Patent Publication Number: US-9422715-B1

Title: Louvered roof apparatus and control system

Description:
I. RELATED APPLICATIONS 
     The present application is a Continuation-in-Part of application Ser. No. 13/873,730, filed on Apr. 30, 2013, which claims the benefit of priority to U.S. Provisional Application No. 61/640,839, filed on May 1, 2012. The entire contents of said related applications are incorporated herein by reference. 
    
    
     II. TECHNICAL FIELD OF THE INVENTION 
     This invention relates to the control and configuration of a louvered roof with a series of louvers controlled by a linear drive mechanism. 
     III. BACKGROUND OF THE INVENTION 
     Conventionally, louvered roof assemblies generally include a plurality of parallel louvers which are pivotally supported on a frame above a patio or portion of a home. The louvered roof assemblies are adjustable and may be opened or closed from a motor operated by a battery and/or person. 
     There are numerous deficiencies with louvered roof assemblies that exist today. For example, the louvered roof panels are not configured to close directly onto one another. Another shortcoming is the design of the motors and actuators which move to open and close the panels. Conventional designs fail to offer reasonable maintenance options leaving the owner of such assemblies without a reasonable remedy to correct problems which arise unexpectedly. Another known deficiency is the overlapping surface area of the motor assembly being located within the water flow area of a corresponding assembly gutter. Such a configuration may result in water damage to the motor and a short to any corresponding electrical connectors. 
     IV. SUMMARY OF THE INVENTION 
     Example embodiments provide a water resistant and optimized louvered roof system that opens and closes securely and efficiently. The motorized linear drive system ensures durability and long-lasting success to the owner of such a roof system. 
     According to one embodiment of the present invention, a louvered roof assembly includes a pair of support members and several panels mounted between the support members. The panels are pivotally coupled to the support members for rotation about an axis by corresponding pivot pins. Each of the panels has a first end and a second end. One of the pivot pins is coupled to each end of the panels. A linear drive mechanism is coupled to each of the panels. The linear drive mechanism includes a track bar coupled to each of the panels and an actuator mounted to one of the support members and coupled to the track bar. The actuator is configured to move the track bar such that the panels rotate about the axis of their respective pivot pins. 
    
    
     
       V. BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a louvered roof assembly, according to example embodiments. 
         FIG. 2A  illustrates an exterior top view of the louvered roof assembly in a closed position, according to example embodiments. 
         FIG. 2B  illustrates an exterior top view of a louvered roof assembly in a partially closed position, according to example embodiments. 
         FIG. 2C  illustrates an exterior top view of a louvered roof assembly in an open position, according to example embodiments. 
         FIG. 3A  illustrates an interior view of a louvered roof assembly in an open position, according to example embodiments. 
         FIG. 3B  illustrates an interior view of a louvered roof assembly in a partially opened position, according to example embodiments. 
         FIG. 3C  illustrates an interior view of a louvered roof assembly in a closed position, according to example embodiments. 
         FIG. 4  illustrates aside view of an individual louvered panel coupled to a support member, according to example embodiments. 
         FIG. 5  illustrates a front view of an individual louvered panel coupled to a support member, according to example embodiments. 
         FIG. 6  illustrates a side view of a linear drive assembly, according to example embodiments. 
         FIG. 7  illustrates a perspective view of a housing, according to example embodiments. 
         FIG. 8A  illustrates a perspective view of an actuator mount, according to example embodiments. 
         FIG. 8B  illustrates a perspective view of a bushing, according to example embodiments. 
         FIG. 9A  illustrates a front perspective view of an arm, according to example embodiments. 
         FIG. 9B  illustrates a rear perspective view of an arm, according to example embodiments. 
         FIG. 10  illustrates a perspective view of a case, according to example embodiments. 
         FIG. 11  illustrates a front view of an individual louvered panel coupled to a support member and the arm coupled to the support member and track bar, according to example embodiments. 
         FIG. 12  illustrates a perspective view of a manual drive mechanism, according to example embodiments. 
         FIG. 13  illustrates a side view of the manual drive mechanism including a driven arm, according to example embodiments. 
         FIG. 14  illustrates a perspective view of an alternative connection between the output shaft and the track bar, according to example embodiments. 
         FIG. 15A  illustrates a rear perspective of an embodiment of a linear drive mechanism. 
         FIG. 15B  illustrates a front perspective of an embodiment of a linear drive mechanism as depicted in  FIG. 15A . 
         FIG. 15C  illustrates a housing for an embodiment of a linear drive mechanism as depicted in  FIG. 15A  and  FIG. 15B . 
