DISPOSABLE UMBRELLA AND METHOD OF MANUFACTURE

Abstract: The umbrella (100) has two parts: a flexible water impermeable canopy (102) and a rectangular rigid frame (104). Pockets (126, 128) are formed in two parallel sides of the canopy. The frame has outer dimensions substantially matching the outer dimensions of the canopy. A center fold line (138) in the frame defines two equal side panels (140, 142) and allows the side panels to fold together into a closed position. The canopy is fitted on the top of the frame by bending the side panels opposite the closed position until the frame sides (134, 136) slip into the canopy pockets. The panels are then returned to the closed position. Handles (156, 158) cut in the side panels fold down for use and position the umbrella in a peak-roof shape when aligned and held by one hand.

Description: DISPOSABLE UMBRELLA AND METHOD OF MANUFACTURE RELATED APPLICATION This application is a continuation-in-part of applicant's previously filed application Serial No. 06/774,133, filed September 9, 1985. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention pertains to the umbrella art, and more particularly, to an inexpensive disposable umbrella and a method for its manufacture. 2. Background Art Standard umbrellas are inconvenient to carry and are, therefore, often unavailable when.needed. In addition, they are expensive causing their owners to leave them in the closet in order to avoid loss or damage unless they are obviously needed. The result is that many owners end up with several expensive umbrellas — all bought on impulse when required to meet unexpected weather conditions. Numerous inexpensive and disposable umbrellas have been developed allowing purchase at convenient locations at the onset of inclement weather and then disposal after one or a few uses. Some of these disposable umbrellas are disclosed in U.S. Patent Nos. 2,552,461; 2,563,353; 2,757,679; 4,062,369; 4,182,353; 4,215,711; and 4,370,993; and The Netherlands Patent No. 7,607,179 and United Kingdom Patent No. 347,678. While they are relatively inexpensive in relation to the cost of a standard umbrella, many are still expensive per use, difficult to set up, or have limited durability. SUMMARY OF THE INVENTION The present invention is directed to a disposable umbrella and method of manufacture designed to minimize the expense while maximizing the durability and ease of set up. The umbrella is of such a size and configuration that it may be easily stored for use or sale when needed. The canopy and frame material make the umbrella an ideal sitting pad for outdoor sports events. Advertising may be included on the canopy to enhance the appearance or make a statement. In accordance with one important aspect of the invention, the canopy is comprised of a rectangular flexible water impermeable sheet having first and second parallel sides, each side having a pocket. The frame is comprised of a rectangular rigid sheet having outer dimensions substantially matching the outer dimensions of the canopy. The frame sides are parallel to each other and are spaced substantially the width of the canopy. A center fold line is parallel to the frame sides and defines two substantially equal side panels. The side panels may be bent toward each other until the frame sides touch in a closed position. The canopy fits over the outside of the frame with one of the frame sides slipped into one pocket and the other frame side slipped into the second pocket. One feature of the preferred embodiment are tongue cut in each of the side panels. Each tongue has a handle and a tongue fold line for folding out the tongue. When the tongues are folded out and the handles aligned, the umbrella is positioned in a peak-roof shape. In a preferred embodiment, a locking tab is provided on one tongue and a tab lock opening is provided on the other tongue. When the handles are aligned, the locking tab may be positioned in the tab lock opening to retain the tongues together in an aligned position thereby retaining the umbrella in a peak-roof shape without holding by hand. In accordance with one important aspect of a second embodiment, the canopy is a vinyl sheet adhered to the outside of a corrugated cardboard panel. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a perspective view of one embodiment of the invention in use; FIGURE 2 is a bottom perspective view of the embodiment in FIGURE 1 in a flat open position with one handle folded outward; FIGURE 3 is a bottom plan view of another embodiment of the present invention in a flat open position; FIGURE 4 is an enlarged cross sectional view taken along the line 4-4 in FIGURE 3; FIGURE 5 is a perspective view of a preferred embodiment folded for use; FIGURE 6 is a bottom plan view of the frame of the embodiment of FIGURE 5 in a flat open position; FIGURE 7 is a bottom plan view of the canopy of the embodiment of FIGURE 5. FIGURE 8 is a partial end elevational view of the frame of FIGURE 6 in a reverse bend position allowing the installation of the canopy of FIGURE 7; FIGURE 9 is a partial end elevational view of the frame of FIGURE 8 bent to the normal use position with the canopy installed; FIGURE 10 is side elevational view of the embodiment of FIGURE 5; FIGURE 11 is an enlarged sectional view along the line 11 - 11 of FIGURE 10 with one side of the canopy raised; - 4 - FIGURE 12 is an enlarged sectional view similar to FIGURE 11 of another embodiment of the present invention having a plastic frame; FIGURE 13 is an end elevational view of the embodiment of FIGURE 5 open for use; and FIGURE 14 is an end elevational view of the embodiment of FIGURE 13 in a closed position. FIGURE 15 is a bottom plan view of another embodiment of the present invention; and • FIGURE 16 is a perspective view of the embodiment of FIGURE 15 folded. