Removably mountable roof frame for use with an expandable canopy

An erectable canopy framework comprising a base frame and a roof frame. The roof frame is operative to support a canopy above the base frame and is removably mountable to the base frame. The base frame includes a plurality of upright support members, a plurality of cross members, each interconnecting adjacent upright support members, and a plurality of mounts disposed on the upright support members. Each mount includes a mount opening and each cross member includes a scissor assembly to permit movement of the base frame between expanded and a collapsed states. The mounts are operative to fasten the cross members to the upright support members. The roof frame includes a plurality of rafters each connectable to a corresponding mount opening. The framework comprises a plurality of rafter fittings each adapted for insertion into a corresponding mount opening and connectable to a corresponding rafter.

BACKGROUND

Collapsible canopies are well-known in the art of portable shelters. Collapsible canopies may be expanded to support a flexible canopy covering to protect people front the elements, such as rain and sunshine. These canopies may also be collapsed into a compact state such that they are more easily transported. Typically, the framework includes upright support members, or legs, interconnected by a plurality of expandable and collapsible scissor assemblies. The framework often includes central support provided for supporting the canopy covering in a peaked configuration in order to shed water.

As collapsible canopies have gained in popularity for use at sporting events, trade shows, flea markets, concerts, and the like, advertisers have recognized the opportunity to exploit the surface area of the canopy's roof for advertising. However, the peaked configuration of traditional collapsible canopies is not always conducive to display large logos, slogans, pictures, etc. The peaked dome typically only provides a small vertical margin area on each side of the canopy for displaying advertising material. The sloped portions of the peaked configuration are typically not easily visible from the ground.

There are some collapsible canopies that have different roof configurations, such as a gabled configuration. However, typically these other roof configurations are part of the expandable mechanism in the canopy's framework. Thus, the roof configuration is fixed. Moreover, the framework complexity is increased by the expandable roof portion and is therefore more susceptible to damage and is more expensive to produce. Having integrated roof that is permanently attached also increases the weight of the canopy framework. Furthermore, in order to have multiple roof configurations available for various circumstances, a user must purchase and maintain several complete canopy frames.

Accordingly, there is a need for a collapsible canopy with a versatile roof frame that is capable of being changed between different roof configurations in order to suit a user's needs.

SUMMARY

Provided herein is an erectable canopy framework comprising a base frame and a roof frame. The base frame includes a plurality of upright support members, a plurality of cross members, each interconnecting adjacent upright support members, and a plurality of mounts disposed on the upright support members. Each cross member may include a scissor assembly or, more generally, an expansion and contraction assembly to permit movement of the base frame between an expanded and a contracted state. The mounts are operative to fasten the cross members to the upright support members. In an embodiment, each mount includes a mount opening. The roof frame is operative to support a canopy above the base frame and is removably mountable to the base frame. The roof frame includes a plurality of rafters each connectable to a corresponding mount opening.

In an embodiment, each rafter includes a stub portion and an arm portion extending at an angle therefrom. The stub portion is adapted for insertion into a corresponding mount opening. In one instance, the arm portion extends from the stub portion at approximately a 45 degree angle. Each rafter may be comprised of a piece of bent tubing. A ridge member extends between distal ends of the rafter portions. A pair of ridge fittings interconnects a pair of rafters with opposite ends of the ridge member. The rafters and ridge member may each comprise multiple rafter or ridge segments, respectively.

In another embodiment, the framework comprises a plurality of rafter fittings each adapted for insertion into a corresponding mount opening and connectable to a corresponding rafter. Each rafter listing comprises a male portion insertable into the corresponding mount opening and a socket, which may be in the form of a ferrule, pivotably attached to the male portion. Each socket is adapted to receive a corresponding rafter and each rafter extends arcuately from the corresponding socket. In one aspect of the technology, each rafter comprises at least one flexible rod. In yet another embodiment, each rafter extends diagonally between opposite upright support members. In another aspect of the technology, the framework may be fitted with a canopy that is extendable over the roof frame forming an expandable canopy. In yet another aspect of the technology described herein, the framework comprises a plurality of mounts, each including a socket pivotably attached thereto such that each rafter is received in a corresponding socket.

