COLLAPSIBLE UMBRELLA WITH QUICK CONNECT RIBS TO HUBS

Abstract

A collapsible umbrella having a support structure, a frame structure supported by the support structure, which includes: a support hub assembly; a plurality of long ribs, wherein each long rib has an end removably coupled to an upper hub at an upper end of the support hub assembly; a plurality of short rib sections, each comprising a first end pivotally coupled to a point along the long rib and a second end removably coupled to a lower hub at a lower end of the support hub assembly. The upper and lower hubs each has a plurality of hub connectors arranged around the circumference of the hub. The hub connectors each has a coupling slot and a dove tail groove or channel at the end of the slot towards the axis of the upper hub. The coupling slot releasably receives a pivot coupler pivotally attached to an end of a rib.

Claims

1. A collapsible umbrella comprising: a support structure; and a frame structure supported by the support structure, comprising: a support hub assembly comprising an upper hub and a lower hub; a plurality of long ribs, wherein each long rib has an end removably coupled to the upper hub at an upper end of the support hub assembly; and a plurality of short ribs, each comprising a first end pivotally coupled to a point along the long rib and a second end removably coupled to a lower hub at a lower end of the support hub assembly; wherein the upper and lower hubs each comprises a plurality of hub connectors arranged around the circumference of the hub, wherein each hub connector comprises a coupling slot and a dove tail groove or channel at the end of the slot towards the axis of the upper hub, and wherein the coupling slot releasably receives a pivot coupler pivotally attached to an end of a long or short rib.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIGS. 1-5 are various perspective general views of a collapsible umbrella, depicted in a fully extended state, comprising a frame structure supported on a central support post, in accordance with one embodiment of the present invention.

[0012] FIGS. 6-10 are various perspective close-up views depicting the structures of lower and upper hubs of a collapsible umbrella, depicting the quick connect ribs to hubs feature, in accordance with one embodiment of the present invention.

[0013] FIGS. 11 (A) and (B) are top and bottom perspective views of an upper or a lower hub, in accordance with one embodiment of the present invention.

[0014] FIGS. 12 (A) and (B) are top and side views of an upper or a lower hub, in accordance with one embodiment of the present invention.

[0015] FIG. 13 is an axial section view of an upper or a lower hub, in accordance with one embodiment of the present invention.

[0016] FIGS. 14 (A) and (B) are top and bottom perspective views of the pivot coupler, in accordance with one embodiment of the present invention.

[0017] FIGS. 15 (A) to (D) are top, side, end and front views of the pivot coupler, in accordance with one embodiment of the present invention.

[0018] FIGS. 16 (A) and (B) are top and bottom perspective views of a collar for locking the pivot couplers in the respective coupling slots of an upper or a lower hub, in accordance with one embodiment of the present invention.

[0019] FIGS. 17 (A) and (B) are top and bottom perspective views of a crown for connecting to the top of the central support post, in accordance with one embodiment of the present invention.

[0020] FIGS. 18 (A) and (B) are top and bottom perspective views of a crown for connecting to the top of the central support post, in accordance with another embodiment of the present invention.

[0021] FIGS. 19 (A) and (B) are top and bottom perspective views of a post coupler having a thread end for a crown having a threaded bottom hole, in accordance with one embodiment of the present invention.

[0022] FIG. 20 is a perspective view of a pivot coupler coupled to one end of a rib via a post extending through the walls of the pivot coupler, in accordance with one embodiment of the present invention.

[0023] FIG. 21 is a close-up perspective view of the pivot coupler of FIG. 20 coupled to an upper or a lower hub, in accordance with one embodiment of the present invention.

[0024] FIG. 22 depicts the coupling slots of a lower or an upper hub each receiving a pivot coupler (the posts and ribs not shown), in accordance with one embodiment of the present invention.

[0025] FIG. 23 depicts a collar locking the pivot couplers in the respective coupling slots of an upper or a lower hub, in accordance with one embodiment of the present invention.

