises a cylindrical shell to which is attached the first awning material30. Mounted within the cavity21of the primary roller is a cylindrical housing comprising two substantially matching half-cylinder components70. An electric motor72is held within the housing and the half-cylinder components of the housing are held together at one end by screws71and a washer77. A connector74is screwed to the opposite end of the housing and is attached to a collar76by means of a C-clip, snap ring or the like. One end of the collar76fits within a hollowed-out portion of the bracket14and is secured to the bracket. The other end of the collar76that is attached to the spacer74extends through the central opening75in the end cap13. The lead wires78of the motor72are threaded through central bores in the spacer74and the collar76and out the opening73in the bracket14. From there, the lead wires can run along the folding arms (not shown) that support the awning assembly back to a control mechanism such as a microprocessor (also not shown) that can be located on the structure at which the awning assembly is mounted.

A driving component82is secured to the first end41of the secondary roller40that is also located within the cavity21of the primary roller20and is fixed to the rotating shaft79of the motor72. Through this arrangement, rotation of the shaft79rotates the secondary roller40. A spacer80is located between the motor72and the driving component82. The spacer includes a number of projections that engage ribs91and93and/or recesses24and25of the primary roller20and is thereby held in place.

The second end42of the secondary roller40is provided with a closure component84having a central opening that is similar in construction to the driving component82. A mechanical stop comprising elements86and88, each of which has a central opening, is located within the secondary roller shell40. The mechanical stop and the closure component84are held together by means of a bolt85and a nut87.

Also located within the cavity21of the primary roller20is a torsion spring90having a hook-like element or catch94at its one end. The outer diameter of the torsion spring can be such that it fits somewhat closely in the space within the primary roller20delimited by the cylindrical recesses24and25and inwardly projecting ribs91and93within the interior of the primary roller. A retaining clip92is secured to the interior of the primary roller20adjacent the end of the torsion spring from which the hook-like element or catch94depends. The clip92has a first pair of projections95and a second pair of projections96. The first pair of projections95engage the ribs91and93of the primary roller20so that the clip92cannot rotate within the primary roller. At the same time, the catch94is hooked around one of the projections96. This assembly functions to provide a degree of assistance to the motor72for the purpose of rotating roller20when the awning material is wound onto the roller.

A rod100is located within the torsion spring90. A bushing102and a sleeve104are arranged on the rod. When the primary roller20rotates in the direction to deploy the awning30, the torsion spring90is wound so that additional turns are created in the spring causing the length of the spring to increase. On the other hand, when the roller20is rotated for the purpose of winding the awning30onto the roller, the number of turns in the torsion spring decreases resulting in a shortening of the spring. Because the clip92is attached to the hook-like element94of the spring, the clip is displaced back and forth along the longitudinal axis of the primary roller20. The rod100provides a guide for this displacement and also prevents the clip92from twisting. The bushing102allows for the back and forth movement of the spring as well as its rotation about rod100. The sleeve104is part of an assembly that anchors to the rod100the end of the spring90that is opposite catch94.

The end16of the primary roller20is closed by means of the closure cap17to which bracket18is secured. The rod100extends through the cap17, which is free to rotate about the rod, and is fastened to the bracket18. One method of fastening the rod to the bracket is to provide aligned holes in the bracket18and the rod100and a press-fit pin driven into the holes.

Based on the foregoing description, it will be understood that the awning assembly when provided with an electric motor and the components illustrated inFIG. 2functions as follows: When the awning assembly is in a deployed condition and is to be returned to the structure at which it is mounted, the electric motor is energized so as to cause the secondary roller40to rotate in the direction shown by the directional arrow61. As described above, this causes the awning material50to be wound on the secondary roller40and as the wraps of the second awning material accumulate on the secondary roller, the space63between the shoulder26of the primary roller20and the outermost wrap becomes smaller. Finally, as the dowel55on the second awning material50reaches the shoulder26on the primary roller, the space63is so small as to prevent the dowel55from passing through the space. As a result, continued rotation of the secondary roller in the direction of the directional arrow61will cause the primary roller20to rotate in the same direction. The first awning material30will thereby be wound onto the primary roller20. The winding of the awning material30on the primary roller20will continue until the awning material is essentially completely wound and neither the primary roller nor the secondary roller can rotate any longer. At this time the motor will stall out. This stalled-out condition will be sensed by the microprocessor to which the lead wires78are connected and a motor brake will be energized so that the awning assembly can safely be stowed in the awning assembly housing. The return of the awning assembly to the structure at which it is mounted is aided by the torsion spring90which will have been wound to a loaded condition when the awning assembly is deployed as described above.

To deploy the awning assembly, first, the motor brake that is set when the awning assembly is stored is released. The folding extension arms (not shown) that are secured to the brackets14and18and support the awnings are spring loaded and biased towards extending the awning assembly away from the structure at which it is mounted in a manner familiar to those of ordinary skill in the art. Additionally, in some instances, the geometry of the apparatus is such that gravity will cause the awning assembly to move outwardly in a downward direction from the structure at which the awning assembly is mounted. During deployment of the awning assembly, torsion spring90will be wound to a loaded condition. Thus, during deployment of the awning assembly, the spring90will counteract the springs driving the folding extension arms and the force of gravity resulting in a smooth deployment of the awning assembly. Additionally, when the awning assembly is returned to the structure at which it is mounted, the force of rotation created by the motor72and the torsion spring90work against the force of the springs driving the folding extension arms and the force of gravity which results in a smooth return of the awning assembly to the structure at which it is mounted. When the awning material30is completely unwound, the motor72can be energized by means of the microprocessor so as to cause secondary roller40to rotate in the direction of the directional arrow60, whereby the awning material50is unwound to a desired extent at which time the motor is turned off. In this regard, mechanical stop components86and88prevent the secondary roller40from continuing to rotate after the second awning material has reached its full extension thereby preventing the second awning material from rolling up in a backwards direction.

Although a particular embodiment of the invention has been described in detail above, it will be understood that the invention is not limited to that embodiment but includes all changes and modifications that are within the literal and equivalent scope of the claims that follow.