Removably mountable roof frame for use with an expandable canopy

Abstract

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.

Claims

1. A rafter fitting for use with an erectable canopy framework, wherein the erectable canopy framework includes a base frame and a roof frame removably mountable to the base frame, wherein 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 comprising: a male portion insertable into a corresponding mount opening; a clevis bracket having a pair of opposed sidewalls disposed on the male portion; and a ferrule removably attached to the clevis bracket via a clevis pin inserted through the ferrule along a pivot axis, wherein the ferrule is configured to receive a portion of a corresponding rafter.

2. A rafter fitting according to claim 1, wherein the pivot axis is oriented such that the corresponding rafter extends diagonally between opposite upright support members.

3. A rafter fitting according to claim 1, wherein the male portion has a rectangular cross-section.

4. A rafter fitting according to claim 3, wherein the pivot axis is oriented at approximately a 45 degree angle with respect to the rectangular cross-section.

5. A roof frame removably mountable to an expandable base frame wherein the base frame includes a plurality of cross members, each interconnecting adjacent upright support members and a plurality of mounts disposed on the upright support members, wherein each mount includes a mount opening, the roof frame comprising: a plurality of rafter fittings each comprising: a male portion insertable into a corresponding mount opening; a clevis bracket having a pair of opposed sidewalls disposed on the male portion; and a ferrule removably attached to the clevis bracket via a clevis pin inserted through the ferrule along a pivot axis; a plurality of rafters each insertable into a corresponding ferrule; a ridge member configured to extend between distal ends of the rafters; and a pair of ridge fittings each operative to interconnect a pair of rafters with opposite ends of the ridge member.

6. The roof frame according to claim 5, wherein each rafter comprises at least one flexible rod.

7. The roof frame according to claim 6, wherein each rafter comprises multiple rafter segments.

8. The roof frame according to claim 5, wherein each ridge fitting comprises a plurality of rafter sockets.

9. The roof frame according to claim 5, wherein the ridge member comprises multiple ridge segments.

10. The roof frame according to claim 5, wherein each rafter extends arcuately from a corresponding ferrule.

11. The roof frame according to claim 5, further comprising a pair of cross member rafters extending arcuately between opposed cross members.

12. The roof frame according to claim 11, wherein each cross member includes a pair of scissor units connected together by upper and lower cross member mounts, and wherein the upper cross member mount includes an insert opening adapted to receive a cross member rafter insert connectable with the cross member rafters.

13. A roof frame removably mountable to an expandable base frame wherein 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, the roof frame, comprising: a plurality of rafter fittings each comprising: a male portion insertable into a corresponding mount opening; a clevis bracket having a pair of opposed sidewalls disposed on the male portion; and a ferrule removably attached to the clevis bracket via a clevis pin inserted through the ferrule along a pivot axis; and a plurality of rafters each insertable into a corresponding ferrule, wherein the rafters extend diagonally and arcuately between opposite upright support members.

14. The roof frame according to claim 13, wherein each rafter comprises at least one flexible rod.

15. The roof frame according to claim 14, wherein each rafter comprises multiple rafter segments.

16. An erectable canopy framework, comprising: a base frame, including: a plurality of upright support members; a plurality of expansion and contraction assemblies, each interconnecting adjacent upright support members to permit movement of the base frame between an expanded and a contracted state; and a plurality of mounts disposed on the upright support members operative to fasten the expansion and contraction assemblies thereto, wherein each mount includes a clevis bracket having a pair of opposed sidewalls and a ferrule pivotably attached thereto with a clevis pin extending through the ferrule; and a roof frame removably mountable to the base frame, the roof frame including: a plurality of rafters each insertable into a corresponding ferrule, wherein each rafter extends arcuately between opposed upright support members.

17. An erectable canopy frame, comprising: a plurality of upright support members; a plurality of mount assemblies, each disposed on an upper end portion of a corresponding one of the upright support members and including: a corner mount, comprising: a central portion including a mount opening extending therethrough and aligned with an interior channel of the corresponding one of the plurality of upright support members; and a pair of clevis portions extending from the central portion; and a rafter fitting, comprising: a male portion insertable into a corresponding mount opening; a clevis bracket having a pair of opposed sidewalls disposed on the male portion; and a ferrule pivotably attached to the clevis bracket by a clevis pin extending through the ferrule, wherein the ferrule is positioned to receive a corresponding rafter of an associated roof frame; and a plurality of cross members, each connected to a corresponding pair of the plurality of mount assemblies.

18. An erectable canopy frame according to claim 17, further comprising a roof frame operative to support a canopy and removably mountable to the plurality of mount assemblies, wherein the roof frame includes a plurality of rafters each insertable into a corresponding ferrule.

