Abstract
A modular architectural canopy system is disclosed. The architectural canopy system may include a frame, a panel ceiling disposed in the frame, an architectural element snap fit to the frame, and a hanging rod support. The architectural canopy system further may include a bottom infill ceiling and/or a skylight.
Claims
1. A structural member for a modular architectural canopy system, the structural member having a longitudinal axis and comprising: a first vertical wall which comprises a superior end, a catch adjacent to the superior end, an indexing ledge extending upward from the superior end, and an inferior end; a second vertical wall spaced from the first vertical wall, which comprises an upper end, a lower end, and a cantilevered track adjacent to the upper end, which comprises a base segment abutting the second vertical wall, an interior segment abutting the base segment, a rear ledge abutting the interior segment, and a front ledge abutting the second vertical wall, the front ledge being spaced from the rear ledge and disposed opposite the rear ledge, the rear ledge and the front ledge defining a slot, and the base segment, the interior segment, the rear ledge, the front ledge, and the second vertical wall framing a cantilever track receptacle, an inferior hook disposed opposite from the catch on the first vertical wall, a superior hook disposed adjacent to the cantilevered track, and an intermediate hook disposed between the hook and the superior hook; and a first transverse wall disposed between the first vertical wall and the second vertical wall, wherein the first vertical wall, the first transverse wall, and the second vertical wall frame a gutter.
2. The structural member of claim 1, further comprising a second transverse wall disposed between the first vertical wall and the second vertical wall, the first vertical wall, the first transverse wall, the second vertical wall, and the second transverse wall framing an inferior duct.
3. The structural member of claim 1, further comprising: an exterior wall spaced from the second vertical wall, which comprises a superior end, and an inferior end, a superior partition extending between the second vertical wall and the exterior wall, an intermediate partition extending between the second vertical wall and the exterior wall, and an inferior partition extending between the second vertical wall and the exterior wall.
4. The structural member of claim 3, wherein the second vertical wall, the superior partition, the exterior wall, and the intermediate partition comprise a superior hollow structural section, and the second vertical wall, the intermediate partition, the exterior wall, and the inferior partition comprise an intermediate hollow structural section.
5. The structural member of claim 4, wherein the second vertical wall, the superior partition, the exterior wall, and the intermediate partition frame a superior duct, and the second vertical wall, the intermediate partition, the exterior wall, and the inferior partition frame an intermediate duct.
6. The structural member of claim 3, wherein: the exterior wall further comprises an inferior front edge adjacent the inferior end, and an inferior front ledge disposed between the inferior front edge and the inferior partition; and the second vertical wall further comprises an inferior rear edge adjacent to the lower end, and an inferior rear ledge disposed between the inferior rear edge and the inferior partition; wherein the inferior front ledge is spaced from the inferior rear ledge and disposed opposite the inferior rear ledge, and the inferior front edge is spaced from the inferior rear edge and disposed opposite the inferior rear edge, the inferior rear edge and the inferior front edge comprising an inferior exterior accessory seat, and the inferior rear ledge, the second vertical wall, the inferior partition, and the inferior front ledge comprising an inferior exterior corner bracket receptacle.
7. The structural member of claim 4, wherein: the exterior wall further comprises a superior front edge adjacent the superior end, and a superior front ledge disposed between the superior front edge and the superior partition; and the second vertical wall further comprises a superior rear edge adjacent to the upper end, and a superior rear ledge disposed between the superior rear edge and the superior partition; wherein the superior front ledge is spaced from the superior rear ledge and disposed opposite the superior rear ledge, and the superior front edge is spaced from the superior rear edge and disposed opposite the superior rear edge, the superior rear edge and the superior front edge comprising a superior exterior accessory seat, and the superior rear ledge, the second vertical wall, the superior partition, and the superior front ledge comprising a superior exterior corner bracket receptacle.
8. The structural member of claim 7, further comprising: a superior interior wall spaced from the first vertical wall, which comprises an upper end, and a lower end, an upper partition extending between the first vertical wall and the superior interior wall, a lower partition extending between the first vertical wall and the superior interior wall.
9. The structural member of claim 8, wherein the first vertical wall, the upper partition, the superior interior wall, and the base partition comprise an interior hollow structural section.
10. The structural member of claim 9, wherein the first vertical wall, the upper partition, the superior interior wall, and the base partition frame an interior duct.
11. The structural member of claim 8, wherein: the superior interior wall further comprises an upper rear ledge abutting the upper end, and the first vertical wall further comprises an upper front ledge abutting the superior end, the upper rear ledge being spaced from the upper front ledge and disposed opposite the upper front ledge, and the superior interior wall, the upper rear ledge, the upper front ledge, the first vertical wall, and the upper partition comprising a superior interior corner bracket receptacle.
12. The structural member of claim 8, further comprising: an inferior interior wall spaced from the first vertical wall, which comprises a top end, a bottom end, and a base partition extending between the first vertical wall and the inferior interior wall.
13. The structural member of claim 12, wherein: the inferior interior wall further comprises an inferior rear edge adjacent to the bottom end, and an inferior rear ledge disposed between the inferior rear edge and the base partition; and the first vertical wall further comprises an inferior front edge adjacent to the inferior end, and an inferior front ledge disposed between the inferior front edge and the base partition, the inferior front ledge being spaced from the inferior rear ledge and disposed opposite the inferior rear ledge, and wherein the inferior front edge is spaced from the inferior rear edge and disposed opposite the inferior rear edge, the inferior rear edge and the inferior front edge comprise a inferior interior accessory seat, and wherein the inferior rear ledge, the inferior interior wall, base partition, the first vertical wall, and the inferior rear ledge comprise an inferior interior corner bracket receptacle.
14. The structural member of claim 12, wherein: the lower partition further comprises an upper edge adjacent to the lower end, and an upper ledge disposed between the upper edge and the first vertical wall; and the base partition further comprises a lower edge adjacent to the top end, and a lower ledge disposed between the lower edge and the first vertical wall, the lower ledge being spaced from the upper ledge and disposed opposite from the upper ledge, and wherein the upper edge is spaced from the lower edge and disposed opposite the lower edge, and the upper edge and the lower edge comprise an intermediate interior accessory seat, and the upper ledge, the lower partition, the first vertical wall, the base partition, and the lower ledge comprise an intermediate interior corner bracket receptacle.
15. An apparatus for constructing an architectural canopy frame comprising: the structural member of claim 1, and a fastening bracket which comprises a first plate comprising an upper surface and a lower surface, a second plate connected to the first plate, the second plate comprising a front surface adjacent to the lower surface, the front surface and the lower surface being disposed to form a right angle, and a rear surface adjacent to the upper surface, the rear surface comprising an upper hook, and a lower hook, and a bottom surface between the front surface and the rear surface, the fastening bracket being arranged between the first vertical wall and the catch, the front surface abutting the first vertical wall, and the rear surface abutting the catch.
16. The apparatus for constructing an architectural canopy frame of claim 15, wherein the catch further comprises a texture, and the rear surface of the fastening bracket comprises a mating texture, the texture and the mating texture being configured and dimensioned to engage when the bottom surface of the fastening bracket is received between the first vertical wall and the catch.
17. An apparatus for constructing an architectural canopy comprising: the apparatus for constructing an architectural canopy frame of claim 15, and a panel which comprises a top surface, a bottom surface, and a side surface extending from the top surface to the bottom surface, the panel being arranged with the side surface abutting the indexing ledge and the bottom surface overlaying the superior interior corner bracket receptacle.
18. The apparatus for constructing an architectural canopy of claim 17, wherein the lower surface of the fastening bracket is arranged over the top surface of the panel to hold the panel against the superior interior corner bracket receptacle.
19. The apparatus for constructing an architectural canopy of claim 18, wherein the panel has rectangular shape.
20. The apparatus for constructing an architectural canopy of claim 19, wherein the panel comprises a longitudinal axis and a cross-section perpendicular to the longitudinal axis, and the cross-section comprises a tongue-in-groove profile.
21. The apparatus for constructing an architectural canopy of claim 17, further comprising another panel.
22-25. (canceled)
26. The apparatus for constructing an architectural canopy of claim 17, wherein the panel comprises a fiberglass core and an exterior aluminum coating.
27. The apparatus for constructing an architectural canopy of claim 26, wherein the panel is an insulated roofing sandwich panel.
28. The apparatus for constructing an architectural canopy of claim 17, wherein the panel comprises a polyisocyanurate foam core and an exterior aluminum coating.
29. The apparatus for constructing an architectural canopy of claim 28, wherein the panel further comprises an internal reinforcing member.
30. The apparatus for constructing an architectural canopy of claim 29, wherein the internal reinforcing member is an aluminum tube.
31-87. (canceled)
Description
DESCRIPTION OF THE DRAWINGS
[0005] In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals (or designations) are used to indicate like parts in the various views:
[0006] FIG. 1 is a perspective view of an illustrative embodiment of an architectural canopy;
[0007] FIG. 2 is a partial sectional view of FIG. 1 showing an illustrative embodiment of a modular apparatus for constructing an architectural canopy;
[0008] FIG. 3 is a partial sectional view of another illustrative embodiment of a modular apparatus for constructing an architectural canopy;
[0009] FIG. 4 is a partial sectional view of another illustrative embodiment of a modular apparatus for constructing an architectural canopy;
[0010] FIG. 5 is a plan view of an exemplary structural member of FIG. 2;
[0011] FIG. 6 is a perspective view of the structural member of FIG. 5;
[0012] FIG. 7 is a plan view of an exemplary corner bracket for the architectural canopy of FIG. 1;
[0013] FIG. 8 is a perspective view of the corner bracket of FIG. 7;
[0014] FIG. 9 is an exploded view of an exemplary corner joint of the architectural canopy of FIG. 1;
[0015] FIG. 10 is a cross-sectional view of an exemplary L-bracket of FIG. 2;
[0016] FIG. 11 is a perspective view of the L-bracket of FIG. 10;
[0017] FIG. 12 is a side view of an exemplary channel cover for the frame of FIG. 1;
[0018] FIG. 13 is a perspective view of the channel cover of FIG. 12;
[0019] FIG. 14 is a perspective detail view of an exemplary hanger joint of FIG. 1;
[0020] FIG. 15 shows an exemplary hanger eye and T-slot mounting track for the hanger joint of FIG. 14
[0021] FIG. 16 is a cross-sectional view of a crown add-in track for the structural member of FIG. 5;
[0022] FIG. 17 is a perspective view of the crown add-in track of FIG. 10;
[0023] FIG. 18 is a partial sectional view of another arrangement for the canopy of FIG. 1, the other arrangement including the first arrangement of FIG. 2, along with a superior crown add-in and an inferior crown add-in secured to the front upper channel and the front lower channel, respectively;
[0024] FIG. 19 is a partial sectional view of the other arrangement of FIG. 18;
[0025] FIG. 20 is a cross-sectional view of a channel add-in track for the structural member of FIG. 5;
[0026] FIG. 21 is a perspective view of the channel add-in track of FIG. 20;
[0027] FIG. 22 is a cross-sectional view of a crown add-in track for the structural member of FIG. 5;
[0028] FIG. 23 is a perspective view of the crown add-in track of FIG. 22;
[0029] FIG. 24 is a cross-sectional view of an LED add-in track for the structural member of FIG. 5;
[0030] FIG. 25 is a perspective view of the LED add-in track of FIG. 24;
[0031] FIG. 26 is a cross-sectional view of an LED side add-in track for the structural member of FIG. 5;
[0032] FIG. 27 is a perspective view of the LED side add-in track of FIG. 26;
[0033] FIG. 28 is a cross-sectional view of a tube add-in track for the structural member of FIG. 5;
[0034] FIG. 29 is a perspective view of the tube add-in track of FIG. 28;
[0035] FIG. 30 is a cross-sectional view of a shelf add-in track for the structural member of FIG. 5;
[0036] FIG. 31 is a perspective view of the shelf add-in track of FIG. 30;
[0037] FIG. 32 is a partially exploded view of the architectural canopy of FIG. 1;
[0038] FIG. 33 is a partial sectional view of another embodiment of a modular apparatus for constructing the architectural canopy of FIG. 1;
[0039] FIG. 34 is a partial sectional view of FIG. 33, along with a superior crown add-in, an inferior crown add-in, and a hanger arm assembly secured to the structural member;
[0040] FIG. 35 is a perspective view of FIG. 34;
[0041] FIG. 36 is a cross-sectional profile of a second embodiment of a structural member for a canopy frame, along with a cross-sectional view of second embodiment of an L-bracket (or panel clip);
[0042] FIG. 37 is a cross-sectional view of a third embodiment of a structural member for a canopy frame;
[0043] FIG. 38 shows the structural member and panel clip of FIG. 36, in combination with a gutter screen.
