Abstract:
There is provided an improved adjustable tension rod that allows length adjustment and activation of end cap adjustment without having to move one&#39;s holding position on the rod.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/780,609, filed Mar. 13, 2013, which is incorporated herein by reference in its entirety. 
     
    
     FIELD 
       [0002]    The present invention relates generally to an adjustable tension rod and, more particularly, to an adjustable tension rod that installs in a more convenient manner. 
       BACKGROUND 
       [0003]    Adjustable tension rods are commonly used to support curtains, such as shower curtains. Adjustable tension rods commonly have two tubes where one slides inside the other one to adjust the relative length of the combined tubes. The tensions rods include a locking system to set the tubes relative to one another and adjustable end caps to apply the appropriate amount of pressure on a pair mounting walls between which the rod extends. This will secure the rod in place. 
         [0004]    Known shortcomings with current tension rods include their difficulty to install. For example, they commonly require movement of one&#39;s hands to a different position on the rod during installation. That is, one uses one position to adjust the tubes relative lengths and another position to adjust the end caps. This latter adjustment commonly requires going to one or both ends of the rod to adjust the end caps, while still having to hold the rod from one end so that it does not slide relative to the mounting walls. This process tends to permit the rod to slip on the walls and be installed in an out of level manner. 
         [0005]    Thus, there exists the need for an improved adjustable tension rod that is more easily installed in a level manner. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of a tension rod in accordance with a preferred embodiment of the present invention; 
           [0007]      FIG. 2  is longitudinal cross-section showing an adjustment mechanism for the tension rod of  FIG. 1 ; 
           [0008]      FIG. 3  is a perspective view of an insert of a lock assembly of the adjustment mechanism of  FIG. 2 ; 
           [0009]      FIG. 4  is a top plan view of the insert of  FIG. 3 ; 
           [0010]      FIG. 5  is a perspective view of the insert of  FIG. 3  with a lock disc attached thereto; 
           [0011]      FIG. 6  is a top plan view of the lock disc of  FIG. 5 ; 
           [0012]      FIG. 7  is a perspective view down an inside of an inner tube of the tension rod of  FIG. 1  showing the insert of the lock assembly of  FIG. 3 ; 
           [0013]      FIG. 8  is a perspective view down an inside of an outer tube of the tension rod of  FIG. 1  showing the lock disc of  FIG. 6 ; 
           [0014]      FIG. 9  is a perspective view of a left end cap of the adjustment mechanism of  FIG. 2 ; 
           [0015]      FIG. 10  is a perspective view of a right end cap of the adjustment mechanism  FIG. 2 ; 
           [0016]      FIG. 11  is a perspective view of a left end cap adjustment screw insert of the adjustment mechanism  FIG. 2 ; 
           [0017]      FIG. 12  is a perspective view of a right end cap adjustment screw insert of the adjustment mechanism  FIG. 2 ; 
           [0018]      FIG. 13  is a perspective view of a left end outer tube insert of the adjustment mechanism  FIG. 2 ; 
           [0019]      FIG. 14  is a perspective view of a right end inner tube insert of the adjustment mechanism  FIG. 2 ; 
           [0020]      FIG. 15  is a cross-section view of an alternative adjustment mechanism for the tension rod of  FIG. 1 ; 
           [0021]      FIG. 16  is a perspective view of a lock assembly for the alternative adjustment mechanism of  FIG. 15 ; 
           [0022]      FIG. 17  is a perspective view of a lock ramp of the lock assembly of  FIG. 16 ; 
           [0023]      FIG. 18  is a perspective view of an inner tube left end insert of the lock assembly of  FIG. 16 ; and 
           [0024]      FIG. 19  is a perspective view of a lock sleeve of the lock assembly of  FIG. 16 ; 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    With reference to  FIG. 1 , there is illustrated a universal tension rod  10  designed to be easily installed between two walls to support hanging items, such as for supporting a shower curtain in a shower enclosure. The shower rod adjusts in length from a contracted length to an extended length to accommodate different distances between the mounting walls. Once adjusted to a level distance between the mounting walls, the tension rod if further adjusted to apply the appropriate amount of force on the walls to facilitate sufficient supporting strength. The adjustment mechanisms described herein permits simple installation of the tension rod without having to move one&#39;s hands along the rod during installation and without undesired walking of the ends of the rod on the mounting wall. 
         [0026]    More specifically, the tension rod  10  includes an inner tube  12  partially received in an outer tube  14 . The inner tube  12  extends telescopically from the outer tube  14  to provide a coarse adjustment of the rod  10  to engage the mounting walls. The outer tube  14  includes a left end cap  16 , and the inner tube  12  includes a right end cap  18 . The end caps  16 ,  18  adjust relative to their respective tubes  14 ,  12  to provide fine adjustments to further apply force against the mounting walls. These adjustments, as explained further below, place the rod  10  in sufficient tension between the mounting walls to enable the rod  10  to support items such as a shower curtain. 