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring initially to FIGURES 1 and 2, there is illustrated a disposable umbrella, generally designated 10, of the present invention. FIGURE 1 is a perspective view of the umbrella 10 open for use and FIGURE 2 is a bottom perspective view with the umbrella partially opened for use. The umbrella 10 has a frame 12 on which there is stretched a canopy 14. The frame is die-cut from a corrugated cardboard panel and the canopy 14 is an opaque thin vinyl plastic film or sheet laminated onto the frame making the umbrella 10 water proof and able to shield out strong sun rays. The frame 12 is square or rectangular shaped measuring approximately two feet by two feet for a most practical size. A center fold line 16 divides the frame 12 into two side panels 18. A pair of fold out right triangular tongues 20 are die-cut along cut line 22 on each side of the center fold line 16. One edge 21 of each tongue 20 is parallel to the center fold line 16 when the umbrella 10 is closed. The tongues 20 fold away from the side panels 18 along fold lines 24 perpendicular to the center fold line 16 and in the same plane with each other. Each triangular tongue 20 also has a hypotenuse edge 25 between the edge 21 and the fold line 24. An extended portion forms a handle 26 in each tongue 20 lying in the plane of the tongue 20 and perpendicular to the fold line 24. If desired, the handles 26 may be optionally reinforced with a wooden stick 27 adhered thereto by suitable adhesive. A second piece of material 50 is laminated and adhered by suitable adhesive to the outside 51 of the frame 12 to form the canopy 14 on the upper side of the frame. The material 50 has the same overall size as the frame 12. An advertising message 48 may be imprinted on the upper side of the canopy 14. A carry handle 28 is provided for carrying the umbrella 10 in folded flat, non-use position. The carry handle 28 comprises a thong 30 extending through holes 32 in the canopy 14 and frame 12 along the fold line 16 and secured either by a knot at each end or by connecting the ends together to form a loop. Loop and hook pile mating fastener pads 34 and 36 such as sold under the trademark Velcro securely hold the side panels 18 together in closed, non-use position. To open for use, the tongues 20 are folded downwardly along the fold lines 24 and the side panels 18 are then folded along the fold line 16 until both handles 26 are aligned adjacent each other. A hand may then gasp both handles 26 retaining the side panels 18 in a peak-roof-shape as shown in Figure 1 for protecting a person 38 from rain or sun. Another embodiment of the disposable umbrella, generally designated 40, is shown in FIGURES 3 and 4. FIGURE 3 is a bottom plan view of the umbrella 40 in a flat open position and FIGURE 4 is an enlarged cross sectional view along the line 4-4 of FIGURE 3. Element's of the umbrella 40 that are similar to the elements of the umbrella 10 in FIGURES 1 and 2 have identical reference numerals. A pair of aligned die-cut loops 42 along one edge of the frame 12 are substituted for the carry handle 28 of umbrella 10 in FIGURE 1. Cut-out areas 44 and 46 in the frame 12 lighten the frame without a noted loss of strength. A tab 52 is substituted for the loop and hook pile mating fastener pads 34 and 36. The tab 52 is foldable about a line 56 and fits into a corresponding mating notch 54. in the other side allowing the umbrella 40 to be securely held together in a closed, non-use position. FIGURE 5 is a perspective view similar to FIGURE 1 of a preferred embodiment of the disposable umbrella of the present invention, generally designated 100, with a canopy 102 stretched over a frame 104 indicated in shadow outline folded into a peak roof shape configuration ready for use. The canopy 102 is fabricated from a flexible sheet shown in..FIGURE 7 and the frame 104 is fabricated from a rigid sheet shown in FIGURE 6. FIGURE 7 is a bottom plan view of the canopy 102. The flexible sheet material of the canopy 102 is preferably a water impermeable plastic vinyl in order to provide an inexpensive waterproof cover for the umbrella 100. The canopy 102 comprises a rectangular piece of the sheet material by folding narrow panels 106 and 108 along the first and second parallel sides 110 and 112, respectively. The narrow ends 114, 116, 118, and 120 of the panels 106 and 108 are then coupled, such as by welding, to the adjacent two sides 122 and 124 to form two pockets 126 