[0044] FIG. 39 shows the structural member and panel clip of FIG. 37, in combination with a gutter screen.
[0045] FIG. 40 shows an exemplary mesh configuration for a gutter screen.
[0046] FIG. 41 shows an exemplary embodiment of a hanger rod assembly connected to a pair of jaw ends by knuckle bolts;
[0047] FIG. 42 is an exploded view of the left end assembly of FIG. 41;
[0048] FIG. 43 is a cross section of FIG. 41, along line 43-43;
[0049] FIG. 44 is a detail view of the left end assembly of FIG. 43;
[0050] FIG. 45 is a cross section of FIG. 44, along line 45-45;
[0051] FIG. 46 is a cross section of another embodiment of a hanger rod assembly perpendicular to the longitudinal axis of the hanger rod, the hanger rod including a generally square external profile;
[0052] FIG. 47 is a cross section of another embodiment of a hanger rod assembly perpendicular to the longitudinal axis of the hanger rod, the hanger rod including side tracks and round covers which combine to provide a generally circular external profile;
[0053] FIG. 48 is a cross section of another embodiment of a hanger rod assembly perpendicular to the longitudinal axis of the hanger rod, the hanger rod including side tracks and flat covers which combine to provide a generally square external profile;
[0054] FIG. 49 is a partially exploded perspective view of FIG. 47 showing an LED strip and a round translucent cover;
[0055] FIG. 50 is a partially exploded perspective view of FIG. 48 showing an LED strip and a flat translucent cover;
[0056] FIG. 51 is a perspective view of an exemplary scupper assembly, including a scupper and a scupper sleeve, as well as a hole saw drill bit for cutting opposing openings in the superior intermediate wall and the inferior intermediate wall of the structural member of FIG. 36 for receiving the scupper assembly;
[0057] FIG. 52 is partially exploded view of the scupper assembly of FIG. 51, the scupper sleeve being fitted into the opposing openings in the superior intermediate wall and the inferior intermediate wall;
[0058] FIG. 53 is perspective view of the scupper assembly of FIG. 51, fitted into the opposing openings in the superior intermediate wall and the inferior intermediate wall, the scupper being in a closed or ready configuration;
[0059] FIG. 54 is bottom perspective view of the scupper assembly of FIG. 53;
[0060] FIG. 55 is a cross section of FIG. 53, along line 55-55;
[0061] FIG. 56 is perspective view of the scupper assembly of FIG. 53, the scupper being in an open or deployed configuration;
[0062] FIG. 57 is bottom perspective view of the scupper assembly of FIG. 56;
[0063] FIG. 58 is a cross section of FIG. 56, along line 58-58;
[0064] FIG. 59 is an exploded view of the scupper of FIG. 51;
[0065] FIG. 60 is a preferred embodiment of a structural member for constructing an architectural canopy;
[0066] FIG. 61 is a preferred embodiment of an L-bracket for constructing an architectural canopy;
[0067] FIG. 62 is a preferred embodiment of a cover trim for constructing an architectural canopy;
[0068] FIG. 63 is a preferred embodiment of another structural member for constructing an architectural canopy;
[0069] FIG. 64 is a preferred embodiment of a bottom cover plate for the structural member of FIG. 63.
[0070] FIG. 65 shows the structural member of FIG. 63 with an L-bracket and gutter screen.
[0071] FIG. 66 shows the structural member of FIG. 60 with an L-bracket and gutter screen.
[0072] FIG. 67 is a preferred embodiment of an architectural profile add-on for constructing an architectural canopy, the architectural profile being a chase.
[0073] FIG. 68 is a preferred embodiment of an architectural profile add-on for constructing an architectural canopy, the architectural profile being a shelf.
[0074] FIG. 69 is a preferred embodiment of an architectural profile add-on for constructing an architectural canopy, the architectural profile being a crown.
[0075] FIG. 70 is a perspective view of an exemplary embodiment of a fixed corner bracket for connecting two structural members of a canopy frame;
[0076] FIG. 71 is a top view of the fixed corner bracket of FIG. 70;
[0077] FIG. 72 is a side view of the fixed corner bracket of FIG. 70;
[0078] FIG. 73 is a perspective view of another exemplary embodiment of a fixed corner bracket for connecting two structural members of a canopy frame;
[0079] FIG. 74 is a top view of the fixed corner bracket of FIG. 73;
[0080] FIG. 75 is a side view of the fixed corner bracket of FIG. 73;
[0081] FIG. 76 is a perspective view of an exemplary embodiment of an adjustable corner bracket for connecting two structural members of a canopy frame;
[0082] FIG. 77 is a top view of the adjustable corner bracket of FIG. 76;
[0083] FIG. 78 is a side view of the adjustable corner bracket of FIG. 76;
[0084] FIG. 79 is an exploded view of the adjustable corner bracket of FIG. 76;
[0085] FIG. 80 is a top view of the starboard leaf of the adjustable corner bracket of FIG. 79;
[0086] FIG. 81 is a side view of the starboard leaf of the adjustable corner bracket of FIG. 79;
[0087] FIG. 82 is a top view of the port leaf of the adjustable corner bracket of FIG. 79;
[0088] FIG. 83 is a side view of the port leaf of the adjustable corner bracket of FIG. 79;
[0089] FIG. 84 is a cross-sectional view of the adjustable corner bracket of FIG. 76, along line 84-84;
[0090] FIG. 85 is a perspective view of an another exemplary embodiment of an adjustable corner bracket for connecting two structural members of a canopy frame;
[0091] FIG. 86 is a top view of the adjustable corner bracket of FIG. 85;
[0092] FIG. 87 is a side view of the adjustable corner bracket of FIG. 85;
[0093] FIG. 88 is an exploded view of the adjustable corner bracket of FIG. 85;
[0094] FIG. 89 is a top view of the starboard leaf of the adjustable corner bracket of FIG. 85;
[0095] FIG. 90 is a side view of the starboard leaf of the adjustable corner bracket of FIG. 85;
[0096] FIG. 91 is a bottom view of the starboard leaf of the adjustable corner bracket of FIG. 85;
[0097] FIG. 92 is a top view of the port leaf of the adjustable corner bracket of FIG. 85;
[0098] FIG. 93 is a side view of the port leaf of the adjustable corner bracket of FIG. 85;
[0099] FIG. 94 is a bottom view of the port leaf of the adjustable corner bracket of FIG. 85;
[0100] FIG. 95 is a perspective view of the cap nut of FIG. 88;
[0101] FIG. 96 is another perspective view of the cap nut of FIG. 88;
[0102] FIG. 97 is a top view of the cap nut of FIG. 88;
[0103] FIG. 98 is a side view of the cap nut of FIG. 88;
[0104] FIG. 99 is a bottom view of the cap nut of FIG. 88;
[0105] FIG. 100 shows a sectional view of the corner joint of the adjustable corner bracket of FIG. 85 disposed in a corner bracket receiving slot of a structural member, the corner joint being in an adjustable configuration;
[0106] FIG. 101 shows a sectional view of the corner joint of the adjustable corner bracket of FIG. 85 disposed in a corner bracket receiving slot of a structural member, the corner joint being in a fixed configuration;
[0107] FIG. 102 is a perspective view of an exemplary embodiment of a moldable corner bracket for connecting two structural members of a canopy frame;
[0108] FIG. 103 is another perspective view of the moldable corner bracket of FIG. 102, the moldable bracket being in a straight configuration;
[0109] FIG. 104 is another perspective view of the moldable corner bracket of FIG. 102, the moldable bracket being in an angled configuration;
[0110] FIG. 105 is a top view of the moldable corner bracket of FIG. 102;
[0111] FIG. 106 is a side view of the moldable corner bracket of FIG. 102;
[0112] FIG. 107 is a bottom view of the moldable corner bracket of FIG. 102;
[0113] FIG. 108 is partially exploded view of an exemplary joint of a canopy frame formed by two structural members and two corner brackets;
[0114] FIG. 109 is a sectional view of an unsecured corner bracket arranged in a corner bracket receptacle of FIG. 108, along line 110-110;
[0115] FIG. 110 is a sectional view of a secured corner bracket arranged in a corner bracket receptacle of FIG. 108, along line 110-110;
[0116] FIG. 111 is a perspective view of a preferred screw for a corner bracket shown in FIG. 108;
[0117] FIG. 112 is another perspective view of the fastener screw of FIG. 111;
[0118] FIG. 113 is atop view of the screw of FIG. 111;
[0119] FIG. 114 is a bottom view of the screw of FIG. 111;
[0120] FIG. 115 is a side view of the screw of FIG. 111;
[0121] FIG. 116 is a cross-sectional view of the screw of FIG. 111;
[0122] FIG. 117 is a perspective view of a preferred embodiment of a reinforced structural panel for constructing an architectural canopy;
[0123] FIG. 118 is another perspective view of the reinforced structural panel of FIG. 117;
[0124] FIG. 119 is atop view of the reinforced structural panel of FIG. 117;
[0125] FIG. 120 is a cross-sectional view of the reinforced structural panel of FIG. 119;
[0126] FIG. 121 is a cross-sectional view of the structural panel of FIG. 120 without tubular reinforcing members;
[0127] FIG. 122 shows two structural panels of FIG. 117 connected by a tongue in groove joint.
[0128] FIG. 123 shows a preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a one-inch flat trim cover;
[0129] FIG. 124 shows another preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a two-inch flat trim cover;
[0130] FIG. 125 shows another preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a two-inch to one-inch flat adaptor trim cover;
[0131] FIG. 126 shows another preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a one-inch round trim cover.
[0132] FIG. 127 shows another preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a one-inch flat translucent cover;
[0133] FIG. 128 shows another preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a one and three sixteenth-inch rectangular translucent cover;
[0134] FIG. 129 shows another preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being a one-inch round translucent cover;
[0135] FIG. 130 shows a preferred embodiment of a light diffusing architectural element for constructing an architectural canopy, the light diffusing architectural element being a rectangular block;
[0136] FIG. 131 shows a preferred embodiment of an architectural cover for constructing an architectural canopy, the architectural cover being an aluminum trim cover and elastomeric plug.
[0137] FIG. 132 shows the aluminum trim cover and elastomeric plug of FIG. 131 fitted in an exemplary accessory seat.
[0138] FIG. 133 shows a cross-sectional view of the elastomeric plug of FIG. 131.
[0139] FIG. 134 shows a perspective view of another aluminum trim cover for another embodiment of an aluminum trim cover and elastomeric plug.
[0140] FIG. 135 shows another perspective view of aluminum trim cover of FIG. 134.
[0141] FIG. 136 shows a perspective view of an elastomeric plug for the aluminum trim cover of FIG. 134.
[0142] FIG. 137 shows the other embodiment of an aluminum trim cover and elastomeric plug fitted in an exemplary accessory seat.
[0143] FIG. 138 is a cross-sectional view of the aluminum trim cover of FIG. 134.
[0144] FIG. 139 is a cross-sectional view of the elastomeric plug of FIG. 136.