SUMMARY OF THE INVENTION

[0026] The present invention provides a simple, reliable and easy to assemble collapsible umbrella frame structure that incorporates releasable, removable and replaceable quick connect ribs to hubs, which addresses the above noted concerns to optimize structural integrity along with reduced manufacturing, shipping, and material costs. The inventive collapsible umbrella assembly can be easily assembled for use and repaired with replacement rib sections after damage to the ribs in the frame structure. The present invention balances and optimizes structural integrity along with reduced manufacturing, shipping, and material costs.

[0027] In one aspect of the present invention, the inventive collapsible umbrella comprises a support structure, a frame structure supported by the support structure comprising: a support hub assembly; a plurality of long ribs, wherein each long rib has an end removably coupled to an upper end (e.g., an upper hub) of the support hub assembly; a plurality of short rib sections, each comprising a first end pivotally coupled to a point along the long rib and a second end removably coupled to a lower end (e.g., a lower hub) of the support hub assembly. In one embodiment, the support hub assembly comprises an upper hub at the upper end of the support hub assembly and a lower hub at the lower end of the support hub assembly, each hub having a plurality of hub connectors arranged around the circumference of the hub. The upper hub connectors each comprises a coupling slot and a dove tail groove or channel at the end of the slot towards the axis of the upper hub. The upper hub may be structured and configured similar to the upper hub.

[0028] The upper and/or the lower hubs could be made of an appropriate rigid material, such as metal (e.g., aluminum, iron or steel), composite materials, plastics, etc. Each long/short rib is in the form of an elongated, slender beam, e.g., in the form of a straight tubing having a uniform cross section along its length, as depicted in the illustrated embodiment. Other configurations of the beam, uniform or non-uniform, could be used. The rib sections could be made of appropriate rigid material, such as metal (e.g., aluminum, iron or steel), composite materials, plastics, etc.

[0029] The umbrella support structure may comprise a central support post, wherein the frame structure is supported at an upper end of the central support post, or a side support post and an arm cantilevered from the side support post, wherein the frame structure is supported at an extended end of the arm. A canopy comprising a flexible material (e.g., canvas, fabric, etc.) is supported on the frame structure, with the flexible material spanning over the long ribs. Once assembled, the collapsible umbrella can be operated to open/extend or close/collapse the canopy in similar fashion to known collapsible umbrellas, e.g., by using a handle, by varying the distance between the upper and lower hubs.

[0030] In one aspect, the present invention is directed to a collapsible umbrella comprising: a support structure; a frame structure supported by the support structure, comprising: a support hub assembly comprising an upper hub and a lower hub; a plurality of long ribs, wherein each long rib has an end removably coupled to an upper hub at an upper end of the support hub assembly; a plurality of short ribs, each comprising a first end pivotally coupled to a point along the long rib and a second end removably coupled to a lower hub at a lower end of the support hub assembly; wherein the upper and lower hubs each comprises a plurality of hub connectors arranged around the circumference of the hub, wherein each hub connector comprises a coupling slot and a dove tail groove or channel at the end of the slot towards the axis of the upper hub, and wherein the coupling slot releasably receives a pivot coupler pivotally attached to an end of a long or short rib.

DESCRIPTION OF ILLUSTRATED EMBODIMENTS

[0031] The detailed description set forth below is intended as a description of the presently exemplary device provided in accordance with aspects of the present invention and is not intended to represent the only forms in which the present invention may be prepared or utilized. It is to be understood, rather, that the same or equivalent functions and components may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

[0032] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of the ordinary skill in the art to which this invention belongs. Although any methods, devices and materials similar or equivalent to those described can be used in the practice or testing of the invention, the exemplary methods, devices and materials are now described.

[0033] All publications mentioned are incorporated by reference for the purpose of describing and disclosing, for example, the designs and methodologies that are described in the publications that might be used in connection with the presently described invention. The publications listed or discussed above, below and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.

[0034] The present invention provides a simple, reliable and easy to assemble collapsible umbrella frame structure that incorporates releasable, removable and replaceable quick connect ribs to hubs, which addresses the above noted concerns to optimize structural integrity along with reduced manufacturing, shipping, and material costs. The inventive collapsible umbrella assembly can be easily assembled for use and repaired with replacement rib sections after damage to the ribs in the frame structure. The present invention balances and optimizes structural integrity along with reduced manufacturing, shipping, and material costs.