         FIG. 16A  illustrates a retractable louvered roof in a closed positon. 
         FIG. 16B  illustrates a retractable louvered roof with the individual louvered panels rotated approximately 90 degrees. 
         FIG. 16C  illustrates a retractable louvered roof in a partially opened position. 
         FIG. 16D  illustrates pins for retracting the louvered roof. 
         FIG. 16E  illustrates pins completely retracted. 
         FIG. 17A  illustrates a perspective view of corner connectors for the beams and the gutters. 
         FIG. 17B  illustrates a perspective view of the beam corner connectors as depicted in  FIG. 17A . 
         FIG. 17C  is a top right perspective view of a beam corner connector, in accordance to one embodiment of the present invention. 
         FIG. 17D  is an exploded perspective view of the corner connector assembly, in accordance to one embodiment of the present invention. 
     
    
    
     VI. DETAILED DESCRIPTION OF THE INVENTION 
     It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments as represented in the attached figures, is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. 
     The features, structures, or characteristics of the invention described throughout this specification may be combined in any suitable manner in one or more embodiments. For example, the usage of the phrases “example embodiments”, “some embodiments”, or other similar language, throughout this specification refers to the fact that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present invention. Thus, appearances of the phrases “example embodiments”, “in some embodiments”, “in other embodiments”, or other similar language, throughout this specification do not necessarily all refer to the same group of embodiments, and the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
       FIG. 1  illustrates a louvered roof assembly  100 , according to example embodiments. Referring to  FIGS. 1, 4 and 5  several elongated rectangular louvered roof panels  110  are shown engaged in a closed position. In the closed position, roof panels  110  protect an underlying area from rain or sunlight. Roof panels  110  have a cross-section that is generally S-shaped. Roof panels  110  have opposed ends  112  and  114 . Roof panels  110  are formed with a center wall  116 . Rails  118  extend perpendicularly away from center wall  116  on opposite sides of center wall  116 . Rails  118  each terminate in a flange or lip  120  that extend perpendicularly away from the rail  118 . A pair of pivot pin bores  122  are defined in center wall  116  extending perpendicularly into wall  116  from each panel end  112 ,  114 . 
     The louver roof panels  110  engage one another via their overlapping respective flanges or lips and form channels  124  through which rainwater can flow to reach the gutters  166  that are located below each of the ends  112 ,  114 . 
     The louvered roof panels  110  are supported for rotational movement by a pair of elongated support members  160  that are arranged perpendicular to the length of panels  110 . One support member  160  supports panel ends  112  and another support member  160  supports panel ends  114 . Support members  160  have opposite ends  161  and  162 . Support members  160  are formed by the combination of a rectangular shaped beam  164  and an attached gutter  166 . Beam  164  includes an outer side  168 , inner side  170 , top side  172  and bottom side  174 . Gutter  166  has an internal trough  167  to carry rainwater and is attached to inner side  170  by screws  165 . Support members  160  and roof panels  110  can be formed from suitable materials such as aluminum. 
     Referring to  FIGS. 4 and 5 , details of the connection of roof panels  110  to support members  160  are shown. An elongated pivot strip  210  is attached to the inner side  170  of beam  164  by screws  212 . An angled lock bar  220  is attached to the pivot strip  210  by screws  222 . One lock bar  220  is located at each corresponding end of each panel  110 . A pivot pin  230  extends through an aperture in the lock bar  220  and has an end that is received by bore  122 . Roof panel  110  rotates or pivots about an axis defined by the length of pivot pin  230 . A pivot pin  230  is centered about the width of each of the roof panels  110 . 
     Another bore  240  extends perpendicularly into roof panel end  112  at the junction of rail  118  and flange  120 . A track pin  242  extends through an aperture in a track bar  250  and has an end that is received by bore  240 . Track bar  250  rotates or pivots about an axis defined by the length of track pin  242 . Each of the roof panels  110  is attached to the track bar  250  by a track pin  242 . 
     With reference to  FIGS. 2 (A-C),  3 (A-C) and  6 , a linear drive mechanism  300  is shown. Linear drive mechanism  300  comprises a linear actuator  310 , an actuator mount  312  and an output shaft  316 . Actuator mount  312  ( FIG. 8A ) is mounted to the top side  172  of beam  164  by screws. A linear actuator  310  is attached to actuator mount  312  by a bolt  313 . Linear actuator  310  can rotate about bolt  313 . Linear actuator  310  is connected to a power source such as a battery or utility power. 