[0145] FIG. 140 shows an exemplary embodiment of an architectural lighting track including an LED-out track, an LED emitter, and one-inch flat translucent cover;
[0146] FIG. 141 is an exploded view of the architectural lighting track of FIG. 140;
[0147] FIG. 142 depicts a one-inch flat translucent cover being applied to a preferred embodiment of an LED-out track;
[0148] FIG. 143 shows an exemplary embodiment of an architectural lighting track including an LED-down track, an LED emitter, and a light diffusing rectangular block;
[0149] FIG. 144 is an exploded view of the architectural lighting track of FIG. 143;
[0150] FIG. 145 is a front bottom perspective view of an exemplary architectural canopy in accordance with the present disclosure;
[0151] FIG. 146 is a top view of the architectural canopy of FIG. 145;
[0152] FIG. 147 is a bottom view of the architectural canopy of FIG. 145;
[0153] FIG. 148 is a front view of the architectural canopy of FIG. 145;
[0154] FIG. 149 is a cross-sectional view of the architectural canopy of FIG. 146, along line 149-149;
[0155] FIG. 150 is a front, top, left side perspective view of FIG. 149;
[0156] FIG. 151 is a detail view of a right-side portion of FIG. 149;
[0157] FIG. 152 is a front bottom perspective view of another exemplary architectural canopy in accordance with the present disclosure;
[0158] FIG. 153 is a top view of the architectural canopy of FIG. 152;
[0159] FIG. 154 is a bottom view of the architectural canopy of FIG. 152;
[0160] FIG. 155 is a front view of the architectural canopy of FIG. 152;
[0161] FIG. 156 is a cross-sectional view of the architectural canopy of FIG. 153, along line 156-156;
[0162] FIG. 157 is a front, top, left side perspective view of FIG. 149;
[0163] FIG. 158 is a detail view of a right-side portion of FIG. 149;
[0164] FIG. 159 is a front view of an exemplary jaw end assembly (or fork end assembly) for connecting to a hanger rod assembly of the architectural canopy;
[0165] FIG. 160 is a front, top perspective view of the exemplary jaw end assembly of FIG. 159;
[0166] FIG. 161 is a rear, top perspective view of the exemplary jaw end assembly of FIG. 159;
[0167] FIG. 162 is a rear, bottom perspective view of the exemplary jaw end assembly of FIG. 159;
[0168] FIG. 163 is a rear, bottom perspective view of a U-shaped member of the exemplary jaw end assembly of FIG. 159;
[0169] FIG. 164 is a top view of the U-shaped member of FIG. 163;
[0170] FIG. 165 is a side view of the U-shaped member of FIG. 163;
[0171] FIG. 166 is a cross-sectional view of the U-shaped member of FIG. 164, along line 166-166;
[0172] FIG. 167 is a perspective view of the valance for the jaw end assembly of FIG. 159;
[0173] FIG. 168 is a front view of the valance of FIG. 167;
[0174] FIG. 169 is a top view of the valance of FIG. 167;
[0175] FIG. 170 is a top view of the T-nut for the jaw end assembly of FIG. 159;
[0176] FIG. 171 is a side view of the T-nut of FIG. 170;
[0177] FIG. 172 is a cross-sectional view of the T-nut of FIG. 170, along line 172-172;
[0178] FIG. 173 is a perspective view of the T-nut of FIG. 170;
[0179] FIG. 174 is a front bottom perspective view of another exemplary architectural canopy in accordance with the present disclosure;
[0180] FIG. 175 is a bottom view of the architectural canopy of FIG. 174;
[0181] FIG. 176 is a front view of the architectural canopy of FIG. 174;
[0182] FIG. 177 is a cross-sectional view of the architectural canopy of FIG. 175, along line 177-177;
[0183] FIG. 178 is a front, top, left side perspective view of FIG. 177;
[0184] FIG. 179 shows an exemplary embodiment of a louver for constructing an architectural canopy, the louver comprising an elongated member, an end plate, and four fastening screws.
[0185] FIG. 180 shows a partially exploded view of an exemplary louver-structural member connection;
[0186] FIG. 181 is a detail view of an exemplary louver-structural member connection in FIG. 177;
[0187] FIG. 182 is a cross-sectional view of two exemplary louver-structural member connections one each being located on opposite ends of the louver of FIG. 181, along line 182-182;
[0188] FIG. 183 is perspective view of the elongated member of FIG. 179.
[0189] FIG. 184 is plan view of the elongated member of FIG. 179.
[0190] FIG. 185 is perspective view of the end plate of FIG. 179.
[0191] FIG. 186 is plan view of the end plate of FIG. 179.
[0192] FIG. 187 is perspective view of a second embodiment of an elongated member for a louver.
[0193] FIG. 188 is plan view of the elongated member of FIG. 187.
[0194] FIG. 189 is perspective view of an end plate for the elongated member for a louver of FIG. 187.
[0195] FIG. 190 is plan view of the end plate of FIG. 189.
[0196] FIG. 191 is perspective view of a third embodiment of an elongated member for a louver.
[0197] FIG. 192 is plan view of the elongated member of FIG. 191.
[0198] FIG. 193 is perspective view of an end plate for the elongated member for a louver of FIG. 191.
[0199] FIG. 194 is plan view of the end plate of FIG. 193.
[0200] FIG. 195 is a perspective view of an exemplary architectural canopy with a track of decorative features secured into the superior external receptacle of each of three structural members of the frame.
[0201] FIG. 196 is a perspective view of an exemplary architectural canopy with a track of decorative features secured into the inferior external receptacle of each of three structural members of the frame.
[0202] FIG. 197 is a perspective view of an exemplary canopy frame with a track of decorative features secured into an accessory receptacle of each of three architectural profile add-on tracks of the frame.
[0203] FIG. 198 is an exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0204] FIG. 199 is another exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0205] FIG. 200 is another exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0206] FIG. 201 is another exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0207] FIG. 202 is another exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0208] FIG. 203 is another exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0209] FIG. 204 is another exemplary embodiment of a track of decorative features for constructing an architectural canopy.
[0210] FIG. 205 is a top perspective view of an exemplary architectural canopy which includes a circular skylight;
[0211] FIG. 206 is a bottom perspective view of the architectural canopy and skylight of FIG. 205;
[0212] FIG. 207 is a cross-sectional view of the architectural canopy of FIG. 205, along line 207-207;
[0213] FIG. 208 is a detail view of the skylight construction of FIG. 207 which includes an exemplary embodiment of a skylight assembly;
[0214] FIG. 209 is a detail view of the skylight construction of FIG. 207 which includes a preferred embodiment of a skylight assembly;
[0215] FIG. 210 is a top perspective view of another exemplary architectural canopy which includes a skylight;
[0216] FIG. 211 is a bottom perspective view of the architectural canopy and skylight of FIG. 210;
[0217] FIG. 212 is a cross-sectional view of the architectural canopy of FIG. 210, along line 212-212;
[0218] FIG. 213 is a detail view of the skylight construction of FIG. 212, which includes an exemplary embodiment of a skylight assembly;
[0219] FIG. 214 is a detail view of the skylight construction of FIG. 212 which includes a preferred embodiment of a skylight assembly;
[0220] FIG. 215 is a top perspective view of an exemplary architectural canopy which includes a rectangular skylight;
[0221] FIG. 216 is a bottom perspective view of the architectural canopy and skylight of FIG. 215;
[0222] FIG. 217 is a top perspective view of an exemplary architectural canopy which includes a hexagonal shaped skylight;
[0223] FIG. 218 is a bottom perspective view of the architectural canopy and skylight of FIG. 217;
[0224] FIG. 219 is a cross-sectional view of the top skylight bracket of FIG. 208 and FIG. 213;
[0225] FIG. 220 is a cross-sectional view of the bottom skylight bracket of FIG. 208 and FIG. 213;
[0226] FIG. 221 is a cross-sectional view of the top skylight bracket of FIG. 209 and FIG. 214;
[0227] FIG. 222 is a cross-sectional view of the bottom skylight bracket of FIG. 209 and FIG. 214;
[0228] FIG. 223 is a preferred embodiment of an architectural profile add-on track for constructing an architectural canopy, the architectural profile add-on track being a tube.
[0229] FIG. 224 shows another preferred embodiment of an architectural profile add-on track for constructing an architectural canopy, the architectural profile add-on track being configured and dimensioned to receive a two-inch to one-inch flat adaptor trim cover.
[0230] FIG. 225 is a detail view of the architectural profile add-on track being of FIG. 224.
[0231] FIG. 226 is a perspective view of an exemplary free-standing structure constructed from the modular apparatus for constructing an architectural canopy apparatus of the present disclosure.
[0232] FIG. 227 is another perspective view of the exemplary free-standing structure of FIG. 226
DESCRIPTION
[0233] FIG. 1 depicts an exemplary architectural canopy 10. The canopy may include a frame 12, a panel 14 disposed in the frame, and two hanging rod supports 16. Alternatively, the frame may be supported by posts or designed as a cantilever structure. More particularly, referring to FIGS. 2-5, the canopy 10 may be formed from a structural frame which includes four 45-degree cut fascia sections 18 formed from a common aluminum fascia stock. See also FIG. 32.
[0234] As shown in FIG. 5 and FIG. 6, the fascia stock may include a profile (or cross-section perpendicular to the longitudinal axis of fascia stock section) 20. Generally, the profile 20 may be hook shaped and may include a front side section 22, a bottom side section 24, and an inner side section 26. The bottom side section 24 and the inner side section 26 may be about the same length. The front side section 22 may be longer than the inner side section 26.
[0235] The front side section 22 may include a superior slot 28 and an inferior slot 30. The superior slot and the inferior slot may have the same structure but open in opposite directions. The superior slot may open upward, and the inferior slot may open downward. Additionally, the front side section 22 may include a superior track 32 adjacent to the superior slot.
[0236] The inner side section 26 may include a superior slot 34 and an inferior slot 36. The superior slot and the inferior slot of the inner side section also may have the same structure but open in opposite directions. Further the inner side section 26 may have a lateral slot 38 abutting the lower slot.
[0237] The bottom side section 24 between the inferior slot of the inner side section and the outer side section may be flat.
[0238] The interior walls of the inner side section 40, the bottom side section 42, and the front side section 44 may define a channel 46. The channel 46 may form a gutter for the collection and transport of rain or snow melt. See e.g., FIGS. 2-4. Additionally, the superior track 32 may form a cantilever over the channel. The track 32 may be configured and dimensioned to form a track for a T-bolt assembly that may be used to connect the frame 12 to a hanging rod 16. See e.g., FIGS. 14, 15, 18 and 19. The interior side wall 44 of the front side section 22 may include an upper catch 48 and a lower catch 50. Also, the interior side wall 40 of the inner side section 26 may include an inner catch 52. The inner catch 52 may include an elongated slot 54. The inner surface of the elongated slot may include ribbing 56. The inner catch 52 may be opposite the lower catch 50. As shown in FIG. 4, the inner catch 52 and the lower catch 50 may hold a gutter screen 58.
[0239] Referring to FIGS. 7, 8 and 9, two 45-degree cut fascia sections 18 may be structurally connected with a corner bracket 60 that is secured within abutting superior slots 28 and inferior slots 30, respectively. The bracket 60 may be arranged in a portion of the superior slots 28 and inferior slots that are configured and dimensioned to hold the one leg 62 of the corner bracket. Screws 64 may then be advanced into the corner bracket 60 to fix the respective legs 62 of the corner bracket 60 in the superior 28 and inferior slots 30. Access to advance the screws 64 may be provided through the open sides of the respective slots 28, 30. Further, corner brackets 60 may be secured in the superior and inferior slots 34, 36 of the inner side section 40 in a similar manner. Also, abutting architectural element profiles or add-ons 66 may be secured together with one or more corner brackets. See below. Preferably, connections involving corner brackets may preserve the integrity of the fastened components (e.g., the structural members or architectural profile add-on tracks) by not perforating or otherwise creating additional holes through the fastened components. Moreover, connections involving the canopy frame 10 may be disposed within the interior of the fastened components. Hence, connections involving corner brackets 60 may be concealed, and thus may provide a canopy frame 12 which is unblemished by fastener marks, holes or components. Accordingly, the disclosed corner brackets 60 may be used to create a structural joint with the integrity of the fascia segment 18 intact.
[0240] FIGS. 10 and 11 show an exemplary retention clip 68 that may be used to secure a canopy panel 14 to the frame 12. Referring to FIGS. 2, 18, 31 and 33, a panel 14 may rest on the inner side section 40 of the profile. One leg 70 of the retention clip 68 may be received and held in the elongated slot 54, and the other leg 72 may contact the top surface of the panel to fix the panel to the frame 12. An elastomeric gasket may be positioned between the panel 14 and the fascia 18 to seal the connection from rain or drainage. Also, a catch 76 on the clip in cooperation with the upper catch may be used to hold a gutter screen.