In another embodiment, a pair of cross member rafters extend arcuately between opposed scissor assemblies. Each scissor assembly includes a pair of scissor units connected together by upper and lower cross member mounts. The upper cross member mount includes an insert opening adapted to receive a cross member rafter insert that is connectable with a corresponding cross member rafter.

Also disclosed herein is a rafter fitting for use with an erectable canopy framework that includes a base frame and a roof frame removably mountable to the base frame. The base frame includes a plurality of upright support members and a plurality of mounts disposed on the upright support members, wherein each mount includes a mount opening, and wherein the roof frame includes a plurality of rafters. The rafter fitting includes a male portion insertable into a corresponding mount opening and a socket pivotably attached to the male portion. The socket is configured to receive a portion of a corresponding rafter.

In one aspect of the technology, the socket pivots about a pivot axis that is oriented such that the corresponding rafter received therein extends diagonally between opposite upright support members. In an embodiment, the male portion has a rectangular cross-section and the socket pivots about a pivot axis oriented at approximately a 45 degree angle with respect to the rectangular cross-section. A clevis bracket is disposed on the male portion and a clevis pin extends through the ferrule to define the pivot axis.

Also contemplated herein is a method of erecting a canopy. The method comprises expanding a base frame that includes a plurality of upright support members and a plurality of mounts disposed on the upright support members, mounting a roof frame to the base frame, and subsequently removing the roof frame from the base frame. The step of mounting the roof frame to the base frame includes connecting rafter fittings to the mounts. The mounts include mount openings and the rafter fittings are inserted into the mount openings. The method may also include connecting rafters to the rafter fittings and connecting a ridge member to the rafters.

These and other aspects of the technology and its various embodiments will be apparent after consideration of the Detailed Description and Figures herein. It is to be understood, however, that the scope of the invention shall be determined by the claims as issued and not by whether given subject matter addresses any or all issues noted in the background or includes any features or aspects recited in this summary.

DETAILED DESCRIPTION

Described herein are various embodiments of a removably mountable roof frame for use with an expandable canopy, which allows the roof configuration of the canopy to be changed between different configurations in order to suit a user's needs.FIG. 1shows a canopy5according to a first exemplary embodiment that has a rounded gable roof, or otherwise referred to as a barrel-shaped roof. The canopy includes a framework10which supports a canopy cover7. Canopy cover7is configured to conform to an underlying framework structure10that defines the rounded gable shape.FIG. 2illustrates a canopy105according to a second exemplary embodiment that is the form of a dome. Canopy105includes a framework110and a canopy cover107.

With reference toFIG. 3, the underlying framework10of canopy5can be better appreciated. Framework10includes a base frame12and a roof frame14which is removably mountable to the base frame12. As is known in the art, base frame12includes a plurality of upright support members16which are interconnected by a plurality of cross members18. Cross members18may comprise an expansion and contraction assembly which, in the referenced embodiment are shown in the form of a pair of scissor units20, though the artisan will appreciate that the term should not be limited as such and is intended to encompass any cross member construct that can be moved between expanded and contracted states, such as telescopic, folding, bending, etc, whether known or unknown in the art. The scissor units20are connected to the upright support members16by a fixed mount22and a sliding mount24. Accordingly, the cross members allow the base frame to expand and collapse. Each pair of scissor units20that are connected to each other by upper and lower cross member mounts26and28, respectively. Base frame12is constructed similar to the collapsible canopy framework described in U.S. Pat. No. 5,244,001 issued to Lynch, the disclosure of which is incorporated herein by reference in its entirety.

Roof frame14includes a plurality of rafters32, each of which is connectable to a corresponding mount22on base frame12. Rafters32are operative to support the canopy cover7above the base frame12. With reference toFIG. 4, mount22includes central portion80with a mount opening88. Attached to the central portion80is a pair of clevis portions82. Clevis portions82are configured to receive the scissor units20therein. A fastener84secures the scissor units to the clevis portions82. In this case mount22is fabricated from tubing and sheet metal that has been formed into a clevis portion. These components may be welded or fastened together. Furthermore, the mount may be formed as a unitary body, which may be achieved through an injection molding process, all as known in the art.