[0035] In one aspect of the present invention, the inventive collapsible umbrella U comprises a support structure SS, a frame structure FS supported by the support structure SS comprising: a support hub assembly HA; a plurality of long ribs RL, wherein each long rib RL has an end removably coupled to an upper end (e.g., an upper hub HU) of the support hub assembly HA; a plurality of short rib sections RS, each comprising a first end pivotally coupled to a point along the long rib RL and a second end removably coupled to a lower end (e.g., a lower hub HL) of the support hub assembly HA. In accordance with the present invention and in one embodiment, the support hub assembly HA comprises an upper hub HU at the upper end of the support hub assembly HA having a plurality of upper hub connectors HUC arranged around the circumference of the upper hub HU. The upper hub connectors HUC each comprises a coupling slot CS and a dove tail groove or channel DS at the end of the coupling slot CS towards the axis of the upper hub HU. The lower hub HL may be structured similar to the upper hub HU. If the upper hub HU and the lower hub HL are similar in structure, this could reduce component/part variations and reduce replacement part inventory costs. Further, the pivotal couplers PC of the long and short ribs RL/RS may be similar in structure.

[0036] The upper and/or the lower hubs HU/HL could be made of an appropriate rigid material, such as metal (e.g., aluminum, iron or steel), composite materials, plastics, etc. Each long/short rib RL/RS is in the form of an elongated, slender beam, e.g., in the form of a straight tubing having a uniform cross section along its length, as depicted in the illustrated embodiment. Other configurations of the beam, uniform or non-uniform, could be used. The rib sections could be made of appropriate rigid material, such as metal (e.g., aluminum, iron or steel), composite materials, plastics, etc.

[0037] The umbrella support structure SS may comprise a central support post CP, wherein the frame structure FS is supported at an upper section of the support structure SS (e.g., the upper section of the central support post CP), or supported at an extended end of an arm cantilevered from a side support post and (not shown). A canopy CY comprising a flexible material (e.g., canvas, fabric, etc.) is supported on the frame structure, with the flexible material spanning over the long ribs. Once assembled, the collapsible umbrella U can be operated to open/extend or close/collapse the canopy in similar fashion to known collapsible umbrellas, e.g., by using a handle, by varying the distance between the upper and lower hubs HU/HL.

[0038] FIGS. 1-10 are various perspective views of a collapsible umbrella U, depicted in a fully extended state, comprising a frame structure FS supported on a central support post CP, in accordance with one embodiment of the present invention. In particular, FIGS. 1-5 are various perspective general views of a collapsible umbrella U, depicted in a fully extended state, comprising a frame structure FS supported on a central support post CP, in accordance with one embodiment of the present invention. FIGS. 6-10 are various perspective close-up views depicting the structures of lower or upper hubs HU of a collapsible umbrella U, depicting the quick connect ribs RS/RL of a rib assembly RA to hubs HU/HL feature, in accordance with one embodiment of the present invention.

[0039] The rib assembly RA comprises long and short ribs RL/RS. The support hub assembly HA comprises upper and lower hubs HU and HL at the upper and lower ends of the support hub assembly HA. Each upper/lower hub has a plurality of upper/lower hub connectors HUC/HLC arranged around the circumference of the upper/lower hub HU/HL. In one embodiment, the removal quick connect coupling of the corresponding ends of the ribs (long and short HL/HS) to the corresponding upper and lower end of the support hub assembly HA comprises a slidable dove tail joint/coupling comprising the complementary structures discussed below. The views shown in FIGS. 6-10 illustrate the pivotal coupling of the long and short ribs RL/RS to the respective upper and lower hubs HU/HL (some views are shown with the canopy removed). FIG. 10 depicts the umbrella frame structure FS upside down, with the canopy CY on the ground. It is noted that the pivot couplers PC in FIGS. 8 and 9 are depicted without a post pivotally coupling the end of a rib RL/RS to a pivot coupler PC, in accordance with another embodiment of the present invention. In FIG. 8, the hub HU/HL is depicted to have coupling slots CS of slight variation from the other embodiments disclosed herein.