         [0027]    With reference to  FIGS. 2-14 , there is illustrated one embodiment of an adjustment mechanism for the tension rod  10 . The adjustment mechanism includes a lock assembly  20  intermediate the end caps  16 ,  18  to lock the inner and outer tubes  12 ,  14  relative to one another for the coarse adjustment. The adjustment mechanism further includes a left end cap adjustment assembly  22  and a right end cap adjustment assembly  24 . The end cap adjustment assembles  22 ,  24  provide the fine adjustments to apply the appropriate amount of force against the mounting walls. For the adjustment mechanism of  FIG. 2 , the inner and outer tubes  12 ,  14  are roll formed from metal with a longitudinal folded seam along the inside to secure the rounded cross-section (see  FIGS. 7 and 8 ). 
         [0028]    The lock assembly  20  includes a lock assembly insert  26  that fits in an inner end portion  28  of the inner tube  12  such that it is fixed against movement relative to the inner tube  12  and a lock disc  30  that is attached to an outer end  32  of the insert  26  that extends beyond an end  34  of the inner tube  12 . The lock disc  30  engages an inside surface  36  of the outer tube  14  to enable the tubes  12 ,  14  to be extended relative to another but not contracted once extended. 
         [0029]    With reference to  FIGS. 3 and 4 , the lock assembly insert  26  has a cylindrical, hollow body configuration with a flat end wall  38  at one end surrounded by a perimeter flange  40  extending radially from the insert  26 . The flange  40  engages the end  34  of the inner tube  12  as a stop against complete insertion into the inner tube  12 . The flat end wall  38  includes a central threaded bore. The threading may be provided by a metal insert  41  friction fitted into the bore in the flat end wall  38 . The outer diameter of the insert  26  is such that it provides a friction fit with an inner surface  42  of the inner end portion  28  of the inner tube  12  to resist unintentional removal from the inner tube  12 . The insert  26  includes a longitudinal groove  44  extending the entire length for receiving a folded seam  46  ( FIG. 7 ) to resist rotation of the lock assembly relative to the inner tube  12 . The insert  26  also may include a circumferential groove  48  near an inner end  23  of the insert  26 . The circumferential groove  48  may be used to further secure the insert  26  in the inner tube  12 . A portion of inner tube at the groove  48  can be indented into to the groove  48  to provide an interlocking engagement. The insert may be made, such as molded, from a rigid plastic material. 
         [0030]    With reference to  FIGS. 5 and 6 , the lock disc  30  is attached to the flat end wall  38  of the insert  26  with a threaded screw  50  in into the central threaded bore  41 . The lock disc  30  includes a series of radials slits  52  that define a series of petals  54  with an arcuate outer edge  56 . A seam cutout  55  is located at one of the slits  52 . The seam cutout  55  receives the folded seam  57  of the outer tube  12  ( FIG. 8 ). 
         [0031]    The petals  54  enable the lock disc  30  to take on a concave shape facing into the outer tube  14  ( FIG. 2 ). The diameter of the lock disc  30  is sufficiently large so that the outer arcuate edge  56  of the petals  54  engages the inner surface  36  of the outer tube  14 . The concave shape enables the petals  54  to slide along the inner surface  36  as the inner and outer tubes  12 ,  14  are extended relative to one another but wedges against the inner surface  36  to prevent contraction of the inner tube  12  into the outer tube  14 . This provides a one way slip lock configuration for the coarse extension of the tubes  12 ,  14  relative to one another between the mounting walls. The lock disc  30  is preferably made of a metal material, such as spring steel, that retains its shape and of sufficient integrity to lock against the inner wall  36  of the outer tube  14 . 
         [0032]    The left and right end cap assemblies  22 ,  24  are the same except that they are threaded so the rotation of both the inner and outer tubes  12 ,  14  in the same direction causes both the left and right end caps  16 ,  18  to translate in opposite directions with respect to one another. That is, rotation of the tubes  12 ,  14  in clockwise direction when looking at the right end cap  18  causes the end caps  16 ,  18  to translate away from one another (outward) to apply pressure on the mounting walls to secure the tension rod  10  and when rotated in the counterclockwise direction, the end caps  16 ,  18  move toward each other to release the tension rod  10  from the mounting walls. During installation, one simply pulls the tubes  12 ,  14  apart to the desired length between the mounting walls and without moving their hands begins to turn the tubes  12 ,  14  together in the clockwise direction (i.e., toward their body) to translate the end caps  16 ,  18  outward to apply pressure on the mounting walls to secure the tension rod  10 . 