[0241] Referring to FIG. 2, the panel 14 may be formed from a solid material. For instance, the panel 14 may have a fiberglass core 78 and an exterior aluminum coating 80. For example, a panel 14 may be formed from an insulated roofing sandwich panel (SIP). Alternatively, the panel 14 may be formed from a polyisocyanurate (PIR) foam core and an exterior aluminum coating. See e.g., FIGS. 117-122. Also, the panel may include internal reinforcing members. For example, the reinforcing members may include tubes of aluminum. See e.g., FIG. 120. Generally, the panels 14 may be dimensioned from 2-8 in thickness, 4-8 in width, and up to 50 in length. Although, one full seamless panel 14 may be used, multiple modular panels 14 of approximately 4 sections may be arranged one next to the other and individually secured to the frame 12 with retention clips 70. Although adjacent panels 14 may interlock, the panels 14 may sit flush to one another. The panels 14 may be provided in one of a variety of colors and with or without interior recessed ribs 602 for decoration. See e.g., FIGS. 118, 145, and 152. Additionally, the panel 14 may be cut to receive a skylight or window. See e.g., FIGS. 204, 207, 210, 212 and 215-218.
[0242] Referring to FIG. 3, the panel 14 may be a glass panel 82. Preferably, the long leg 70 of the retention clip 68 may be cut or snapped to fit the shorter profile of the glass panel 82 so that the catch 76 on the clip can hold the gutter screen 58. An elastomeric gasket may be positioned between the glass panel 82 and the fascia 18 to seal the connection from rain or drainage.
[0243] Referring to FIG. 18 and FIG. 19, the superior slot 28 and the inferior slot 30 may be configured and dimensioned to receive an architectural element (e.g., a cover trim or an architectural profile add-on track) 66. For instance, in FIGS. 18 and 19, the architectural element may be an architectural profile add-on track. More particularly, the architectural profile of the add-on track may be a crown profile 67 the Accordingly, a fascia segment (or structural member) 18 may be fitted with two architectural elements 66 to form a canopy frame 12 which includes a double crown. See also FIG. 33.
[0244] FIGS. 12-13 and 123-129 present various cover trim architectural profile add-on tracks. Generally, these embodiments of cover trim architectural profile add-on tracks 84 may include a cover 86 with two prongs 88. The cover and two prongs may be configured and dimensioned to interlock with an accessory seat 90. For instance, FIGS. 12, 13 and 123 show a one-inch flat trim cover 92, FIG. 124 shows a two-inch flat trim cover 94, FIG. 125 shows a two-inch to one-inch flat adaptor trim cover 96, FIG. 126 shows a one-inch round trim cover 98, FIG. 127 shows a one-inch flat translucent cover 100, FIG. 128 shows a one and three sixteenth-inch rectangular translucent cover 102, and FIG. 129 shows a one-inch round translucent cover 104. Generally, the cover trim architectural profile add-on tracks 84 may be formed from aluminum, another metal or metal alloy, plastic, elastomer, polymer material, wood or a combination thereof.
[0245] Referring to FIGS. 131-133 and FIGS. 134-139, an aluminum cover trim and elastomeric plug 106 may be configured and dimensioned to securely engage with an accessory seat 90. Preferably, an aluminum cover trim and elastomeric plug 106 may form a secure fit with the accessory seat 90, but may further be removed without damaging the accessory seat or trim cover. For example, FIG. 131 shows a preferred embodiment of a composite aluminum cover trim and elastomeric plug 106. The aluminum may be a powder coated aluminum strip 108 and the elastomeric plug 110 may be formed from EPDM. The aluminum trim 108 may be fixed to the elastomeric plug 110 with an adhesive. FIG. 132 shows the aluminum trim cover and elastomeric plug 106 of FIG. 131 fitted in an exemplary accessory seat. FIG. 133 shows a cross-sectional view of the elastomeric plug of FIG. 131. By contrast, FIG. 134-139 show another embodiment of an aluminum trim cover and elastomeric plug 114. In this embodiment the aluminum sheet 116 may include a flat exterior surface 118 and an interior surface 120 that includes two prongs 122. Referring to FIG. 136, the elastomeric plug 124 further may include two receptacles 126 that are configured and dimensioned to mate with the prongs 122 on the interior surface 120 of the aluminum trim cover 116. FIG. 137 shows the aluminum trim cover 116 and elastomeric plug 124 fitted in an exemplary accessory seat 90.
[0246] Detailed and dimensioned views of the aluminum trim cover 116 and elastomeric plug 124 are presented in FIG. 138-139. Table 1 (below) presents exemplary dimensions for the composite aluminum cover trim and elastomeric plugs. Additionally, FIG. 130 shows a preferred embodiment of a light diffusing architectural element 128, which is shaped like a rectangular block. Preferably, the block may be form from a clear acrylic material.
[0247] Referring to FIGS. 4, 30 and 31, a shelf profile element (or shelf architectural profile add-on track) 130 may be arranged in the lateral slot 38 of the inner side section 40. The shelf profile element 130 may form a shelf for panels 14 or infill sheets. Although the infill sheets may be panels 14, the infill sheets may include wood, plastic, polymer, metal or other materials provided the infill sheets are constructed to be sufficiently strong and rigid to span the canopy frame. The infill sheets have different thickness than the panels. For instance, infill sheets may have a thickness of approximately 0.75 inches. A canopy with an upper panel ceiling and a lower infill ceiling may provide additional architectural combinations. Moreover, a canopy including an upper ceiling and a lower ceiling may provide a concealed space for housing electrical wiring, transformers, mechanical pipes, and other equipment. Accordingly, a canopy including an upper ceiling and a lower ceiling may provide a waterproof utility conduit for lighting and other systems associated with the canopy. Thus may make a separate waterproof box for these items superfluous.
[0248] Referring to FIGS. 20-31, these exemplary architectural profile add-on tracks 132 may snap into slots (e.g., accessory receiving seats) on the fascia profile 20 to provide different architectural finishes for the canopy. Additionally, these exemplary architectural profile add-on tracks 132 may form a housing for LED lighting, as well as associated light transmitting cover trim or structures (e.g., glass or acrylic blocks). See e.g., FIGS. 140-144.
[0249] Moreover, as shown in FIGS. 5 and 6, the fascia stock (or structural member) 18 may include a profile 20 or cross-section perpendicular to the longitudinal axis of the structural member. For instance, referring to FIGS. 5, 36, and 60, the profile 20 may include an exterior wall 134, and a front wall 44 spaced from the exterior wall. A superior partition 138 may extend from the exterior wall to the front wall. Additionally, an intermediate partition 140 may extend from the exterior wall to the front wall. Also, an inferior partition 142 may extend from the exterior wall to the font wall. The front wall, superior partition, and exterior wall may bound a superior external receptacle 28. The superior external receptacle 28 may include a corner bracket receiving segment 144, a cover receiving segment 146 spaced from the corner bracket receiving segment, and an add-on receiving segment 148 disposed between the corner bracket receiving segment and the cover receiving segment. The front wall 44 further may include a cantilevered track 32. The cantilevered track 32 may include a superior intermediate receptacle 150. The superior intermediate receptacle 150 may be configured and dimensioned to receive T-nut for securing an eye or jaw-end of a turnbuckle fitting. Further, the front wall 44 may include a superior hook 48 adjacent to the superior partition, as well as a hook 50 adjacent to the intermediate partition. The exterior wall 134, inferior partition 142, and front wall 134 may bound an inferior external receptacle 30. The inferior external receptacle 30 may include a cover receiving segment 152 and one or more corner bracket receiving segments 154.
[0250] The profile of the structural member further may include a rear wall 40 spaced from the front wall 44. Preferably, the rear wall may be parallel to the front wall. An inferior intermediate 158 wall may extend from the front wall 44 to the rear wall 40. Also, a superior intermediate wall 142 may extend from the front wall to the rear wall. The inferior intermediate wall 158 and the superior intermediate wall 42 may be substantially parallel. The front wall 44, inferior intermediate wall 158, superior intermediate wall 42, and rear wall 40 may define an inferior duct 160. The rear wall 40 may include a catch 52 opposite the hook 50. Moreover, the profile 20 of the structural member 18 may include a superior interior wall 162 and an inferior interior wall 164 spaced from the rear wall. Adjacent to the superior intermediate wall, a base partition 166 may extend from the rear wall 40 to the inferior interior wall 164. The rear wall 40, base partition 166, and inferior interior wall 164 may bound an inferior interior receptacle 36. The configuration of the inferior interior receptacle 36 may be the same as that of the inferior external receptacle 30. A lower partition 168 may extend from the rear wall 40 to the superior interior wall 162. The lower partition 168, rear wall 40, and base partition 166 may bound an intermediate interior receptacle 38. The intermediate interior receptacle 38 may include a cover receiving segment 170 and an add-on receiving segment 172. Moreover, an upper partition 174 may extend from the rear wall 40 to the superior interior wall 162. The rear wall 40, lower partition 168, superior interior wall 162, and upper partition 174 may define an interior duct 176. Also, the superior interior wall 162, upper partition 174, and rear wall 40 may bound a superior interior receptacle 34. The superior interior receptacle 34 may include a cover receiving segment 170 and one or more corner bracket receiving segments 172. The rear wall, superior intermediate wall, and front wall may define a gutter 46 for collecting and transporting rainwater, melted snow or ice.
[0251] Referring to FIG. 34 and FIG. 35, a canopy 10 including a double panel ceiling configuration may be constructed from a structural member (e.g., FIG. 5) 18. More particularly, a flat trim cover 84 may be inserted into the superior interior receptacle 34 and the inferior interior receptacle 36. A shelf add-on profile 130 may be connected to the intermediate interior receptacle 38. A ceiling panel 14 including an aluminum coating and a PIR foam core, may be laid on the shelf add-on profile 130 and secured with an L-bracket 68. The L-bracket may securely connect to a mating fitting 184 on the shelf add-on profile 130 which may be adjacent to the superior interior wall 162. Similarly, another ceiling panel (or upper ceiling panel) 14 may be laid on the flat trim cover 84 disposed in the superior interior receptacle. The upper ceiling panel 14 may be secured to the structural member with a superior L-bracket 68. The superior L-bracket may securely connect to a mating fitting 54 between the rear wall 40 and the catch 52. A gutter screen 58 may be interlocked with a hook 76 on the L-bracket (see e.g., FIG. 10 and FIG. 11) and the hook 48 on the front wall. Also, a top crown 67 may be connected to the superior external receptacle 28, and a bottom crown 67 may be connected to the inferior external receptacle 30.
[0252] Referring to FIG. 36 and FIG. 60, the structural member 14 further may include a profile which may include an intermediate hook 186 on the front wall 44 and an indexing ledge 188 adjacent the superior interior receptacle 34 and rear wall 40. Additionally, the inferior external receptacle 30 and inferior internal receptacle 36 may each include a combined cover and add-on profile receiving segment 190, as well as a corner bracket receiving segment 154. Also, an L-bracket 192 including an upper hook 194 and a lower hook 196 may be configured and dimensioned to securely engage with a slot 54 defined by the catch 52 and rear wall 40. See e.g., FIG. 61.
[0253] Referring to FIGS. 37, 39, 63, 64 and 65, another exemplary embodiment of a fascia segment (or structural member) 202 for forming a canopy 10 is disclosed. In this embodiment, the outer dimensions of the structural member 202 may be reduced. See, FIG. 60 and FIG. 63. Additionally, the L-bracket 206 may be shorter. See e.g., FIG. 65 and FIG. 66. Moreover, the structural member 202 may include four corner bracket receptacles 154. Two of the corner bracket receptacles 154 may be in parallel alignment with the front wall 44 and rear wall 40 of the profile 204 or cross-section perpendicular to the longitudinal axis of the structural member. Also, two of the corner bracket receptacles 154 may be in parallel alignment with the lower wall 42. The profile 204 or cross-section perpendicular to the longitudinal axis of the structural member further may include two accessory seats 90 which may be configured and dimensioned to receive and interlock with an architectural element (e.g., a cover trim 86 or an architectural profile add-on track 66). One corner bracket receptacle may be located inside each of the accessory seats. For instance, one accessory seat 90 may be configured and dimensioned to mate with a 1-inch cover track or an architectural profile add-on track. See FIG. 62. Whereas, the second accessory seat 90 may be configured and dimensioned to mate with a 2-inch cover track 94. See e.g., FIGS. 37, 63 and 64.