[0040] FIGS. 11-13 are top perspective, bottom perspective, top, side and axial section views of, for example, the upper hub HU (which can also be the lower hub HL; i.e., FIGS. 11 (A) and (B) and FIGS. 12 (A) and (B) may be top and bottom perspective views and top and side views of an upper or a lower hub HU/HL), in accordance with one embodiment of the present invention. FIG. 13 is an axial section view of an upper or a lower hub HU/HL, in accordance with one embodiment of the present invention.

[0041] Each short or long rib RS/RL has an end pivotally coupled to a pivot coupler PC. FIGS. 14-15 are top and bottom perspective, top, side, end and front views of the pivot coupler PC, in accordance with one embodiment of the present invention. The pivot coupler PC comprises a generally U-shaped body, with parallel walls defining the vertical sides of the U, and a dove tail extension DE at the base of the U (i.e., at the bottom of the U-shaped body/walls W as illustrated). The U-shaped body defines a U-shaped space receiving the end of a long or short rib RL/RS. In the illustrated embodiment of FIG. 20, the end of the long/short rib RL/RS is pivotally coupled to the pivot coupler PC via a post p (e.g., a rivot, screw, bolt, etc.) across the U-shaped space of the pivot coupler PC. Complementary holes h are provided on opposing side walls of the U-shaped body of the pivot coupler PC to accommodate the post p for pivotal coupling of the end of a rib RL/RS to the pivot coupler PC. FIG. 20 is a perspective view of a pivot coupler PC coupled to one end of a rib via a post extending through the walls of the pivot coupler PC, in accordance with one embodiment of the present invention.

[0042] The outline of the coupling slot CS of the upper/lower hub HU/HL generally corresponds to the outline of the pivot coupler PC at the end of the long/short rib RL/RS. Specifically, the dove tail pivot coupler PC of a rib is removably received in a corresponding coupling slot CS, with the dove tail extension DE of the pivot coupler PC slidably received in the dover tail groove or slot DS of the coupling slot CS. A pivot coupler PC can be slid into a coupling slot CS by sliding the dove tail extension DE into the dove tail groove DS. To accommodate the ends of the post P which may extend beyond the parallel walls W, the coupling slot CS may include shallow channels S having longitudinal axis parallel to the longitudinal axis of the dove tail groove DS. See, also, FIGS. 21 and 22. FIG. 21 depicts the pivot coupler PC of FIG. 20 coupled to an upper or a lower hub HU/HL, in accordance with one embodiment of the present invention. FIG. 22 depicts the coupling slots CS of a lower or an upper hub HL/HU each receiving a pivot coupler PC (the posts p and ribs RS/RL not shown), in accordance with one embodiment of the present invention.

[0043] In one embodiment, the dove tail joints of the ribs to the corresponding hubs are user finger operated releasable coupling that does not require using an external tool for a user to couple or release the coupling. For example, the external profile of the pivot coupler PC and the internal profile of the coupling slot CS may be relatively sized such the pivot coupler PC may be seated into the coupling slot CS with a small clearance, or with a small interference fit, between the dove tail extension DE received in the dove tail groove DS. Further interfacing features, such as complementary protrusion(s) and dimple(s) may be provided on interfacing surfaces between the pivot coupler PC and the coupling slot to provide an indication (e.g., with a click) of positive engagement of the pivot coupler PC having fully seated into the coupling slot to provide an indication of a positive seating of the component. (See, also, embodiment depicted in FIG. 8 having features in the coupling slots for interfacing/engaging the pivot coupler PC.)

[0044] Referring to FIGS. 16, a collar C having a flange f is provided to lock the pivot couplers PC in the respective coupling slots CS of the upper/lower hubs HU/HL. FIGS. 16 (A) and (B) are top and bottom perspective views of a collar C for locking the pivot couplers PC in the respective coupling slots of an upper or a lower hub HU/HL, in accordance with one embodiment of the present invention. In the illustrated embodiment, the collar C is provided with an axial cylindrical internally threaded through-hole TTH. The through hole TTH is sized to slidably receive the central support post CP with a clearance. Referring also to FIGS. 11 to 13, the upper/lower hub HU/HL is provided with an axial extension having an axial cylindrical through-hole TH (sized to receive the central support post CP) and a complementary outer external threaded extension TE to the internal threaded hole TTH of the collar C. The collar C is screwed onto the threaded extension TE of the upper/lower hub HU/HL, with the flange f locking in place the pivot couplers PC in coupling slots in the upper/lower hub HU/HL. See, also, FIGS. 7-9 and 23. FIG. 23 depicts a collar C locking the pivot couplers PC in the respective coupling slots CS of an upper or a lower hub HU/HL, in accordance with one embodiment of the present invention.