         [0033]    With reference to  FIGS. 9 and 10 , the left end cap  16  and the right end cap  18  are identical. The end caps  16 ,  18  each include an end wall  62  with an outer surface  64  that is generally flat, a tapering outer surface  66  extending away from the outer surface  64  to the other end of the end cap, and a cylindrical, hollow interior  68 . A driver  70  projects from a center of the end wall into the interior  68  of the end cap. The driver  70  may be hexagonal in form. The end caps  16 ,  18  may be made a rubber type material designed to provide a friction engagement with the mounting walls to prevent the end caps from rotating and walking on the mounting walls during rotation of the tubes for installation. 
         [0034]    With reference to  FIGS. 11 and 12 , the left and right end cap assemblies  22 ,  24  include a left and right end cap adjustment screw insert  72 ,  74 , respectively. A head  76  of each screw insert  72 ,  74  includes a drive socket  78  to receive the driver  70  of the end caps  16 ,  18 . The socket may be hexagonal in configuration. The diameter of the head  76  is sized to provide a friction fit with an inner surface  80  of the interior  68  ( FIG. 10 ) of the end caps  16 ,  18 . The left end cap adjustment screw insert  72  includes right hand threading  82 , and the right end cap adjustment screw insert  74  includes a left hand threading  84 . The left and right end cap adjustment screw inserts  72 ,  74  may be made, such as molded, from a rigid plastic material. 
         [0035]    With reference to  FIGS. 13 and 14 , the left and right end cap assemblies  22 ,  24  include a left and right end tube insert  86 ,  88 , respectively. Each insert  86 ,  88  is generally cylindrical with a hollow pass through  90 . The left end cap insert  86  fits with a friction fit in a left end  94  of the outer tube  14 , and the right end cap insert  88  fits in a right end  96  of the inner tube  12  with a friction fit ( FIG. 2 ). An outer diameter of the left end cap insert  86  is slightly larger than that of the right end cap insert  88  to accommodate a larger diameter of the outer tube  14 . A circumferential flange  92  extends about the perimeter of one end of the left and right end cap inserts  86 ,  88  for engaging the left and right ends  94 ,  96  of the outer and inner tubes  14 , respectively, to prevent complete insertion therein. Each insert  86 ,  88  includes a longitudinal extending groove  98  that receives the outer tube seam  57  and the inner tube seam  46 , respectively. This engagement fixes the left and right end tube inserts  86 ,  88  for rotation with the outer and inner tubes  14 ,  12  during installation. 
         [0036]    The left end cap insert  86  includes a left hand thread  100  in its interior  90 , and the right end cap insert  88  includes a right hand thread  102  in its interior  90 . The right and left hand threads  100 ,  102  cooperate with the right and left hand threading  82 ,  84  of the right and left end cap adjustment screw inserts  72 ,  74 . These threading engagements enable the end caps  16 ,  18  to move away from one another as the tubes  12 ,  14  are rotated during installation. More specifically, the friction between the mounting walls and the end surfaces  64  of the end caps  16 ,  18  limits rotation of the end caps  16 ,  18  as the tubes  12 ,  14  are rotated. The driver  70  of the end caps  16 ,  18  and the sockets  78  lock the left and right end cap adjustment screw inserts  72 ,  74  against rotation relative to the end caps  16 ,  18 . Accordingly, as the tubes  12 ,  14  are rotated toward an installer, the left and right end tube inserts  86 ,  88  are turned causing the end caps  16 ,  18  to move away from one another, thereby applying force on the mounting surface to further lock the tension rod  10  to the mounting walls. Rotating the tubes  12 ,  14  away from the installer causes the end caps to move towards one another, thereby removing force from the mounting surface to uninstall the tension rod  10 . The left and right end cap inserts may be made, such as molded, from a rigid plastic material. 
         [0037]    To install the tension rod  10  with the locking mechanism  20  and the left and right end cap adjustment assemblies  22 ,  24 , the outer tube  14  is held with one&#39;s left hand, and the inner tube  12  is held with one&#39;s right hand. The tubes  12 ,  14  are extended from one another until their respective end caps  16 ,  18  engage the mounting walls. Next, one rotates both the inner and outer tubes  12 ,  14  in the same direction toward one&#39;s body (i.e., clockwise looking at the right end cap  18 ). This will cause the end caps  16 ,  18  to move away from another to provide the appropriate force on the mounting walls to secure the tension rod  10 . The tubes  12 ,  14  can be rotated in the opposite direction to release the pressure to remove the tension rod  10 , such as for repositioning. 