With reference toFIGS. 5,6A, and7, the roof framework includes a plurality of rafter fittings30, each of which is adapted for insertion into a corresponding mount opening88and is connectable to a corresponding rafter32. With particular reference toFIG. 7, rafter fitting30includes a male portion50which is insertable into the mount opening88. Cap52, which is disposed on the top of mount portion50, provides an end stop for the fitting. A clevis bracket54is attached to cap52and rotatably supports a socket56. Socket56is retained in clevis54by a clevis pin58. In this case, clevis pin58is in the form of a threaded fastener as known in the art. In this case, socket56is in the fun of a ferrule which has a socket opening60for receiving an end portion of a corresponding rafter32.

An alternative construction of a mount422is shown inFIG. 6B. Mount422includes a clevis bracket454disposed directly on central portion480. Clevis454rotatably supports a socket456for receiving an end portion of a corresponding rafter32. Mount422also includes clevis portions482for connecting to scissor units20. Accordingly, mount422combines the mount22and rafter fitting30, described above, into an integrated component.

Returning toFIG. 3, roof frame14includes rafters32disposed on the ends of the framework with a cross member rafter33located between the two end rafters32. Each rafter32and33is, in this case, comprised of a pair of rafter segments36which are connected together by a splice lifting40. A ridge member34is configured to extend between the distal ends of the rafters32. In this case, the ridge member34comprises multiple ridge segments38which are connected together by splice fittings40. Where the ridge member intersects the cross member rafters33, a cross fitting44joins the various segments in a cross pattern. With reference toFIG. 5, it can be appreciated that socket56is sized and configured to receive an end portion of an associated rafter segment36. In this embodiment, each rafter32,33extends arcuately between opposed cross members18. It can also be appreciated in the figures that the rafters32,33are parallel to each other. In this case, each rafter segment is comprised of flexible rod, such as fiberglass, composite, or aluminum rod, all as known in the art. The rafters may also include stretchable shock chord threaded through and between the rafter segments, also as known in the art.

Referring again toFIG. 3, the cross member rafters33extend from the upper cross member mounts26. With further reference toFIG. 10, the upper cross member mount26includes an insert opening64sized and configured to receive a cross member rafter insert46. Cross member rafter insert46includes a receptacle62which is configured to receive an end portion of rafter segment36of cross member rafter33.

Referring toFIG. 11, cross fitting44includes a hollow tube72configured to receive a pair of ridge segments38. Extending from hollow tube72is a pair of branches74configured to receive end portions of rafter segments36of the cross member rafter33. As shown inFIG. 12, the ridge fitting42includes a hollow tube68that is closed on one end69. Extending from the hollow tube68adjacent closed end69is a pair of branches70for receiving end portions of rafters32.FIG. 3illustrates splice fitting40as a hollow tube66.FIG. 14shows the mount opening plug76which comprises a male portion75and a plug cap78configured as shown.FIG. 15illustrates an alternative construction for a mount322which includes a central portion386and a pair of clevis portions382. In this embodiment, the central portion386and clevis portions382are integrally formed as a unitary body. For example, mount322may be injection molded. Mount322also includes a mount opening388for connecting a rafter thereto.

FIG. 16illustrates the construction of the dome framework110for use with a canopy105shown inFIG. 2. Dome framework110includes base frame12as described above but with a different roof frame construction114. Roof frame114comprises rafter fittings130from which extend a plurality of rafters132. Each rafter132is comprised of rafter segments136joined by splice fittings40. The rafters extend arcuately from rafter fittings130, and the rafters extend diagonally between opposite upright support members16. Accordingly, in this embodiment the rafters cross cadi other in contrast to the parallel rafters described above with respect to the first exemplary embodiment.

With reference toFIGS. 8 and 17, the rafter fitting130used with the dome canopy105has a similar construction to the rafter fitting30described above with the first exemplary embodiment. However, in this case, clevis154is mounted at an angle—with respect to cap152and male portion150. The angle of clevis154is approximately 45 degrees with respect to the male portion150. Accordingly, because the male portion150is rectangular or square in shape, the ferrule156is directed at a diagonal angle with respect to each upright support member16. Rafter fitting130also includes a socket156that is pivotably disposed on clevis154by a clevis pin158. Socket156may be in the form of a ferrule as shown with a socket opening160for receiving a rafter segment136.