     A housing  340  ( FIG. 7 ) has an internal cavity  342 . Housing  340  is mounted over linear actuator  310  to protect the actuator and linear drive system from outdoor conditions. Housing  340  is mounted to the topside  172  of beam  164  by screws. Housing  340  protects the linear drive mechanism  300  from the outdoor environment and may be easily removed for maintenance. 
     Linear actuator  310  has an output shaft  316 . Linear actuator  310  can move output shaft  314  in a linear reciprocating manner along an axis generally parallel to the length of support member  160 . 
     Output shaft  316  has a distal end with a thru bore  318 . Connecting bolt and bushing  352  extends through an end of arm  350  and through bore  318 . Connecting bolt and bushing  352  couples arm  350  to output shaft  316 , while allowing rotation between arm  350  and output shaft  316 . With additional reference to  FIGS. 9A and 9B , arm  350  has an upper rectangular shaped section  360  and a lower hexagonal shaped section  370 . Upper section  360  has a hole  362  and an elongated slot  364 . Lower section  370  has an aperture  372  that is dimensioned to receive another bushing  374 . Bushing  352  is received by hole  362  and is retained to upper section  360 . 
     Referring to  FIGS. 8B, 10 and 11 , case  380  is mounted to the inner side  170  of beam  166 . Case  380  has flanges  382  with apertures  384 . Screws extend through apertures  384  are fixed to side  170 . Case  380  further has a bushing hole  386 . Bushing  374  extends through arm hole  372  and is press fit into bushing hole  386 . Bushing head  375  rests against one side of lower section  370 . In this manner, arm  350  can rotate about bushing  374 . A drive coupling  355  such as a bolt and nut couples the track bar  250  to the arm  350 . Drive coupling  355  extends through slot  364  and through a hole in track bar  250 . Track bar  250  and arm  350  rotate about drive coupling  355 . During operation, drive coupling  355  can slide along the length of slot  364 . 
     Turning back to  FIG. 6 , louvered roof assembly  100  further includes a control system  400 . Control system  400  can cause linear actuator  310  to open and close roof panels  110 . Control system  400  includes a controller  410  and a user input device  420 . Controller  410  includes an electronic circuit to drive linear actuator  310  and a transceiver that can receive and send signals such as wired or wireless signals  412 . Signals  412  can be RF, IR or wired signals. In one embodiment, user input device  420  is a remote control unit that can send and receive signals such as wireless signals  412  to and from controller  410 . User input device  420  has an open button  422  that causes linear actuator  310  to open roof panels  110  and a close button  424  that causes linear actuator  310  to close roof panels  110 . 
     Referring to  FIGS. 2 (A-C) and  3 (A-C), linear drive mechanism  300  can open and close roof panels  110 .  FIG. 2A  illustrates a top view of the louvered roof assembly  100  in a closed position with the individual roof panels  110  in an overlapping arrangement. The track bar  250  runs parallel to the support member  160  and engages each of the louvered panels  110  to provide a secure mounting fixture that connects the track bar  250  with each of the panels  110 . As the linear actuator  310  extends, the track bar will shift position and each of the panels  110  will begin to move in unison with one another to open according to the present position of the louver panels. 
       FIG. 2B  illustrates a top view of the louvered roof assembly  100  in a partially open position. In this illustration, the louver panels  110  have been partially opened and the output shaft  316  has begun to shift outside the housing  340 . As the linear actuator  310  extends, output shaft  316  pushes on arm  350  causing arm  350  to rotate about bushing  374 . At the same time, the movement of arm  350  causes the track bar  250  to move via the connection of coupling  355 . The movement of track bar  250 , which is connected to roof panels  110  via track pins  242 , causes the louver panels  110  to rotate in unison about pivot pins  230 . 
       FIG. 2C  illustrates a top view of the louvered roof assembly  100  in a fully open position. Referring to  FIG. 2C , the roof panels  110  are in a full and upright position allowing maximum light to pass through the area between the louver panels  110 . The linear actuator  310  and track bar  250  are in a fully extended position with track bar  250  shifted above support member  160 . 
       FIG. 3A  illustrates a bottom view of the louvered roof assembly  100  in an open position. Referring to  FIG. 3A , the track bar  250  and the arm  350  move together to open each of the louver roof panels  110  in unison. 
       FIG. 3B  illustrates a bottom view of the louvered roof assembly  100  in a partially opened position. The louver roof panels  110  are partially closed. In  FIG. 3C , the roof panels  110  are in a fully closed overlapping position such that any rainwater accumulates in channels  124  ( FIG. 2A ) and is directed to gutter trough  167  ( FIG. 5 ). 