[0254] Referring to FIGS. 32, 146, 153 and 174, a canopy frame 12 may be constructed from four segments of aluminum fascia 18 that includes a profile 20 of the preferred embodiment of the structural member. See e.g., FIG. 36 and FIG. 60. Each segment 18 may be formed by cutting a straight length of the aluminum fascia at a 45-degree angle such that adjoining segments 18 may abut to form a right angle. Referring to FIG. 108, a corner bracket 60 may be arranged in each pair of adjacent corner bracket receiving receptacles to join the aluminum fascia segments together to form a structural joint. The structural joint may securely fix one structural member to another structural member. As shown in FIG. 108, the two structural members 18 may form a right angle. The intersection of the two structural members 18 may form a corner of a canopy frame 12.
[0255] FIGS. 70-72 show a first embodiment of a corner bracket 60, 210. The corner bracket may be formed from steel. The corner bracket may include a first plate 212 and a second plate 214. The upper and lower surfaces 216, 218 of the first plate and the second plate may be parallel and lie and the same horizontal planes. The first plate and the second plate form a right angle. The inner corner formed by the first plate and second plate may include a circular cut out. The first plate may include three screw holes 222. The screw holes 222 may have a central axis that is perpendicular to the upper and lower surfaces of the plates. The right angle formed by the first and second plate may be measured in a plane perpendicular to the central axes of the screw holes. The screw holes may be configured and dimensioned to receive the screw 224 of FIGS. 111-116. Generally, the corner bracket may have a smooth finish and tapered ends 226 to facilitate positioning the corner bracket 60 into the corner bracket receiving segments of the respective adjacent fascia (or structural members) or other components that are to be joined. For instance, the thickness and the width may taper near the distal ends of the first and second plates. For example, over the last inch of the plate, the width may taper by about 1 mm on each side. Additionally, the thickness may taper by about 1 mm between the upper surface and the lower surface of the plate over the same distance. The corner brackets may include ridges. Referring to FIGS. 36 and 60, the first embodiment of the corner bracket 60, 210 may be used in the inferior corner bracket receptacles 225 and the superior corner bracket receptacles 225 to form a joint of a structural corner for a canopy frame.
[0256] Referring to FIGS. 108-110, the corner bracket 210 may cooperate with a generally flat headed screw 224 to lock the upper surface of the bracket 216 against the bottom side of the ledges 228 which form the corner bracket receptacle 22|. The screw 224 may include a generally flat or concave distal tip 230 in order to bear upon but preferably not perforate the lower wall 232 of the corner bracket receptacle 225. Also, the length of the screw 224 may be such that advancing the screw within the corner bracket screw hole causes the plate 210 to advance up the length of the screw to press against the bottom side of the ledges 228 which form the corner bracket receptacle 225 while the distal end 230 of the screw presses against the opposite (i.e., lower wall) 232 of the corner bracket receptacle 225 to fix the relative positions of the screw 224, plate 210 and receptacle 225. Exemplary dimensions for the corner bracket receptacle are shown in FIG. 60 and presented in Table 1 (below); whereas exemplary dimensions of the screw are shown in FIGS. 114 and 116 and presented in Table 1 (below).
[0257] FIGS. 73-75 show a second embodiment of a corner bracket 234. The second embodiment may be substantially similar is to the corner brackets of FIGS. 70-72, except that the right angle formed by the first plate 212 and the second plate 214 may be measured in a plane aligned with the central axes of the screw holes 222. Referring to FIGS. 63-65, the second embodiment of the corner bracket may be used in the inferior corner bracket receptacles 236, but the first embodiment of the corner bracket 210 may be used in the upper corner bracket receptacles to form a joint of a structural corner for a canopy frame 12.
[0258] FIGS. 76-81 show a third embodiment of a corner bracket 240. The third embodiment embodiment may be similar to the second embodiment 234 of a corner bracket (i.e., FIGS. 73-75), except that the angle formed by the first plate 212 and the second plate 214 may be adjustable. For example, the third embodiment of the corner bracket 240 may include a first leaf plate 242 and a second leaf plate 242 which cooperate to form a hinge 246 with a set screw 248. The first leaf and the second leaf may rotate about the set screw 248. Once an angle is selected the set screw 248 may be tightened to fix the relative positions of the first leaf plate 242 and the second leaf plate 244.
[0259] FIGS. 76-84 show a third embodiment of a corner bracket 240. The third embodiment embodiment may be similar to the second embodiment 234 of a corner bracket (i.e., FIGS. 73-75), except that the angle formed by the first plate 212 and the second plate 214 may be adjustable. For example, the third embodiment of the corner bracket 240 may include a first leaf plate 242 and a second leaf plate 244 which cooperate to form a hinge 246 with a set screw 248. The first leaf and the second leaf may rotate about the set screw 248. Once an angle is selected the set screw 248 may be tightened to fix the relative positions of the first leaf plate 242 and the second leaf plate 244.
[0260] FIGS. 85-99 show a fourth embodiment of a corner bracket 250. The fourth embodiment may be similar to the first embodiment of a corner bracket 210 (i.e., FIGS. 70-72), except that the angle formed by the first plate 212 and the second plate 214 may be adjustable. For example, the fourth embodiment of the corner bracket 250 may include a first blade plate 252 and a second blade plate 254. The first blade plate 252 may include a cylindrical projection 256. The cylindrical projection may include a screw thread. The second blade plate 254 may be seated over the cylindrical projection 256. A low-profile cap nut 258 may be advanced on to the cylindrical projection 256 to form the adjustable bracket. Referring to FIG. 100, the first blade plate 252 and the second blade plate 254 may rotate about the cylindrical projection 254. Referring to FIG. 101, once an angle is selected the cap-nut may be tightened to fix the relative positions of the first blade plate 252 and the second blade plate 254. The joint of the corner bracket 250 may be solid and the corner bracket may be drawn up against the ledges 228 of the corner bracket receptacle 225, without adverse impact to the capability or performance of the corner bracket 250 to fix the relative positions of the screw 260, plate 252, 254, and receptacle 225.
[0261] FIGS. 102-107 an exemplary embodiment of a moldable corner bracket 262 for connecting two structural members of a canopy frame. The moldable corner bracket 262 may be similar to the second embodiment of a corner bracket 234 (i.e., FIGS. 73-75), except that in the initial configuration the first plate 212 and the second plate 214 may be full alignment. The initial configuration may be used to splice two structural segments in common alignment. Referring to FIGS. 36 and 60, the moldable corner bracket 262 may be used in the inferior corner bracket receptacles 225 and the superior corner bracket receptacles 225 to form a straight joint for a structural canopy frame. Moreover, the first plate 212 and the second plate 214 may be bent to form a fixed angle between the first plate and the second plate. The fixed angle may be measured in a plane perpendicular with the central axes of the screw holes 222.
[0262] As shown in FIGS. 149, 150, 156, 157, 177 and 178, interlocking panels 14 may be positioned on top of the superior interior receptacle 34 and against abutting indexing ledge 188 to span the frame 12 and form a ceiling. Additionally, the width of another interlocking panel 14 may be cut to furnish fill pieces 264 for the ceiling as may be necessary. As shown in FIGS. 151, 157 and 177, the interlocking panels 14 and any fill pieces 264 may be secured to the structural members 18 by an L-bracket 192 which captures the interlocking panel 14 on one side of the L-bracket 192 and mates on the other side with a catch 52 on the rear wall 40. See also FIGS. 61, 65, 66.
[0263] Gutter screens 58 may be measured and cut to fill the space between the front wall 44 and rear wall 40 of the structural member 18 of each adjoining segment of the frame 12. The gutter screens 58 may rest on the upper hook 48 of the L-bracket and the superior hook 48 of the front wall. See e.g., FIG. 38 and FIG. 66. By contrast, in an canopy frame 12 constructed the structural member disclosed in FIGS. 37, 39, 63 and FIG. 64, the gutter screen may rest on the lower hook 196 of the L-bracket and the intermediate hook 186 on the front wall. An exemplary embodiment of a gutter screen 58 is shown in FIG. 40. The size and shape of the openings 256 in the screen may be adapted for a particular application.
[0264] Referring to FIGS. 41-50, an exemplary hanging rod assembly is disclosed. Referring to FIG. 41 an apparatus for constructing an architectural canopy may include a hanging rod assembly 16 for securing the architectural canopy frame 12 to a structure. The hanger rod assembly 16 may connected to a pair of jaw ends 268 by knuckle bolts 270. See e.g., FIGS. 160-173.
[0265] Referring to FIG. 41-42, the hanger rod assembly 16 may include a hanger rod 272, and a left-hand end assembly 274 secured to one end of the hanger rod. Referring to FIG. 43, the hanger rod 272 may include an interior passage 278 extending from one end of the hanger rod to the other end of the hanger rod. Additionally, the hanger rod may include an outer surface 280 and a slot extending from the outer surface to the interior passage. The slot 282 may include a screw thread 284. Moreover, a right-hand end assembly 276 may be secured to the other end of the hanger rod.
[0266] As shown in FIG. 44, an end assembly 274, 276 further may include a rod 286 which comprises a proximal end 288 that includes an eye fitting 290 and a mechanical connector 292. The mechanical connector 292 may include a first transverse plate 294, a first stem 296, and a socket 298 extending through the first mechanical connector. As shown in FIGS. 42-45, the stem may include a groove 300 that bisects the stem. The stem 296 may further include holes 302 that extend from the outer surface of the stem to the socket. The holes 302 may include a screw thread. Also, the socket further may include a side wall with a screw thread.
[0267] Additionally, the rod 286 may include a threaded segment 308 which is configured and dimensioned to mate with the screw thread 306 on the side wall 304 of the socket. The rod 286 may be advanced into the socket 298, and the socket may be inserted into the interior passage 278 of the hanger rod. As shown in FIGS. 45-50, the slot 300 in the stem may engage with two projections 310 on the inner surface of the interior passage. Fastener screws 312 may then be advanced in the threaded fastener receiving holes 302 on the stem to fix the end assembly 274 in the hanger rod 272.
[0268] Moreover, the outer surface 280 of the hanging rod 272 may include one or more channels 314 extending from the one end to the other end. The channel 314 may have a cross-section 316 perpendicular to the longitudinal axis, which frames an accessory receiving seat 90. As shown in FIGS. 45-50, the accessory receiving seat 90 forms a receptacle for receiving an architectural channel cover trim 84. See also FIG. 62.
[0269] Referring to FIG. 45, the cross section of the hanger rod 272 perpendicular to the longitudinal axis of the hanger rod provides the hanger rod assembly 16 with a rounded external profile 318.
[0270] Referring to FIG. 46, the cross section of the hanger rod 272 perpendicular to the longitudinal axis of the hanger rod, along with a flat cover trim 84 interlocked with the receptacle 90 provides the hanger rod assembly 16 with a square external profile 320.
[0271] Referring to FIG. 47 and FIG. 49, the cross section of the hanger rod 272 perpendicular to the longitudinal axis of the hanger rod, along with a three rounded cover trim 84 interlocked with the three receptacles 90 provides the hanger rod assembly 16 with a round external profile 322. Additionally, an LED strip 324 may be deployed in two of the receptacles, along with a round translucent cover to provide an architectural light accent for the hanger rod assembly 16.
[0272] Referring to FIG. 48 and FIG. 50, the cross section of the hanger rod 272 perpendicular to the longitudinal axis of the hanger rod, along with a three flat cover 84 interlocked with the three receptacles 90 provides the hanger rod assembly 16 with a square external profile 326. Additionally, an LED strip 324 may be deployed in two of the receptacles, along with a flat translucent cover to provide an architectural light accent for the hanger rod assembly.
[0273] Accordingly, a hanging rod assembly 16 may include a hanger rod 272 having a longitudinal axis and a first end, a second end spaced from the first end along the longitudinal axis, an outer surface 280 extending from the first end to the second end, and an interior passage 278 extending from the first end to the second end. The interior passage 278 may include a side wall, a first projection 310 extending from the side wall into the interior passage, and a second projection 310 extending from the side wall into the interior passage. The second projection may be disposed opposite the first projection. The hanger rod 272 further may include a slot 282 extending from the outer surface 280 to the interior passage 278. The slot 282 may include a first side wall having a screw thread 284, and a second side wall opposite the first side wall. The second side wall may include a complementary screw thread such that the slot 282 may be configured and dimensioned to mate with a fastener 312 having a mating screw thread.