19. An erectable canopy frame according to claim 18, further comprising a canopy extendable over the roof frame.

20. An erectable canopy frame according to claim 17, wherein the central portion and the pair of clevis portions are integrally formed as a unitary body.

21. An erectable canopy frame according to claim 20, wherein each clevis portion includes a pair of opposed sidewalls and a top wall extending therebetween.

22. A mount assembly for use with an erectable canopy framework, wherein the erectable canopy framework includes a plurality of upright support members and a plurality of cross members, each interconnecting adjacent upright support members, the mount assembly comprising: a corner mount, comprising: a central portion; a support member receptacle extending into the central portion and configured to receive an end portion of a corresponding one of the plurality of upright support members; and a pair of clevis portions extending from the central portion, each positioned to connect with a corresponding one of the plurality of cross members; and a rafter fitting, comprising: a clevis bracket having a pair of opposed sidewalls; and a ferrule pivotably attached to the clevis bracket by a clevis pin extending through the ferrule, wherein the ferrule is positioned to receive a corresponding rafter of an associated roof frame.

23. A mount assembly according to claim 22, wherein the central portion, the pair of clevis portions, and the clevis bracket are integrally formed as a unitary body.

24. A mount assembly according to claim 23, wherein each clevis portion includes a pair of opposed sidewalls and a top wall extending therebetween.

25. A mount assembly according to claim 22, wherein the corner mount includes a mount opening intersecting the support member receptacle and aligned with an interior channel of the corresponding one of the plurality of upright support members.

26. A mount assembly according to claim 25, wherein the rafter fitting includes a male portion insertable into the mount opening, and wherein the clevis bracket is disposed on the male portion.

Description

DRAWINGS

(1) Non-limiting and non-exhaustive exemplary embodiments of the removably mountable roof frame, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

(2) FIG. 1 is a perspective view of a canopy having a rounded gable roof;

(3) FIG. 2 is a perspective view of a canopy with a domed roof;

(4) FIG. 3 is a perspective view of the framework for the canopy shown in FIG. 1;

(5) FIG. 4 is an enlarged close-up view of a mount as shown in FIG. 3;

(6) FIG. 5 is an enlarged perspective view of the rafter fitting as shown in FIG. 3;

(7) FIG. 6A is an enlarged perspective view of the rafter fitting as shown in FIG. 3;

(8) FIG. 6B is an enlarged perspective view of a mount with an integral socket;

(9) FIG. 7 is a perspective view of the rafter fitting shown in FIG. 3;

(10) FIG. 8 is a rafter fitting according to an alternative construction for use with the domed canopy as shown in FIG. 2;

(11) FIG. 9 is yet another alternative construction of a rafter fitting;

(12) FIG. 10 is an enlarged perspective view of the upper cross member mount and rafter insert;

(13) FIG. 11 is an enlarged perspective view of the cross fitting shown in FIG. 3;

(14) FIG. 12 is an enlarged perspective view of a ridge fitting as shown in FIG. 3;

(15) FIG. 13 is an enlarged perspective view of the splice fitting shown in FIG. 3;

(16) FIG. 14 is an enlarged perspective view of a mount opening plug as shown in FIG. 4;

(17) FIG. 15 is an enlarged perspective view of a mount according to an alternative exemplary embodiment;

(18) FIG. 16 is a perspective view of the canopy framework as shown in FIG. 2;

(19) FIG. 17 is an enlarged perspective view of the rafter fitting as shown in FIG. 16;

(20) FIG. 18 is a perspective view of a canopy with a peaked gable roof;

(21) FIG. 19 is a perspective view of the framework shown in FIG. 18;

(22) FIG. 20 is an enlarged perspective view of the rafter and mount as shown in FIG. 19; and

(23) FIG. 21 is a perspective view of the components of the roof frame shown in FIG. 19.

(24) FIG. 22 is a perspective view of an alternate embodiment of a framework; and

(25) FIG. 23 is a perspective view of a representative rafter for a roof frame.

DETAILED DESCRIPTION

(26) Embodiments are described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense.

(27) 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. 1 shows a canopy 5 according to a first exemplary embodiment that has a rounded gable roof, or otherwise referred to as a barrel-shaped roof. The canopy includes a framework 10 which supports a canopy cover 7. Canopy cover 7 is configured to conform to an underlying framework structure 10 that defines the rounded gable shape. FIG. 2 illustrates a canopy 105 according to a second exemplary embodiment that is the form of a dome. Canopy 105 includes a framework 110 and a canopy cover 107.