     Turning to  FIGS. 12 and 13 , according to another example embodiment louvered roof assembly  100  can include a manual drive mechanism  500 . Manual drive mechanism  500  replaces the linear drive mechanism  300  previously described. Referring to  FIGS. 12 and 13 , manual drive mechanism  500  includes a ninety degree gear box  510  that is mounted to the outer side  168  of beam  164  by threaded bolts  512 . Gear box  510  has a housing  514  that contains internal gears  516  and a through shaft  517 . 
     A bolt  518  is connected to the internal gears  516  of gear box  510 . Bolt  518  extends outwardly from housing  514 . The manual drive mechanism  500  includes an elongated pole  520  with a hooked end  522  that engages the bolt  518 . A user can rotate pole  520  to turn the bolt  518  thereby causing through shaft  517  to rotate via the internal gears  516  of gear box  510 . 
       FIG. 13  illustrates details of a manually driven arm  540  used in manual drive mechanism  500 . Referring to  FIG. 13 , case  530  is mounted to the inner side  170  of beam  166 . Case  530  has flanges  531  with apertures  532 . Screws  534  extend through apertures  532  and are fixed to side  170 . Case  530  further has a bushing hole  536 . Bushing  374  extends through arm hole  545  and is press fit into bushing hole  536 . Arm  540  can rotate about bushing  374 . 
     Driving arm  350  has an upper rectangular shaped end section  550  and a lower semi-circular shaped section  542 . Upper section  550  has an elongated slot  552 . Lower section  370  has teeth  544  formed on the outer circumferential edge of semi-circular shaped gear  543 . A drive coupling  554  such as a bolt and nut couples the track bar  250  to the manually driving arm  540 . 
     Drive coupling  554  extends through slot  552  and through a hole in track bar  250 . Track bar  250  and arm  540  can pivot about drive coupling  554 . During operation, drive coupling  554  can also slide along the length of slot  552 . Roof panels  110  rotate or pivot about an axis defined by the length of pivot pin  230 . A pivot pin  230  is centered about the width of each of the roof panels  110 . 
     The distal end of shaft  517  faces into gutter trough  167  and has an attached gear  536  with teeth  538 . Gear  538  has a much smaller diameter than gear  543  such that many turns of gear  538  are required to move gear  543  a small amount thereby providing force multiplication. 
     An operator can elect to manually open or close roof panels  110  using manual drive mechanism  500 . In order to open or close roof panels  110 , the operator rotates pole  520 , turning the bolt  518  thereby causing rotation of through shaft  517  via the internal gears  516  of gear box  510 . The rotation of through shaft  517  rotates gear  517 , which in turn rotates gear  543  causing arm end  550  to move track bar  250  along an axis generally parallel to support members  160 . The movement of arm end  550  causes the track bar  250  to move via the connection of coupling  355 . The movement of track bar  250 , which is connected to roof panels  110  via track pins  242 , causes the louver panels  110  to rotate in unison about pivot pins  230  and move towards either an open or closed position depending upon the rotational direction of bolt  518 . 
       FIG. 14  illustrates an alternative embodiment of a connection between the output shaft  316  and the track bar  250 . Triangular shaped arm  610  has an apex  612 , abase  614  and a center section  616 . Several holes  618  are defined in base  614 . Fasteners such as bolts  620  extend through holes  618  and through holes (not shown) in track bar  250 . Nuts  622  are threaded onto bolts  620 . Bolts  620  and nuts  622  retain arm  610  to track bar  250 . Arm  610  is rigidly held to track bar  250   
     An aperture  624  is located in arm  610  toward apex  612 . A connecting rod  626  is mounted through aperture  624 . Connecting rod  626  has a headed end that is adjacent to arm  610  and a threaded end  628  that extends through output shaft bore  318  at output shaft end  319 . A nut  630  is threaded onto end  628  in order to retain connecting rod  626  to output shaft  316 . Connecting rod  626 , aperture  624  and bore  318  are sized to allow connecting rod  626  to rotate or pivot within aperture  624  and bore  318 . Connecting rod  626  can rotate with respect to arm.  620  and can rotate with respect to output shaft  316 . Arm  610  provides a connecting link between output shaft  316  and track bar  250  in order to open and close roof panels  110 . 