[0045] Instead of a threaded interface, other means may be implemented to lock a collar onto a respective hub. For example, the collar may be pushed against the pivot couplers PC and a cotter pin, screw, bolt, etc. may be used to restrict axial sliding of the pivot coupler PC along the central support post CP.

[0046] A crown C is provided to cap the umbrella canopy CY supported by the frame structure FS. FIGS. 17 (A) and (B) illustrate top and bottom perspective views of a crown C for connecting to the top of the central support post CP in accordance with one embodiment of the present invention. The top end of the central support post CP may be threaded. The bottom hole BH in the crown may be provided with a complementary threaded hole. With the canopy CY supported on the frame structure FS, and the central support post CP extending through the center of the top of the canopy CY, the crown C is screwed onto the end of the central support post CP. In another embodiment, the bottom hole BH of the crown C may be a smooth hole, which is press-fitted onto a smooth end of the central support post.

[0047] FIG. 18 illustrates an alternate embodiment of a crown C, functionally similar to the previous embodiment, with different aesthetics. FIGS. 18 (A) and (B) are top and bottom perspective views of a crown C for connecting to the top of the central support post CP, in accordance with another embodiment of the present invention.

[0048] FIG. 19 illustrates a post coupler CPC having a threaded end for a crown C (or C) with a threaded bottom hole BH, and another end to be supported at the upper end of the central support post CP having complementary features to engage said another end of the cylindrical body of the post coupler CPC. FIGS. 19 (A) and (B) are top and bottom perspective views of a post coupler PC having a thread end for a crown C (or C) having a threaded bottom hole BH, in accordance with one embodiment of the present invention. This post coupler CPC is a small/short part, which can be more easily handled (e.g., machined, molded, etc.) to provide a threaded end, as compared to providing a thread end of a long central support post CP.

[0049] In one embodiment (e.g., as illustrated by FIG. 7), the support hub assembly HA comprises only a lower hub HL at the lower end of the support hub assembly HA having a plurality of lower hub connectors HLC arranged around the circumference of the lower hub HL. In one embodiment, the lower hub HU/HL can have structures and features substantially similar to the upper/lower hubs HU/HL in the previous embodiments, at least with respect to the coupling slots CS and collar C.

[0050] The lower hub connectors HLC each comprises a coupling slot CS and a dove tail groove or channel or slot DS at the end of the coupling slot CS (i.e., at the bottom of the U-shaped body/walls as illustrated) towards the axis of the lower hub HL. Each short rib RS has an end (i.e., the second end) pivotally coupled to a pivot coupler PC, similar to that of the long/short rib RL/RS discussed above. The pivot coupler PC comprises a generally U-shaped body, with parallel walls W defining the vertical sides of the U, and a dove tail extension DE at the base of the U. The U-shaped body defines a U-shaped space receiving the end of a short rib RS. The end of the short rib RS is pivotally coupled to the pivot coupler PC via a post p (e.g., a rivot, screw, bolt, etc.) across the U-shaped space. Complementary holes h are provided on the U-shaped body of the coupler to accommodate the post p.

[0051] The outline of the slot of the lower hub HL generally corresponds to the outline of the pivot coupler PC at the end of the short rib RS. Specifically, the dove tail pivot coupler PC of a short rib RS is removably received in a corresponding coupling slot PC, with the dove tail extension DE of the pivot coupler PC received in the dover tail groove DS of the coupling slot CS. To accommodate the ends of the post p which may extend beyond the parallel walls W, the coupling slot CS may include shallow channels S having longitudinal axis parallel to the longitudinal axis of the dove tail groove DS.