         [0038]    With references to  FIGS. 15-19 , there is illustrated another embodiment of an adjustment mechanism for the tension rod  10 . The adjustment mechanism includes a lock assembly  220  intermediate the end caps  16 ,  18  to lock the inner and outer tubes  12 ,  14  relative to one another for the coarse adjustment. The adjustment mechanism further includes a left end cap adjustment assembly  222  and a right end cap adjustment assembly  224 . The end cap adjustment assemblies  222 ,  224  provide the fine adjustments to apply the appropriate amount of force against the mounting walls. The end cap assemblies  222  and  224  are identical to the end assemblies  22  and  24  discussed above. For the adjustment mechanism of  FIG. 15 , the inner and outer tubes  12 ,  14  are roll formed from metal with a longitudinal welded seam along the inside to secure the rounded cross-section. 
         [0039]    With reference to  FIGS. 16-19 , the lock assembly  220  includes a lock ramp  226 , an inner tube left end insert  228 , and a lock sleeve  230 . The lock ramp  226  and the inner left end insert  228  may be molded from a rigid plastic material. The lock sleeve  230  also may be molded from rigid type plastic but must be flexible enough to expand and provide a sufficient frictional engagement with an inner surface of the outer tube to lock the tubes against relative movement. 
         [0040]    The lock ramp  226  includes a frusto-conical wedge portion  232  and a threaded portion  234  with a right hand thread  236 . The wedge portion  232  includes a circumferential flange  238  at its free end and a pair of diametrically opposed grooves  240  extending longitudinally from the flange  238  to the threaded portion  234 . The flange  238  centers the lock ramp  226  in the outer tube  14  and provides a small amount of frictional engagement with an inner surface  242  of the outer tube  14 . The longitudinal grooves  240  guide longitudinal movement of the lock sleeve  230  along the wedge portion  232 . 
         [0041]    The inner tube left end insert  228  is generally a hollow cylindrical with a through hole  244 . The insert  228  fits with a friction fit in a left end  246  of the inner tube  12 . A circumferential flange  248  extends about a perimeter of one end of the insert  228  for engaging the left end  246  of the inner tube  12  to prevent complete insertion therein. The friction engagement in the inner tube  12  fixes the insert  228  against rotation relative to the inner tube. The insert  228  includes a left hand thread  250  in its interior. The thread  236  of the threaded portion  234  of the lock ramp  226  meshes with the thread  250  of the insert  228 . As the threaded portion  234  is turned into the insert  228  the lock sleeve  230  expands to lock to tubes  12 ,  14  relative to one another. 
         [0042]    More specifically, the lock sleeve  230  has an elongated slot  252  its entire axial length to form a split ring configuration. This enables the lock sleeve  230  to be expanded from a first state that allows relative movement of the tubes  12 ,  14  to a second state to lock the tubes  12 ,  14  against relative movement. The lock sleeve  230  includes a pair of longitudinally extending ribs  254  on its inside that are offset 90 degrees from the slot  252 . The lock sleeve  230  receives the wedge portion  232  of the lock ramp  226  with the ribs  254  each in one of the grooves  240  of the lock ramp. 
         [0043]    To install the tension rod  10  with the locking mechanism  220  and the left and right end cap adjustment assemblies  222 ,  224 , the outer tube  14  is held with one&#39;s left hand, and the inner tube  12  is held with one&#39;s right hand. The tubes  12 ,  14  are extended from one another until their respective end caps  16 ,  18  engage the mounting walls. Then, the outer tube  14  is held stationary with the left hand, and the inner tube  12  is rotated clockwise (when looking at the right end cap  18 —i.e., toward an installer&#39;s body) with the right hand. This causes the threaded engagement between the lock ramp  226  and the insert  228  to draw the wedge portion  232  toward the insert  228  which, in turn, causes the wedge portion  232  to push into the lock sleeve  230  guided by the grooves  240  and ribs  254  and expand the lock sleeve  230 . Once expanded sufficiently, the lock sleeve  230  becomes wedged tightly between the wedge portion  232  and the inner surface  242  of the outer tube  14  causing the inner and outer tubes  12 ,  14  to be locked against relative movement. 
         [0044]    Next, one rotates both the inner and outer tubes  12 ,  14  in the same direction toward the one&#39;s body (i.e., clockwise looking at the right end cap  18 ). This will cause the end caps  16 ,  18  to move away from another to provide the appropriate force on the mounting walls to secure the tension rod  10 . The tubes  12 ,  14  can be rotated in the opposite direction to release the pressure to remove the tension rod  10 , such as for repositioning. 
         [0045]    It will be understood that various changes in the details, materials, and arrangements of parts and components which have been herein described and illustrated in order to explain the nature of the sprinkler may be made by those skilled in the art within the principle and scope of the tension rod as expressed in the appended claims. Furthermore, while various features have been described with regard to particular embodiments, it will be appreciated that features described for one embodiment also may be incorporated with the other described embodiments.