(28) With reference to FIG. 3, the underlying framework 10 of canopy 5 can be better appreciated. Framework 10 includes a base frame 12 and a roof frame 14 which is removably mountable to the base frame 12. As is known in the art, base frame 12 includes a plurality of upright support members 16 which are interconnected by a plurality of cross members 18. Cross members 18 may comprise an expansion and contraction assembly which, in the referenced embodiment are shown in the form of a pair of scissor units 20, 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 units 20 are connected to the upright support members 16 by a fixed mount 22 and a sliding mount 24. Accordingly, the cross members allow the base frame to expand and collapse. Each pair of scissor units 20 that are connected to each other by upper and lower cross member mounts 26 and 28, respectively. Base frame 12 is 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.

(29) Roof frame 14 includes a plurality of rafters 32, each of which is connectable to a corresponding mount 22 on base frame 12. Rafters 32 are operative to support the canopy cover 7 above the base frame 12. With reference to FIG. 4, mount 22 includes central portion 80 with a mount opening 88. Attached to the central portion 80 is a pair of clevis portions 82. Clevis portions 82 are configured to receive the scissor units 20 therein. A fastener 84 secures the scissor units to the clevis portions 82. In this case mount 22 is 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.

(30) With reference to FIGS. 5, 6A, and 7, the roof framework includes a plurality of rafter fittings 30, each of which is adapted for insertion into a corresponding mount opening 88 and is connectable to a corresponding rafter 32. With particular reference to FIG. 7, rafter fitting 30 includes a male portion 50 which is insertable into the mount opening 88. Cap 52, which is disposed on the top of mount portion 50, provides an end stop for the fitting. A clevis bracket 54 is attached to cap 52 and rotatably supports a socket 56. Socket 56 is retained in clevis 54 by a clevis pin 58. In this case, clevis pin 58 is in the form of a threaded fastener as known in the art. In this case, socket 56 is in the fun of a ferrule which has a socket opening 60 for receiving an end portion of a corresponding rafter 32.

(31) An alternative construction of a mount 422 is shown in FIG. 6B. Mount 422 includes a clevis bracket 454 disposed directly on central portion 480. Clevis 454 rotatably supports a socket 456 for receiving an end portion of a corresponding rafter 32. Mount 422 also includes clevis portions 482 for connecting to scissor units 20. Accordingly, mount 422 combines the mount 22 and rafter fitting 30, described above, into an integrated component.

(32) Returning to FIG. 3, roof frame 14 includes rafters 32 disposed on the ends of the framework with a cross member rafter 33 located between the two end rafters 32. Each rafter 32 and 33 is, in this case, comprised of a pair of rafter segments 36 which are connected together by a splice lifting 40. A ridge member 34 is configured to extend between the distal ends of the rafters 32. In this case, the ridge member 34 comprises multiple ridge segments 38 which are connected together by splice fittings 40. Where the ridge member intersects the cross member rafters 33, a cross fitting 44 joins the various segments in a cross pattern. With reference to FIG. 5, it can be appreciated that socket 56 is sized and configured to receive an end portion of an associated rafter segment 36. In this embodiment, each rafter 32, 33 extends arcuately between opposed cross members 18. It can also be appreciated in the figures that the rafters 32, 33 are 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.

(33) Referring again to FIG. 3, the cross member rafters 33 extend from the upper cross member mounts 26. With further reference to FIG. 10, the upper cross member mount 26 includes an insert opening 64 sized and configured to receive a cross member rafter insert 46. Cross member rafter insert 46 includes a receptacle 62 which is configured to receive an end portion of rafter segment 36 of cross member rafter 33.

(34) Referring to FIG. 11, cross fitting 44 includes a hollow tube 72 configured to receive a pair of ridge segments 38. Extending from hollow tube 72 is a pair of branches 74 configured to receive end portions of rafter segments 36 of the cross member rafter 33. As shown in FIG. 12, the ridge fitting 42 includes a hollow tube 68 that is closed on one end 69. Extending from the hollow tube 68 adjacent closed end 69 is a pair of branches 70 for receiving end portions of rafters 32. FIG. 3 illustrates splice fitting 40 as a hollow tube 66. FIG. 14 shows the mount opening plug 76 which comprises a male portion 75 and a plug cap 78 configured as shown. FIG. 15 illustrates an alternative construction for a mount 322 which includes a central portion 386 and a pair of clevis portions 382. In this embodiment, the central portion 386 and clevis portions 382 are integrally formed as a unitary body. For example, mount 322 may be injection molded. Mount 322 also includes a mount opening 388 for connecting a rafter thereto.