and 128. FIGURE 6 is a bottom plan view of the frame 104 in an open position after cutting and prior to bending. The frame 104 is preferrably fabricated of corrugated cardboard although plastic corrugated board, plastic foam board, plastic, or other bendable rigid sheet material may be used. If the frame 104 is fabricated of corrugated cardboard, the cardboard is preferrably coated with wax to protect the cardboard from water. A steel rule die may be used to cut the entire frame 104 with cutouts, cuts, and/or dents if desired. The frame 104 has a rectangular shape substantially matching the outer dimensions of the canopy 102. The two ends 130 and 132 are parallel to each other and perpendicular to the frame sides 134 and 136. The frame sides 134 and 136 are also parallel to each other and spaced from each other substantially the width of the canopy 102. A center fold line 138 parallel to the frame sides 134 and 136 defines two substantially equal sized side panels 140 and 142. The center fold line 138 is initially denting or cut into the rigid sheet material in the direction of the corrugations in order to permit the rigid.sheet material to be accurately bent. Tongues 144 and 146 are cut in the side panels 140 and 142, respectively, creating open areas 148 and 150. Tongue fold lines 152 and 154 are initially dented into the sheet material perpendicular to the center fold line 138 to allow the tongues 144 and 146 to be folded out. Handles 156 and 158 cut on the tongues 144 and 146 are sized to facilitate gripping by a hand. When the handles 156 and 158 are lifted and brought into alignment with each other, the side panels 140 and 142 are bent around the center fold line 138 into the peak-roof shape illustrated in FIGURE 5. A locking tab 160 and a tab lock opening 162 cut into the tongues 144 and 146 allow the tongues to be retained together in the aligned position when the locking tab is positioned in the tab lock opening. The canopy 102 of FIGURE 7 is installed on the frame 104 of FIGURE 6 by bending the frame along the center 'fold line 138 until the frame sides 134 and 136 of the side panels 140 and 142 touch in a closed position illustrated in FIGURE 14. The frame 104 is then bent in the reverse direction indicated by the arrow 164 in FIGURE 8 around the center fold line 138. The frame side 134 is slipped into the pocket 126 of the canopy 102 and the other frame side 136 is slipped into the other pocket 128 in the direction of the arrow 166. The frame 104 is then returned to the closed position illustrated in FIGURE 14 retaining the canopy 102 on the frame and insuring the proper positioning of the frame sides 134 and 136 in the side pockets 126 and 128. FIGURE 9 is a partial end elevational view of the frame 104 of FIGURE 8 bent to the normal use position with the canopy 102 installed on the upper surface 168. The locking tab 160 on the first tongue 144 has been bent through the tab lock opening 162 in the second tongue 146 thereby locking the tongues together in an aligned position to retain the umbrella 100 in a peak-roof shape. FIGURE 10 is side elevational view of the umbrella 100 in the peak-roof shape. The position of the locking tab 160 on the first tongue 144 through the tab lock opening 162 in the second tongue 146 is clearly shown. FIGURE 11 is a partial enlarged sectional view along the line 11 - 11 of FIGURE 10 with one side of the canopy 102 slightly raised separating the canopy from the corrugated cardboard frame 104. The canopy 102 is folded around the frame side 134 forming the pocket 106. It will be appreciated that corrugated board fabricated of plastic and similar in appearance to the corrugated cardboard may be used instead of the corrugate cardboard. FIGURE 12 is an enlarged sectional view similar to FIGURE 11 of another embodiment of the present * invention having a solid plastic frame 170. The plastic frame 170 may be fabricated either of one layer of plastic or a sandwich of layers with a hard upper layer 172, a foam core 174, and a hard bottom layer 176. The canopy 178 fits over the frame side 180 in the same manner as in FIGURE 11. FIGURE 13 is an end elevational view of the umbrella 100 of FIGURE 5 open for use. The handles 156 and 158 are in complete alignment allowing the combined handles to be easily held by one hand. FIGURE 15 is a bottom plan view of another embodiment of the umbrella, generally designated 190. The umbrella 190 is identical to the umbrella 100 of FIGURES 5 except for the addition of folding lines 192 and 194 along the length of the umbrella. The folding lines 192 . and 194 allow the umbrella 190 to be folded into quarters as illustrated in FIGURE 16. A rubber band 196 may be utilized to retain the umbrella 190 in the folded condition. In view of the above, it may be seen that a disposable umbrella and method of manufacture are provided. Of course, the structure and method may be variously implemented, performed, and used depending upon specific applications. Accordingly, the scope hereof shall not be referenced to the disclosed embodiments, but on the contrary, shall be determined in accordance with the claims as set forth below.