[0052] A collar C is provided having a flange f to lock the pivot couplers PC in the respective coupling slots CS of the lower hub HL. In one embodiment, the collar C is provided with an axial cylindrical internally threaded through-hole TTH. The through hole TTH may be sized to slidably receive the central support post CP with a clearance. The lower hub HL is provided with an axial externally threaded extension TE, and has an axial cylindrical through-hole TH. The outer external thread TE is complementary to the threaded through hole TTH of the collar C. The collar C is screwed onto the threaded extension TE of the lower hub, with the flange f locking into place the pivot couplers PC in the coupling slots CS in the lower hub HL (similar to the long ribs RL in relation to the upper hub HU in the previous embodiment). Instead of a threaded interface, other means may be implemented to lock the collar onto the lower hub. For example, the collar may be pushed against the pivot couplers PC and a cotter pin, screw, bolt, etc. may be used to restrict axial sliding of the pivot coupler PC along the central support post.

[0053] The umbrella support structure may comprise a central support post, wherein the frame structure is supported at an upper end of the central support post, as depicted in the illustrated embodiment, or a side support post and an arm cantilevered from the side support post, wherein the frame structure is supported at an extended end of the arm. For example, the inventive frame structure features of the present invention may be adopted in a side supported umbrella, such as the one disclosed in U.S. Pat. No. 10,136,709B2, which is incorporated by reference herein. In such side support post embodiment, similar upper and lower hubs may be adopted, with appropriate variations, e.g., to accommodate a central guiding post between the upper and lower hubs.

[0054] It can be appreciated that a long rib RL and a short rib RS form a rib assembly RA, which may be removably replaced with another rib assembly RA in case of a failure of the original rib assembly RA. The user can simply obtain a replacement rib assembly RA and seat the corresponding pivot couplers PC at the respective ends of the long and short ribs RL/RS of the rib assembly RA into the corresponding coupling slots in the upper and lower hubs HU/HL. The benefits of this user replaceable rib assembly RA will be summarized below.

[0055] The inventive frame structure for the collapsible umbrella achieves at least the following advantages over the prior art: [0056] a. The quick connect coupling of the rib sections to the hub structure allows the collapsible umbrella frame to be easily assembled at the point of use, thus not have to rely on full assembly of the collapsible umbrella frame at the point of manufacture. [0057] b. The collapsible umbrella frame structure can be partially assembled at the point of manufacture with the hub structure assembled to the support structure or part thereof, which results in a smaller package that would reduce significant shipping costs compared to shipping costs imposed on a more bulky fully assembled umbrella frame structure. [0058] c. The removable, replaceable and/or interchangeable rib sections (long and short ribs with the pivot couplers at the corresponding ends for coupling to the coupling slots in the upper and lower hubs) permit repairing of damaged rib of an umbrella frame by replacing the damaged rib section, thus not leading to premature waste of the rest of the umbrella. [0059] d. The rib sections facilitate inventory management, with potentially lesser part variations. Further, for the same partially assembled core support structure and hub structure, different size rib sections can be used to assemble a frame structure that can accommodate different size canopies to assemble umbrella of different sizes. So, it would not be necessary to maintain inventory of complete umbrella assemblies of different size canopies. Different size canopies can be accomplished by using rib sections of desired lengths with the same core partially assembled frame structure. [0060] e. Users may decide to change the size of the canopy without having to purchase an entire new umbrella including fully assembled frame structure. Users may simply replace the long and short rib assemblies and replace the canopy. [0061] f. The rib sections may be sold as replacement parts, thus generating more revenue for the seller. [0062] g. The rib assembly facilitate warranty replacement of only damaged rib sections, instead of having to replace an entire umbrella with only a damage rib assembly, thus lessen the burden on fulfillment of warranty claims by the seller/manufacturer and potentially improving customer satisfactions.

[0063] While the present invention has been described above in connection with the illustrated embodiments, the scope of patent invention covers all possible present and future variations and improvements that is apparent from the disclosure above. While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit, scope, and teaching of the invention. Accordingly, the disclosed invention is to be considered merely as illustrative and limited in scope only as specified in the appended claims.