(35) FIG. 16 illustrates the construction of the dome framework 110 for use with a canopy 105 shown in FIG. 2. Dome framework 110 includes base frame 12 as described above but with a different roof frame construction 114. Roof frame 114 comprises rafter fittings 130 from which extend a plurality of rafters 132. Each rafter 132 is comprised of rafter segments 136 joined by splice fittings 40. The rafters extend arcuately from rafter fittings 130, and the rafters extend diagonally between opposite upright support members 16. Accordingly, in this embodiment the rafters cross cadi other in contrast to the parallel rafters described above with respect to the first exemplary embodiment.

(36) With reference to FIGS. 8 and 17, the rafter fitting 130 used with the dome canopy 105 has a similar construction to the rafter fitting 30 described above with the first exemplary embodiment. However, in this case, clevis 154 is mounted at an anglewith respect to cap 152 and male portion 150. The angle of clevis 154 is approximately 45 degrees with respect to the male portion 150. Accordingly, because the male portion 150 is rectangular or square in shape, the ferrule 156 is directed at a diagonal angle with respect to each upright support member 16. Rafter fitting 130 also includes a socket 156 that is pivotably disposed on clevis 154 by a clevis pin 158. Socket 156 may be in the form of a ferrule as shown with a socket opening 160 for receiving a rafter segment 136.

(37) An alternative construction of a rafter fitting 330 is shown in FIG. 9. Rafter fitting 330 is similar in construction to that described above with respect to FIGS. 7 and 8; however, the male portion 350 is, in this case, in the form of a cylinder rather than a square. Accordingly, male portion 350 may rotate within the mount opening 88 of mount 22. Therefore, rafter fitting 330 may 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 portion 350 allows the rafter fitting to orient such that the rafters 132 extend diagonally opposite upright support members 16. Rafter fitting 330 includes male portion 350 with a cap 352 disposed thereon. Clevis 354 is mounted to cap 352 and rotatably supports a socket 356 which rotates about clevis pin 358.

(38) A third exemplary embodiment of a canopy 205 is shown in FIG. 18. In this embodiment, the roof is in the form of a peaked gable. Canopy 205 includes a framework 210 with a canopy cover 207. As shown in FIG. 19, the framework 210 includes base frame 12 as described above and a roof framework 214. Roof frame 214 includes a plurality of rafters 232 extending from mounts 22 which are operative to support the canopy cover 207 above base frame 12. Roof frame 214 also includes a ridge member 234 extending between the rafters 232. A ridge fitting 242 connects the ridge member to rafters 232 as shown. With reference to FIG. 20, in this embodiment, the base frame includes the unitary mount 322 as described with respect to FIG. 15. With further reference to FIG. 21, it can be appreciated that the roof frame 210 may be disassembled into components. Each rafter 232 includes an arm portion 238 with a stub portion 240 extending therefrom at an angle A. Angle A may be approximately 45 degrees. However, the angle at which stub portion 240 extends from arm portion 238 may vary to provide different roof configurations. Each ridge fitting 242 includes a ridge clevis 268 for attachment to the ridge member 234. Extending at angles from the ridge clevis 268 is a pair of branches 270. 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 portion 238 and stub portion 240. Alternatively, the arm portion and stub portion may be welded or otherwise fastened together.

(39) A fourth exemplary embodiment of a framework 310 is shown in FIG. 22. In this embodiment, framework 310 may be used to create a rounded gable roof configuration, such as that shown in FIG. 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 in FIG. 22, the framework 310 includes base frame 12 as described above and a roof framework 314. Roof frame 314 includes a plurality of rafters 332 extending arcuately from mounts 22 which are operative to support a canopy cover, such as canopy cover 207, shown in FIG. 1. Roof frame 314 also includes a ridge member 334 extending between the rafters 332. A ridge fitting 342 connects the ridge member to rafters 332 as shown. With further reference to FIG. 23, it can be appreciated that the roof frame 310 may be disassembled into components. Each rafter 332 includes an arcuate arm portion 338 and a stub portion 340. Ridge fittings 342 have a similar construction to that shown in FIG. 21, albeit the angles between branches may vary to accommodates the arcuate arm portions 338 of the arcuate rafters 332.

(40) Also contemplated herein is a method of erecting a canopy. In one embodiment, the method comprises expanding a base frame 12 that includes a plurality of upright support members 16 and a plurality of mounts 22 disposed on the upright support members 16, mounting a roof frame 14 to the base frame 12, and subsequently removing the roof frame 14 from the base frame 12. The step of mounting the roof frame 14 to the base frame 12 includes connecting rafter fittings 30 to the mounts 22. The mounts 22 include mount openings 88 and the rafter fittings 30 are inserted into the mount openings 88. The method may also include connecting rafters 32 to the rafter fittings 30 and connecting a ridge member 34 to the rafters 32.

(41) 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.

(42) 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.