[0274] Further, the hanger rod assembly may include a first end assembly 274 secured to the first end of the hanger rod 272. The first end assembly 274 may include a first mechanical connector 292. The first mechanical connector 292 may include a first transverse plate 294 having a first exterior face and a first interior face. The first mechanical connector 292 further may include a first stem 296 extending from the first interior face. The first stem 296 may include a first proximal end and a first distal end, a first outer surface, and a groove 300 bisecting the first stem. Moreover, the first mechanical connector 292 may include a socket 298 which extends through the first mechanical connector. The socket 298 may include a side wall which comprises a screw thread 306. Additionally, the hanger rod assembly 16 may include a first rod 286. The first rod 286 may include a first proximal end having a first eye fitting 290, a first smooth segment abutting the first eye fitting, a first distal end, and a first threaded segment 308 disposed between the first smooth segment and the first distal end. The first stem 296 may be arranged in the interior passage 278. The threaded rod 308 may be arranged in the socket 298.
[0275] The hanger rod assembly 16 further may include a second end assembly 276 secured to the second end of the hanger rod 272. Also, the first end assembly 274 may be a right-hand threaded end assembly, and the second end assembly 276 may be a left-hand threaded end assembly. The stem 296 further may include a plurality of screw holes 302 extending from the outer surface to the socket, and the hanger rod assembly 16 further may include a fastener screw 312 arranged in the slot 282 of the hanger rod 272 and one of the plurality of screw holes 302 in the stem 296. In one embodiment, the outer surface 280 of the hanging rod may include a cross-sectional profile perpendicular to the longitudinal axis, the cross-sectional profile comprising a rounded profile 318.
[0276] In another embodiment, the outer surface 280 of the hanger rod 272 further may include a first channel 314 extending from the first end to the second end, and the channel 314 may have a first cross-section perpendicular to the longitudinal axis of the hanger rod 272. The first cross-section may include a first channel wall with a first channel wall end disposed on the periphery of the first cross-section and a first channel wall edge adjacent to the first channel wall end. The first cross-section further may include a first opposing channel wall. The first opposing channel wall end may be disposed on the periphery of the first cross-section. The first opposing channel wall may include a first opposing channel wall edge adjacent to the first opposing channel wall end. Also, the first opposing channel wall may include a first opposing channel wall seat disposed between the first opposing channel wall end and the first opposing channel wall edge.
[0277] Further, the first cross-section of the first channel may include a second channel wall. The second channel wall may include a second channel wall end disposed on the periphery of the first cross-section and a second channel wall edge adjacent the second channel wall end. Additionally, the first cross-section of the first channel may include a second opposing channel wall. The second opposing channel wall may include a second opposing channel wall end disposed on the periphery of the first cross-section, a second opposing channel wall edge adjacent the second opposing channel wall end, and a second opposing channel wall seat disposed between the second opposing channel wall end and the second opposing channel wall edge. Moreover, the first opposing channel wall edge may be disposed opposite the first channel wall edge and the first opposing channel wall seat may be disposed opposite the first channel wall seat, and the first opposing channel wall edge, the first channel wall edge, the first opposing channel wall seat, and the first channel wall seat may frame a first receptacle for receiving an architectural channel cover trim.
[0278] An architectural cover trim 84 may be attached to the first receptacle 90. In one embodiment, the architectural cover trim 84 may be formed from aluminum. In another embodiment, the architectural cover trim may be formed from a plastic material or a polymer material. For instance, the architectural cover trim may be formed from EPDM. Also, the architectural cover trim may be opaque or translucent. Moreover, an architectural cover trim 84 may include a flat exterior surface or a rounded exterior surface. In one embodiment, the outer surface of the hanging rod may include a cross-sectional profile perpendicular to the longitudinal axis including three or more planar segments. For instance, in another embodiment, the cross-sectional profile may include seven planar segments. Also, the outer surface of the hanging rod may include a cross-sectional profile perpendicular to the longitudinal axis including three rounded segments.
[0279] Referring to FIGS. 159-173, the hanger rod assembly 16 may include a fork end assembly 268 for connecting the hanger rod assembly 16 to the architectural canopy frame 12. The fork end assembly 268 may include a U-shaped fitting 328 that includes a first branch 330 having a first through bore 332, a second branch 334 which includes a second through bore 336, and a base 338 disposed between the branch and the second branch. The base 338 may include an upper surface 340 and lower surface 342. The lower surface may be planar. The base 338 further may include a third bore 344 extending from the upper surface to the lower surface, as well as a fixation bolt 270 arranged in the first bore 332 and the second bore 336. Referring to FIGS. 159-162, the U-shaped fitting 328 further may include a fastener 346 arranged in the third bore 344. Referring to FIGS. 162 and 170-173, the fastener 346 may include or resemble a T-bolt or a T-nut 348.
[0280] In another embodiment, the base of the U-shaped fitting may include a front side extending from the upper surface and the lower surface, a rear side extending from the upper surface and the lower surface, a port side extending from the upper surface and the lower surface, a starboard side extending from the upper surface and the lower surface, a front side groove extending from the port side surface to the starboard side surface, and a rear side groove extending from the port side surface to the starboard side surface. Also, the third bore may include a side wall and a first screw thread on the side wall. A bolt which includes a head and a shank may be arranged in the third bore. The head of the bolt may include a tool-fitting. The shank may include a distal end and a second screw thread. The second screw thread may be configured and dimensioned to mate with the first screw thread. The bolt may be advanced in the third bore such that the distal end of the shank may extend beyond the lower surface. Referring to FIGS. 167-169, the fork end assembly 286 may include a valance 350 for the U-shaped fitting. Exemplary dimensions for fork end assembly 286 are provided in Table 1 (below).
[0281] Additionally, referring to FIGS. 148, 150, 157 and 158, architectural elements 66 may be added to the frame 12. For instance, as shown in FIG. 152, tube architectural profile add-on tracks 352 may be added to the front, right side and left side structural members 18 of the frame 12. Moreover, referring to FIG. 151, an LED strip may be positioned in the interior intermediate receptacle 38. The interior intermediate receptacle 38 may then be closed with a flat translucent cover 100 to provide a lighting feature for the canopy. See FIGS. 140-142. Further still, referring to FIG. 158, a double ceiling canopy may be constructed by securing shelf architectural profile add-on tracks 130 to the structural members 18 in place of an LED strip and translucent cover. The LED strip 324 and translucent cover 100, however, may be positioned in the accessory seat 90 of the shelf architectural profile add-on track(s) 130. See, FIGS. 30, 31 and 68.
[0282] Referring to FIGS. 51-58, the frame 12 may further include one or more scupper assemblies 354 disposed in the superior intermediate wall 42 and the inferior intermediate wall 158 of a structural member 18. Referring to FIGS. 54 and 55, the scupper 356 may be normally closed as a counterweight 360 may produce a moment about the hinge pin 362 which keeps the scupper bottom 364 pressed against the scupper basket 366. Referring to FIGS. 56-58, as water 368 from the gutter 46 fills the scupper basket 366 the flow and weight the water may overcome the moment and open the scupper bottom 364 to drain the accumulated or flowing water in the gutter. Once the water has been collected and drained from the gutter, the counterweight 360 may return the scupper bottom 364 to the closed position. See FIGS. 53-55. Also, referring to FIG. 52, a sleeve 358 may be used to seal the penetrations or openings in the superior intermediate wall 42 and the inferior intermediate wall 158 of the structural member.
[0283] As shown in FIG. 59, a concealed scupper 356 for an architectural canopy may include a basket 366. The basket may include an annular surface 370 including an interior opening 372, and a flange 374 surrounding the interior opening. Additionally, basket 366 may include a discharge port 376. The discharge port may be disposed below the interior opening. Also, the basket 366 may include a side wall 378 connecting the interior opening to the discharge port and a cover 364 for the discharge port. The side may include an inner surface which forms a tapered conduit between the interior opening and the discharge port and an outer surface 380. The outer surface 380 may include a first mounting block 382 including a first aperture 384, as well as a second mounting block 386 adjacent to the first mounting block. The second mounting block may include a second aperture 388, the second aperture being aligned with the first aperture. The cover 364 for the discharge port may include an upper surface 390, a lower surface 392, and a side wall 394 disposed along the periphery of the upper surface. The side wall 394 may include a first bore 396 having a first longitudinal axis and a second bore 398 having a second longitudinal axis. The first longitudinal axis and the second longitudinal axis may be coincident. The cover 364 further may include a ledge 400 extending over a segment of the side wall, the upper surface, the ledge, and the segment of the side wall framing a pocket 402. The cover 364 further may include a counterweight 360 arranged in the pocket and a pin 404 arranged through the first aperture 384, the first bore 396, the second bore 398, and the second aperture 388 block. The scupper 356 may include a closed configuration 406 in which the upper surface abuts the discharge port 376, and an open configuration 408 in which the cover is rotated about the pin. In the open configuration the upper surface 390 is spaced from the discharge port. The scupper 356 may be biased into the closed configuration by the counterweight.
[0284] Referring to FIGS. 174-179, one or more louvers 410 may be secured to the interior intermediate receptacles 38 of two opposing structural members 18 to create another architectural element for the canopy. Referring to FIGS. 180-183, each louver may be oriented about a longitudinal axis and fixed in place to further provide varied architectural expression to the canopy frame 12. Moreover, each louver may include an LED strip and translucent cover 100 to provide a desired architectural lighting effect for the canopy.
[0285] As shown in FIGS. 183-194, a louver 410 for constructing an architectural canopy or pergola may include an elongated body 412 having a longitudinal axis. The elongated body may include a proximal end 414, a distal end 416 spaced from the proximal end along the longitudinal axis, and a first cross-section 418 perpendicular to the longitudinal axis. The first cross-section 418 may include a first decorative wall 420. The first decorative wall may include a first exterior side 422 and a first interior side 424. The first interior side may include a first c-shaped channel 426 which comprises a first concavity 428 and a second c-shaped channel 430 which comprises a second concavity 432. The first cross-section 418 further may include a second decorative wall 434 spaced from the first decorative wall 420. The second decorative may include a second exterior side 436 and a second interior side 438. The second interior side 438 may include a third c-shaped channel 440 which includes a third concavity 442 and a fourth c-shaped channel 444 which includes a fourth concavity 446. Additionally, the first cross-section 418 may include a cross-wall 448 extending between the first interior side 424 and the second interior side 438. Also, the elongated body 412 may include a first end plate 450 fixed to the proximal end 416. The first end plate 450 may include a first elongated notch 452, a first fastener receiving hole 454 located for alignment with the first concavity 428, a second fastener receiving hole 456 located for alignment with the second concavity 432, a third fastener receiving hole 458 located for alignment with the third concavity 442, a fourth fastener receiving hole 460 located for alignment with the fourth concavity 446. The elongated body 412 also may include a second end plate 462 fixed to the distal end 414. The second end plate may be identical to the first end plate.
[0286] Moreover, in one embodiment the first end plate 450 may include a first rectangular outer profile 464. Also, the first interior side 424 and the second interior side 438 may form a first accessory seat 466 adjacent to the first elongated notch 452, as well as a first corner bracket receptacle 468 disposed below the first accessory seat 466. An architectural cover 84 may be attached to the first accessory seat. In another embodiment, the first end plate 450 may include a second rectangular outer profile 472. In another embodiment, the first end plate 450 may include a rounded outer profile 474. The first endplate may include a second elongated notch.
[0287] Generally, the louver 410 may include a first screw 478 arranged through the first fastener receiving hole 454 of the first end plate 450 and the first concavity 428 to attach the first end plate to the proximal end 414 of the elongated body 412. The louver also may include a second screw 480 arranged through the second fastener receiving hole 456 of the first end plate 450 and the second concavity 432 to attach the first end plate 450 to the proximal end 414 of the elongated body 412, as well as a third screw 482 arranged through the third fastener receiving hole 458 of the first end plate and third concavity 442 to attach the first end plate to the proximal end of the elongated body. Furthermore, the louver 410 may include a fourth screw 484 arranged through the fourth fastener receiving hole 460 of the first end plate 450 and fourth concavity 446 to attach the first end plate to the proximal end of the elongated body.
[0288] Similarly, the louver 410 may include a fifth screw arranged through the first fastener receiving hole of the second end plate and the first concavity 428 to attach the second end plate 462 to the distal end of the elongated body 416, a sixth screw arranged through the second fastener receiving hole of the second end plate and the second concavity 432 to attach the second end plate to the distal end 416 of the elongated body, a seventh screw arranged through the third fastener receiving hole of the second end plate and third concavity 442 to attach the second end plate to the distal end of the elongated body, and an eighth screw arranged through the fourth fastener receiving hole of the second end plate and fourth concavity 446 to attach the second end plate to the distal end of the elongated body.