An alternative construction of a rafter fitting330is shown inFIG. 9. Rafter fitting330is similar in construction to that described above with respect toFIGS. 7 and 8; however, the male portion350is, in this case, in the form of a cylinder rather than a square. Accordingly, male portion350may rotate within the mount opening88of mount22. Therefore, rafter fitting330may be used for both the rounded gable roof frame and the dome roof frame. In the case of the dome roof frame, the cylindrical male portion350allows the rafter fitting to orient such that the rafters132extend diagonally opposite upright support members16. Rafter fitting330includes male portion350with a cap352disposed thereon. Clevis354is mounted to cap352and rotatably supports a socket356which rotates about clevis pin358.

A third exemplary embodiment of a canopy205is shown inFIG. 18. In this embodiment, the roof is in the form of a peaked gable. Canopy205includes a framework210with a canopy cover207. As shown inFIG. 19, the framework210includes base frame12as described above and a roof framework214. Roof frame214includes a plurality of rafters232extending from mounts22which are operative to support the canopy cover207above base frame12. Roof frame214also includes a ridge member234extending between the rafters232. A ridge fitting242connects the ridge member to rafters232as shown. With reference toFIG. 20, in this embodiment, the base frame includes the unitary mount322as described with respect toFIG. 15. With further reference toFIG. 21, it can be appreciated that the roof frame210may be disassembled into components. Each rafter232includes an arm portion238with a stub portion240extending therefrom at an angle A. Angle A may be approximately 45 degrees. However, the angle at which stub portion240extends from arm portion238may vary to provide different roof configurations. Each ridge fitting242includes a ridge clevis268for attachment to the ridge member234. Extending at angles from the ridge clevis268is a pair of branches270. In this embodiment, it is contemplated that the rafters and ridge members are comprised of tubing, such as steel or aluminum tubing having a square cross-section, for example. However, tubing or bar of other materials and cross sections may be used. It should also be understood that the rafters may be a single piece of bent tubing that forms the arm portion238and stub portion240. Alternatively, the arm portion and stub portion may be welded or otherwise fastened together.

A fourth exemplary embodiment of a framework310is shown inFIG. 22. In this embodiment, framework310may be used to create a rounded gable roof configuration, such as that shown inFIG. 1. However, in this embodiment, it is contemplated that the rafters and ridge members are comprised of tubing, such as steel or aluminum tubing having a square cross-section, for example. As shown inFIG. 22, the framework310includes base frame12as described above and a roof framework314. Roof frame314includes a plurality of rafters332extending arcuately from mounts22which are operative to support a canopy cover, such as canopy cover207, shown inFIG. 1. Roof frame314also includes a ridge member334extending between the rafters332. A ridge fitting342connects the ridge member to rafters332as shown. With further reference toFIG. 23, it can be appreciated that the roof frame310may be disassembled into components. Each rafter332includes an arcuate arm portion338and a stub portion340. Ridge fittings342have a similar construction to that shown inFIG. 21, albeit the angles between branches may vary to accommodates the arcuate arm portions338of the arcuate rafters332.

Also contemplated herein is a method of erecting a canopy. In one embodiment, the method comprises expanding a base frame12that includes a plurality of upright support members16and a plurality of mounts22disposed on the upright support members16, mounting a roof frame14to the base frame12, and subsequently removing the roof frame14from the base frame12. The step of mounting the roof frame14to the base frame12includes connecting rafter fittings30to the mounts22. The mounts22include mount openings88and the rafter fittings30are inserted into the mount openings88. The method may also include connecting rafters32to the rafter fittings30and connecting a ridge member34to the rafters32.

The above described exemplary embodiments of the framework with a removably mountable roof frame provide for a more easily transportable canopy. The base frame and roof frame assembles may now be transported separately, each accounting for a portion of the overall weight of the structure. The disclosed framework also provides more versatility over traditional canopy structures because different roof constructs can be used with a given frame. Accordingly, the overall cost of having multiple roof configurations is reduced because multiple interchangeable removably mountable roof frames may be used with a single base framework.

Accordingly, the removably mountable roof frame has been described with some degree of particularity directed to the exemplary embodiments. It should be appreciated; however, that the present invention is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the exemplary embodiments without departing from the inventive concepts contained herein.