     It is envisioned that an additional embodiment of a liner drive mechanism may be utilized with the general louvered roof assembly description provided above. For example, in  FIG. 15A  through  FIG. 15C  and  FIG. 16A  through  FIG. 16E , a louvered roof assembly  700  is depicted having a support frame comprising beams  702  and gutters  704 . The beams  702  are mutually coupled to one another, and the gutters  704  are mutually coupled to one another. In the embodiment depicted, the mutually coupling of beams with beams and gutters with gutters forms a substantially orthogonal outline of the support frame, with a plurality of louvered panels  706  disposed within and between the support frame. A motor  708  for actuating movement of a linear drive mechanism  710  is mounted within the beam  702  and gutter  704  along one end of the assembly  700 . In one embodiment, the motor  708  pushes or pulls a lower pin assembly  714  along a drive beam slot  712  housing the lower pin assembly  714 , thereby allowing the louvered panels to retract or expand according to user command with the louvered panels rotating and stacking or unstacking. 
     In one embodiment of the linear drive mechanism  710 , the motor and individual elements of the mechanism are encased within the beam  702  of the support frame. As depicted in  FIGS. 15A and 15B , the mechanism  710  includes a linear actuator arm  720  coupled to a drive rack bracket  722  that rides along a drive rack  724 . The drive rack  724  has teeth complementary to the toothed-gear  726  mounted within the beam  702  and coupled with the louvered panel  706  end. The louvered panel  706  end has a lock spacer  730  disposed between the end and the gear plug  726 . As the motor urges retraction or expansion of the louvered panels  706  within the support frame, the actuator arm  720  lengthens or shortens, causing the drive rack bracket  722  to move forward or rearward along the drive rack  724 , and urging the gear  726  to turn either to flatten the louvered panels  706  into an expanded (and sun or weather-blocking) position, or to rotate approximately 90 degrees in preparation for movement along the beams and gutters. A manual override  728  is provided to allow a user to quickly stop movement as required. As is depicted in  FIG. 15C , the beam  702  encases a chute  730  upon which the drive rack  724  moves along. 
     As depicted in  FIGS. 17A-17D , a corner connector assembly  800  having a beam corner connector  802  and a gutter corner connector  804  may be provided and utilized for quickly assembling straight-cut beams  702  and gutters  704 . The beam corner connector  802  comprises a pillar  802   a  having a plurality of inserts  803 . The pillar  802   a  is capped with a top plate  802   aa  mounted thereatop. The pillar  802   a  comprises adjacent faces  802   b  and  802   c  that accommodate the inserts  803 , the inserts  803  receive the straight-cut edges  702   a  of the beams  702  in a slidably engaging manner, thereby coupling the beams  702  to the beam corner connector  802 . As depicted in  FIG. 17D , inserts  803   a  and  803   b  are inserted between the straight-cut edges  702   a  of a first beam  702 ′, and positioned contiguous to face  802   b  and adjacent face  802   c , and inserts  803   c  and  803   d  are inserted between the straight-cut edges  702   a  of a second beam  702 ″, and positioned contiguous to face  802   c  and adjacent face  802   b . The beams  702 ′ and  702 ″ are mechanically coupled to the inserts  803  via fasteners  802   e.    
     The gutter corner connector  804  comprises a pair of upstanding walls  804   a  and  804   b  and a floor  804   c . The walls  804   a  and  804   b  are mutually joined at a corner and the floor  804   c  is joined with the lower edges of the walls  804   a  and  804   b . A triangular-shaped corner brace  804   d  is used to secure the gutters  704 ′ and  704 ″ at the outer edges of the gutter corner connector  804 . The straight-cut edge of each gutter  704 ′ and  704 ″ may be abutted with the respective edges of the walls  804   a  and  804   b  and floor  804   c , with the corner brace  804   d  positioned in the orthogonal corner formed between the converging gutters  704 ′ and  704 ″, utilizing mechanical fasteners  804   e . The outer face  804   f  of the corner brace  804   d  may include a decorative or ornamental face plate  804   g  that is removable and replaceable with a variety of customized monogram, lettering, logos, and the like. 
     It is envisioned that the various embodiments, as separately disclosed, are interchangeable in various aspects, so that elements of one embodiment may be incorporated into one or more of the other embodiments, and that specific positioning of individual elements may necessitate other arrangements not specifically disclosed to accommodate performance requirements or spatial considerations. 
     It is to be understood that the embodiments and claims are not limited in its application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned, but the claims are limited to the specific embodiments. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting the claims. 
     Accordingly, those skilled in the art will appreciate that the conception upon which the application and claims are based may be readily utilized as a basis for the design of other structures, methods, and systems for carrying out the several purposes of the embodiments and claims presented in this application. It is important, therefore, that the claims be regarded as including such equivalent constructions. 
     Furthermore, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially including the practitioners in the art who are not familiar with patent and legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the claims of the application, nor is it intended to be limiting to the scope of the claims in any way. It is intended that the application is defined by the claims appended hereto.