[0289] The louver 410 may include a first fastening bolt 486 and a first T-nut 488. The first T-nut 488 may be arranged in an intermediate interior corner bracket receptacle 225 of a structural member 18 for a modular architectural canopy system. The first fastening bolt 486 may be arranged through the first elongated notch 452 of the second end plate and advanced into the first T-nut to fix the proximal end of the louvre to the structural member. The louver 410 further may include a second fastening bolt 490 and a second T-nut 492. The second T-nut 492 may be arranged in an intermediate interior corner bracket receptacle 225 of another structural member 18 for a modular architectural canopy system. The second fastening bolt 490 may be arranged through the first elongated notch of the second end plate and advanced into the second T-nut 492 to fix the proximal end of the louvre 410 to the other structural member 18. Exemplary dimensions for the louvers may be found in Table 1 (below).
[0290] Referring to FIGS. 205-222, a skylight 500 may be incorporated into a single ceiling canopy 502 (see FIGS. 210-214) or a double ceiling canopy 504 (see FIGS. 205-209 and 215-218). More particularly, a pair of opposing openings 510, 512 may be cut into the upper ceiling 506 and lower ceiling panels 508, respectively. As shown in FIGS. 208 and 209, a top bracket 514 may be seated into the upper opening 510 and a bottom bracket 516 may be arranged in the lower opening 512. The upper panel 506 may be captured between an upper concave profile 518 and an inverted L-bracket 520 that is fitted into a catch 524 on the lower side 522 of the top bracket. The lower panel 508 may be captured between a shelf 526 on the bottom bracket 516 and an L-bracket 528 fitted into a catch 530 near the shelf. An aluminum sheet 532 may be fitted into openings 534, 536 on top bracket 514 and the bottom bracket 516 to form a sidewall for the skylight assembly 538. The top bracket 518 may include a superior track 540 for capturing a nut and receiving a distal end 542 of a threaded bolt 544. The bottom bracket 516 may include an opposing inferior track 546 housing the proximal end 548 of a bolt. The distal end 542 of a bolt may be arranged through the inferior track 546 and the nut and superior track 540 to form a coupling. The bolt 544 may be advanced into the captured nut to secure the skylight assembly 550 to the double panel canopy. A series of bolts 544 may be arranged around the periphery of the skylight assembly 538, 550 to create a generally uniform clamp about the fixture.
[0291] Referring to FIG. 209 and FIG. 214, a glass plate may be positioned above the top profile to create a concave shape 554 to prevent water from entering the skylight assembly. A gasket or sealant material further may be provided between the glass panel 552 and the top bracket 518 to further weather-proof the skylight assembly. Additionally, an adhesive may be applied to the flat annular space 556 defined by top bracket to secure the glass panel 552 in the skylight bracket assembly 550.
[0292] As shown in FIGS. 210-214, the skylight brackets 214, 216 also may be used in an architectural canopy having a single panel ceiling 502. For instance, a single panel skylight 560, 562 may include a top skylight bracket 514, a lower skylight bracket 516, and a bolt 544 which connects the top skylight bracket to the lower skylight bracket. Additionally, the skylight 560, 562 may include a pane of light transmissive material (e.g., a clear glass) 558 disposed within the top skylight bracket. Also, the skylight may include an interior sidewall 532 which includes an upper flange 564 and a lower flange 566. The upper flange may be inserted into a superior interior slot 568 on the top skylight bracket, and the lower flange 566 may be inserted into an inferior interior slot 570 on the bottom skylight bracket. Referring to FIG. 213 and FIG. 214, the single ceiling panel 506, moreover, may be interposed between the top skylight bracket 514 and the lower skylight bracket 516.
[0293] A skylight assembly for an architectural canopy may include an upper skylight bracket, a lower skylight bracket, and a bolt connected to the upper skylight bracket and the lower skylight bracket. Further, the skylight assembly may include an interior sidewall which includes an upper flange that is disposed in a superior interior notch of the upper skylight bracket. The interior side wall may further include a lower flange disposed in an inferior notch of the lower skylight bracket. The interior sidewall may further include a sheet extending between the upper flange and the lower flange. Also, the skylight assembly may include a superior pane of light transmissive material disposed on the upper skylight bracket, and an inferior pane of light transmissive material disposed on the lower skylight bracket.
[0294] Additionally, the upper skylight bracket may include a superior transverse wall which includes an exterior end, an interior end, an upper surface, and a lower surface. The upper surface may include a convex segment adjacent to the exterior end, a superior pane bearing segment adjacent to the interior end, and a side wall extending from the superior pane bearing segment to the convex segment. The lower surface may include a planar segment adjacent to the exterior end, an indexing wall adjacent to the planar segment, an exterior wall spaced from the indexing wall, a first inner wall spaced from the exterior wall, an interior wall spaced from the interior end, and a second inner wall spaced from the interior wall. Moreover, the exterior wall may include a first upper transverse wall and a first lower transverse ledge. The first inner wall may be connected to the first upper transverse wall. The interior wall may include a superior interior projection, a second upper transverse wall opposite the first upper transverse wall, a lower interior projection below the superior interior projection, a lower interior transverse ledge opposite the first lower transverse ledge, and an inferior interior projection below the lower interior projection. The second inner wall may be connected to the second upper transverse wall. Also, the upper skylight bracket further may include an interior superior edge on the lower surface adjacent to the interior end, an interior inferior edge on the superior interior projection, an interior superior edge on the lower interior projection, and an interior inferior edge on the inferior interior projection. Further, the upper skylight bracket may include a first textured segment on the indexing wall, a second textured segment on the exterior wall, a first screw thread on the first inner wall, and a first screw thread on the second inner wall.
[0295] The lower skylight bracket may include a superior central transverse wall which includes an exterior end, an interior end, an upper surface which extends from the exterior end to the interior end. The lower skylight bracket further may include an exterior inferior vertical wall connected to the exterior end. The exterior inferior vertical wall may include a lower end, an inner surface which includes an exterior seat adjacent to the lower end, an exterior edge adjacent to the exterior seat, an exterior ledge located between the exterior edge and the superior central transverse wall. Further, the exterior inferior vertical wall may include an outer surface. The outer surface may include a superior exterior transverse wall which may include an exterior end, an upper surface with an indexing wall adjacent to the exterior inferior vertical wall, and a lower surface. The lower surface may include a superior exterior seat adjacent to the exterior end, a superior exterior edge adjacent to the superior exterior seat, and a superior exterior ledge located between the superior exterior edge and the exterior inferior vertical wall. The outer surface further may include an inferior exterior transverse wall which includes an exterior end. The inferior exterior transverse wall further may include an upper surface which includes an inferior exterior seat adjacent to the exterior end, an inferior exterior edge adjacent to the inferior exterior seat, and an inferior exterior ledge. The inferior exterior ledge may be located between the inferior exterior edge and the exterior inferior vertical wall.
[0296] The lower skylight bracket may include an interior inferior vertical wall connected to the interior end. The interior inferior vertical wall may include a lower end, an inner surface, and an outer surface. The inner surface may include an interior seat adjacent to the lower end, an interior edge adjacent to the interior seat, and an interior ledge located between the interior edge and the superior central transverse wall. The outer surface may include a superior interior transverse wall and an inferior interior transverse wall. The superior interior transverse wall may include an interior end, an upper surface, and a lower surface. The upper surface may include an inferior edge adjacent to the interior inferior vertical wall, a lower surface that may include a superior interior seat adjacent to the interior end, a superior interior edge adjacent to the superior interior seat, and a superior interior ledge located between the superior interior edge and the interior inferior vertical wall. The outer surface further may include an inferior interior transverse wall that includes an interior end and an upper surface. The upper end surface may include an inferior interior seat adjacent to the interior end, an inferior interior edge adjacent to the inferior interior seat, and an inferior interior ledge located between the inferior interior edge and the interior inferior vertical wall. Additionally, the outer surface of the interior inferior vertical wall may include a superior interior projection which comprises a superior interior edge, a lower interior projection which comprises an inferior interior edge, and an inferior interior projection which comprises a superior interior edge.
[0297] Referring to FIGS. 195-204, decorative features 590 including geometric designs, letters and numbers may be secured to the structural member 18 to provide additional architectural components for a canopy frame 12. For example, a group of circles 594 mounted to an up-profile element 592 may be secured into the superior external receptacle 28 of a structural member 18, as depicted in FIG. 195. In another example, a group of circles 594 mounted to an up-profile element 592 may be secured into the inferior external receptacle 30 of a structural member 18, as depicted in FIG. 196. For instance, the up-profile element (or up architectural profile add-on track) may include a base member which is configured and dimensioned to be slidably received on a corner bracket receptacle. The base member may include a bore. A T-fastener (e.g., a mating T-nut and bolt or a mating T-bolt and nut) may be disposed in the bore and under the base member. The base member may be arranged on top of a corner bracket receptacle's ledges, and the T-fastener may be positioned in the corner bracket receptacle (e.g., in the slot and under the corner bracket receptacle's ledges). The T-fastener may then be tightened to fix the base member to the corner bracket receptacle's ledges and thus secure the up architectural profile add-on track within the superior external receptacle of a structural member. Similarly, referring to FIGS. 198-200, a group of decorative features 590 mounted to an up architectural profile add-on track 592 may be secured to a corner bracket receptacle 225 of another profile element (e.g., a tube architectural profile add-on track 352) that is connected to the structural member 18.
[0298] Referring to FIG. 223 is a preferred embodiment of an architectural profile add-on track 352 for constructing an architectural canopy, the architectural profile add-on track being a tube. FIG. 224 shows another preferred embodiment of an architectural profile add-on track 596 for constructing an architectural canopy, the architectural profile add-on track being configured and dimensioned to receive a two-inch to one-inch flat adaptor trim cover. FIG. 225 is a detail view of the architectural profile add-on track being of FIG. 224. Exemplary dimensions for the tube architectural profile add-on track and the lighting adaptor architectural profile add-on track are presented in Table 1 (below).
[0299] FIG. 226 is a perspective view of an exemplary free-standing structure constructed from the modular apparatus for constructing an architectural canopy of the present disclosure. FIG. 227 is another perspective view of the exemplary free-standing structure of FIG. 226.
[0300] Referring to FIG. 36 and FIG. 63, a structural member for a modular architectural canopy system is disclosed. The structural member may include a longitudinal axis and a first vertical (rear) wall which includes a superior end, a catch adjacent to the superior end, an indexing ledge extending upward from the superior end, and an inferior end. The structural member further may include a second vertical (front) wall spaced from the first vertical wall. The second vertical wall may include an upper end, a lower end, and a cantilevered track adjacent to the upper end. The cantilevered track may include a base segment abutting the second vertical (front) wall, an interior segment abutting the base segment, a rear ledge abutting the interior segment, and a front ledge abutting the second vertical (front) wall. The front ledge may be spaced from the rear ledge and disposed opposite the rear ledge. The rear ledge and the front ledge may define a slot. The base segment, the interior segment, the rear ledge, the front ledge, and the second vertical (front) wall may frame a cantilever track receptacle. Additionally, the second vertical (front) wall may include an inferior hook disposed opposite from the catch on the first vertical wall, a superior hook disposed adjacent to the cantilevered track, and an intermediate hook disposed between the hook and the superior hook. The structural member further may include a first transverse (superior intermediate) wall disposed between the first vertical (rear) wall and the second vertical (front) wall. The first vertical wall, the first transverse (superior intermediate) wall and the second vertical wall frame a gutter.
[0301] The structural member further may include a second transverse (inferior intermediate) wall disposed between the first vertical (rear) wall and the second vertical (front) wall. The first vertical wall, the first transverse (superior intermediate) wall, the second vertical (front) wall, and the second transverse (inferior intermediate) wall may frame an inferior duct. Additionally, the structural member may include an exterior wall spaced from the second vertical (front) wall. The exterior wall may include a superior end and an inferior end. Also, the structural member may include a superior partition extending between the second vertical (front) wall and the exterior wall, an intermediate partition extending between the second vertical (front) wall and the exterior wall, and an inferior partition extending between the second vertical (front) wall and the exterior wall.