Claims: I claim: 1. A disposable umbrella, comprising, in combination: a canopy comprising a vinyl sheet; and a frame having said vinyl sheet adhered to the outside of said frame, said frame comprising a corrugated cardboard panel having: a center fold line for folding said frame and canopy, a pair of identical fold out right triangular tongues one on each side of said center line, each tongue having: one edge parallel to said center line, a tongue fold line perpendicular to said center line for folding out said tongue, a connecting hypotenuse edge, and a handle lying in the plane of the tongue and perpendicular to the tongue fold line; whereby said handles align to form a single handle for holding by a hand and simultaneously retaining the umbrella in a peak-roof shape. 2. The disposable umbrella according to claim 1 wherein said canopy is opaque. 3. The disposable umbrella according to claim 1 wherein an advertisement. is imprinted on the outside of said vinyl sheet whereby said vinyl sheet provides both a water proofing for the umbrella and a base for the advertisement. 4. The disposable umbrella according to claim 3 wherein securement means are attached to edges of said frame for holding said two side panels together in a non-use position. 5. An umbrella, comprising: a canopy comprising a rectangular flexible water impermeable sheet having first and second parallel sides, each side having a pocket thereat; and a frame comprising a rectangular rigid sheet having outer dimensions substantially matching the outer dimensions of said canopy; said frame having: ends parallel to each other; sides parallel to each other and spaced from each other substantially the width of said canopy; a center fold line parallel to said sides and defining two substantially equal sized side panels on either side of said center fold line allowing said side panels to be bent toward each other until said sides touch in a closed position; and one of said frame sides removably received in said first pocket and the other of said frame sides removably received in said second pocket. 6. An umbrella according to claim 5 and further including a tongue cut in each of said side panels; each of said tongues having: a tongue fold line for folding out said tongue, and a handle; said handles aligning to position said umbrella in a peak-roof shape. 7. An umbrella according to claim 6 wherein one of said tongues further includes a locking tab and the other of said tongues has a tab lock opening for selectively receiving said locking tab to retain said tongues together in an aligned position. 8. A method for constructing an umbrella comprising the steps of: folding narrow panels along two parallel sides of a rectangular flexible sheet; coupling the narrow ends of the narrow panels to the adjacent two sides of the flexible sheet forming a canopy haying two side pockets; cutting a rigid sheet into a frame having outer dimensions substantially matching the outer dimensions of said canopy; bending said frame to form a center fold line with substantially equal sized side panels until the sides of said side panels touch in a closed position; reverse bending said frame in the opposite direction along said center fold line and slipping one of said sides of said frame into one of said side pockets and the other of said sides into the other of said side pockets; and returning said umbrella to said closed position with said canopy retained on said frame. 9. A method for constructing an umbrella as recited in claim 8 wherein the step of cutting includes cutting said frame to form a tongue having a handle on each side of said center fold line; and further comprising the steps of: bending the tongues along tongue fold lines into the same plane substantially perpendicular to the respective side panels; and aligning the handles with each other into an aligned position positioning said umbrella in a peak-roof shape. 10. A method for constructing an umbrella as recited in claim 9 wherein the step of cutting further includes cutting a locking tab in one of said tongues and a tab lock opening in the other of said tongues; and further comprising the step of bending said locking tab into said tab lock opening locking said tongues together in said aligned position.

Inventors: REX JAMES R, REX, JAMES, R.
Applicants: REX JAMES R, REX, JAMES, R.
Application year: 1986
Main classification: A45B13
IPC codes: A45B13, A45B19