[0302] Additionally, the second vertical wall, the superior partition, the exterior wall, and the intermediate partition may frame a superior hollow structural section (HSS). Also, the second vertical wall, the intermediate partition, the exterior wall, and the inferior partition may frame an intermediate hollow structural section. The second vertical wall, the superior partition, the exterior wall, and the intermediate partition may frame a superior duct. The second vertical wall, the intermediate partition, the exterior wall, and the inferior partition may frame an intermediate duct.
[0303] Moreover, the exterior wall may include an inferior front edge adjacent the inferior end and an inferior front ledge disposed between the inferior front edge and the inferior partition. Also, the second vertical (front) wall may further include an inferior rear edge adjacent to the lower end, and an inferior rear ledge disposed between the inferior rear edge and the inferior partition. The inferior front ledge may be spaced from the inferior rear ledge and disposed opposite the inferior rear ledge. The inferior front edge may be spaced from the inferior rear edge and disposed opposite the inferior rear edge. The inferior rear edge and the inferior front edge may form an inferior exterior accessory seat. The inferior rear ledge, the second vertical (front) wall, the inferior partition, and the inferior front ledge may form an inferior exterior corner bracket receptacle.
[0304] Further, the exterior wall may include a superior front edge adjacent to the superior end and a superior front ledge disposed between the superior front edge and the superior partition. Additionally, the second vertical (front) wall may include a superior rear edge adjacent to the upper end and a superior rear ledge disposed between the superior rear edge and the superior partition. The superior front ledge may be spaced from the superior rear ledge and disposed opposite the superior rear ledge. The superior front edge may be spaced from the superior rear edge and disposed opposite the superior rear edge, the superior rear edge and the superior front edge forming a superior exterior accessory seat. The superior rear ledge, the second vertical (front) wall, the superior partition, and the superior front ledge may form a superior exterior corner bracket receptacle.
[0305] The structural member may include a superior interior wall spaced from the first vertical (rear) wall. The superior interior wall may include an upper end, and a lower end. The structural member also may include an upper partition extending between the first vertical (rear) wall and the superior interior wall, and a lower partition extending between the first vertical (rear) wall and the superior interior wall. The first vertical wall, the upper partition, the superior interior wall, and the base partition form an interior hollow structural section. Additionally, the first vertical wall, the upper partition, the superior interior wall, and the base partition may frame an interior duct.
[0306] Further still, the superior interior wall further may include an upper rear ledge abutting the upper end, and the first vertical (rear) wall may include an upper front ledge abutting the superior end. The upper rear ledge may be spaced from the upper front ledge and disposed opposite the upper front ledge. The superior interior wall, the upper rear ledge, the upper front ledge, the first vertical (rear) wall, and the upper partition may form a superior interior corner bracket receptacle.
[0307] The structural member may further include an inferior interior wall spaced from the first vertical (rear) wall. The inferior interior wall may include a top end, a bottom end, and a base partition. The base partition may extend between the first vertical (rear) wall and the inferior interior wall. The inferior interior wall further may include an inferior rear edge adjacent to the bottom end and an inferior rear ledge disposed between the inferior rear edge and the base partition. The first vertical (rear) wall further may include an inferior front edge adjacent to the inferior end and an inferior front ledge disposed between the inferior front edge and the base partition. The inferior front ledge may be spaced from the inferior rear ledge and disposed opposite the inferior rear ledge. The inferior front edge may be spaced from the inferior rear edge and disposed opposite the inferior rear edge. The inferior rear edge and the inferior front edge may form an inferior interior accessory seat. The inferior rear ledge, the inferior interior wall, base partition, the first vertical (rear) wall, and the inferior rear ledge may form an inferior interior corner bracket receptacle.
[0308] Additionally, the lower partition may include an upper edge adjacent to the lower end and an upper ledge disposed between the upper edge and the first vertical (rear) wall. The base partition further may include a lower edge adjacent to the top end and a lower ledge disposed between the lower edge and the first vertical (rear) wall. The lower ledge may be spaced from the upper ledge and disposed opposite from the upper ledge. The upper edge may be spaced from the lower edge and disposed opposite the lower edge. The upper edge and the lower edge may frame an intermediate interior accessory seat. The upper ledge, the lower partition, the first vertical (rear) wall, the base partition, and the lower ledge may frame an intermediate interior corner bracket receptacle.
[0309] Referring to FIGS. 36, 60 and 61, an apparatus for constructing an architectural canopy frame 12 is disclosed. The apparatus may include the structural member 18 of FIGS. 36 and 60. Referring to FIGS. 60 and 61, the apparatus may include a fastening bracket 192. The fastening bracket may include a first plate comprising an upper surface and a lower surface, as well as a second plate connected to the first plate. The second plate may include a front surface adjacent to the lower surface, the front surface and the lower surface being disposed to form a right angle. Also, second plate may include a rear surface adjacent to the upper surface. The rear surface may include an upper hook 194 and a lower hook 196. The second plate further may include a bottom surface between the front surface and the rear surface. The fastening bracket may be arranged between the first vertical (rear) wall and the catch. The front surface of the second plate may abut the first vertical (rear) wall, and the rear surface of the second plate may abut the catch. Moreover, the catch may include a texture, and the rear surface of the fastening bracket may include a mating texture. The texture and the mating texture may be configured and dimensioned to engage when the bottom surface of the fastening bracket is received between the first vertical (rear) wall and the catch.
[0310] Referring to FIGS. 151 and 158, an apparatus for constructing an architectural canopy is disclosed. The apparatus may include architectural canopy frame 12 and a panel 14, 264. The panel may include a top surface, a bottom surface, and a side surface extending from the top surface to the bottom surface. The panel 264 may be arranged with the side surface abutting the indexing ledge 188 and the bottom surface overlaying the superior interior corner bracket receptacle 34. The lower surface of the fastening bracket 72 may be arranged over the top surface of the panel 14, 264 to hold the panel against the superior interior corner bracket receptacle 34.
[0311] Referring to FIGS. 117-122, 150 and 157, the panel 14 may have rectangular shape. The panel may include a longitudinal axis and a cross-section perpendicular to the longitudinal axis, and the cross-section may be a tongue-in-groove profile. Additionally, the apparatus may include another panel. Generally, the panel may be constructed from a wood, a glass, a polymer material, or a metallic material. For example, the panel may include a fiberglass core and an exterior aluminum coating. In another example, the panel may be an insulated roofing sandwich panel. In a preferred embodiment, the panel may include a polyisocyanurate foam core 78 and an exterior aluminum coating 80. The panel further may include an internal reinforcing member 600. For instance, the internal reinforcing member is an aluminum tube.
[0312] Referring to FIGS. 55, 60-66, 67, 68, 69, 119-122, 131-133, 137-139, 163-173, 184, 188, 190, 192, 194, 219, 220, 221, 222, 223, 225, exemplary dimensions for selected parameters of the architectural canopy system are provided in Table 1 (below). Illustrative values for length and diameter dimensions are presented to the least significant digit without rounding but within standard manufacturing tolerances.
TABLE-US-00001 TABLE 1 Selective Illustrative Dimensions Length Dimension (mm) FIG. L1 203.2 60 L2 127 60 L3 7 60 L4 19.9 60 L5 20.4 60 L6 21.94 60 L7 24.04 60 L8 134.48 60 L9 127 60 L10 1.5 60 L11 6.35 60 L12 68.85 60 L13 2 60 L14 32.05 60 L15 101.6 60 L16 15 60 L17 52.34 60 L18 6.35 60 L19 15.53 60 L20 50.33 60 L21 8 60 L22 20.4 60 L23 6.35 60 L24 57.03 60 L25 6.03 60 L26 12.7 60 L27 6.03 60 L28 67.5 61 L29 45.14 61 L30 39.79 61 L31 2.4 61 L32 10.89 61 L33 5 61 L34 3.5 61 L35 6.03 61 L36 19.36 61 L37 6.03 61 L38 2.09 61 L39 3.5 61 L40 5.38 62 L41 24.63 62 L42 24.04 62 L43 18.74 62 L44 .6 62 L45 1.1 62 L46 1.1 62 L47 0.6 62 L48 152.4 63 L49 101.6 63 L50 17.22 63 L51 75.08 63 L52 9.3 63 L53 25.4 63 L54 65.85 63 L55 10.35 63 L56 7.34 63 L57 12.7 63 L58 12.41 63 L59 18.88 63 L60 25.4 63 L61 75.04 64 L62 70.94 64 L63 0.6 64 L64 1.1 64 L65 1.1 64 L66 5.38 64 L67 0.6 64 L68 70 65 L69 5.53 65 L70 1.5 65 L71 72.5 66 L72 5.53 66 L73 1.5 66 L74 74.67 67 L75 22.06 67 L76 5.82 67 L77 50.8 68 L78 25.4 68 L79 19.94 68 L80 12.7 68 L81 3.5 68 L82 6.1 68 L83 86.4 69 L84 76.2 69 L85 50.8 69 L86 63.31 69 L87 15.55 69 L88 9.85 69 L89 12.51 69 L90 9.85 69 L91 15.55 69 L92 1.6 116 L93 6.5 116 A1 135 116 L94 2243.2 119 L95 995 119 L96 978.11 119 L97 50 120 L98 2 120 D1 38 120 L99 16.89 122 L100 21.37 133 L101 6.32 133 L102 20.73 133 L103 18.75 133 L104 76.2 133 L105 25.4 133 L106 19.4 133 L107 27.36 133 L108 21.48 133 L109 27.36 133 L110 12.7 186 L111 12.7 186 L112 11.47 186 L113 53.26 186 L114 11.47 186 L115 76.2 188 L116 50.8 188 L117 44.8 188 L118 34.64 188 L119 6.92 188 L120 34.64 188 L121 25.4 190 L122 25.4 190 L123 11.28 190 L124 53.63 190 L125 11.28 190 L126 47 192 L127 40.08 192 L128 32.25 192 L129 26.91 192 R1 23.5 192 R2 22.5 192 L130 47 194 L131 20.68 194 L132 26.32 194 L133 26.91 194 R3 23.5 194 A2 34 194 L134 24.87 219 L135 75.2 219 L136 18.46 219 R4 120.47 219 L137 38.1 220 L138 71.2 220 L139 30.83 221 L140 72.48 221 L141 33.99 221 L142 22.62 221 L143 50.86 221 L144 6.61 221 L145 24.22 221 L146 40.4 222 L147 71.2 222 L148 16.25 222 L149 2 222 L150 13 222 L151 25.4 222 L152 46 223 L153 66.68 223 L154 25.4 223 L155 41.28 223 L156 15.88 223 L157 25.4 223 L158 37.68 223 L159 16.01 223 L160 21.67 223 L161 2.5 223 L162 40.18 223 L163 82.02 225 L164 25.4 225 L165 25.4 225 L166 50.8 225 L167 27.4 55 D2 61 55 D3 70 55 L168 5.76 138 L169 23.64 138 L170 11.97 138 L171 0.5 138 L172 6.32 139 L173 21.37 139 L174 4.7 139 L175 20.73 139 L176 18.75 139 L177 21.76 164 L178 50 164 L179 10 164 L180 30 164 D4 5.1 164 L181 21.76 165 L182 1.78 165 D5 5.1 165 D6 10.1 165 L183 37.55 166 L184 39.16 166 L185 10.12 166 L186 25 166 D7 5.1 166 D8 10.1 166 L187 16 168 L188 28.04 169 L189 33.37 169 L190 5.52 169 L191 1.75 169 L192 27.58 169 L193 1.75 169 L194 7 170 L195 20 170 L196 7 171 L197 3 171 L198 20 172 L199 7.5 172 L200 7.5 172 D9 5 172
[0313] In use, the disclosed exemplary embodiments of a system, components, and apparatus may be used to construct an architectural canopy, pergola, or another free-standing structure (e.g., an exhibition display stand 604).
[0314] While it has been illustrated and described what at present are considered to be embodiments of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention. For example, different fascia profiles, add-on elements and panels may be designed and constructed for modular in a similar fashion. Additionally, features and/or elements from any embodiment may be used singly or in combination with other embodiments. Therefore, it is intended that this invention not be limited to the particular embodiments disclosed herein, but that it have the full scope defined by the language of the following claims, and equivalents thereof.
