US20130099185A1

US20130099185A1 - Louver shade assembly

Info

Publication number: US20130099185A1
Application number: US13/694,083
Authority: US
Inventors: Roger Rountree
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-03-29
Filing date: 2012-10-29
Publication date: 2013-04-25

Abstract

A canopy tensioner adapted for use with a louver system wherein the canopy tensioner is mounted in pairs on the short and long arms of rib arm unit that traverse the body of the tensioner via an arm connecting chase is connected to a fiber anchor extrusion (keder) and wherein a rotating a nut positioned on the end of the rib arm unit changes the tension on the shade canopy element of the louver system. In an alternative mode, the tensioner unit is adapted for use with shade canopies, wherein the shade canopy is connected to and supported by poles that are connected by headers that are connected at right angles to rafters; support/connector blockes are positioned in the lumen of the rafter thereby connecting the tensioned to the support structure, and the tensioner is also mechanically connected to the front and rear keders of the shade canopy fabric element.

Description

PRIORITY

This U.S. patent application is a continuation-in-part of, and claims priority of U.S. patent application Ser. No. 13/065,756, filed Mar. 29, 2011 which U.S. patent application is hereby incorporated in its entirety by reference.

FIELD OF THE INVENTION

This invention comprises a canopy tensioner device that is adapted to adjustably maintain the fabric element of a shade canopy in a physically, uniformly stretched or taut (wrinkle-free) state or condition when the shade canopy is part of a louver assembly or is individually supported by a frame structure. The invention includes fabric tensioners that can tension the shade cover fabric, thereby eliminating unsightly sagging and fostering drainage from the shade canopy and optimizing the design appearance of the shade canopy.
The tensioners also allow the use of fabrics that otherwise would be too dimensionally unstable for conventional frame based awnings.

BACKGROUND OF THE INVENTION

The term louver traces to the French l'ouvert, the opening. This loose definition is appropriate for the original usages of louvers, reportedly sometime in the Middle Ages, from the fifth century to about AD 1350. The definition of louver conveys certain specific concepts: initially a more-or-less open-sided structure to let out smoke, prevent rain from entering, and admit light, and it contemplates a support structure with side pieces positioned vertically or horizontally, slats or veins, that allowed smoke to flow out, excluded rain, and permitted light to enter. The term louver now is applied variably to the individual slats or veins, or to an entire structure.
In U.S. patent application Ser. No. 13/065,756, louver shade assembly refers to the entire structure and shade canopy refers generally to what has been considered a slate or vein. Exterior shade louvers have been demonstrated to be effective in providing shade, reducing solar heat gain, and promoting ventilation.
Louvers have been allowed subject matter of U.S. patents for more than 150 years. U.S. 21417 issued Sep. 7, 1858 describes a l'ouver system that functions as a “window blind,” including screening also to serve as an insect net. Claims for a louver bracket assembly that extended the height of a louvered fence were allowed in U.S. Pat. No. 4,938,445 issued Jul. 3, 1996.
Louvers are used to promote privacy and to reduce glare/provide shade. U.S. Pat. No. 5,873,202 issued Feb. 23, 1999 discloses a slidably adjustable awning in which louver veins or slats replace a solid, fabric awning on a frame.
U.S. Pat. No. 5,906,083 issued May 25, 1999 disclose and claim a modular form of louvers that provide both the benefits of shading and cooling as well as representing/satisfying unique architectural design opportunities. Louvers have been allowed subject matter of design patents; see, for example D605,281, “Louver Vent”, issued Dec. 1, 2009.
Shade canopies are distinguished in the prior art from louvers or louver systems. The canopy has been distinguished from, but considered as part of an awning. Awnings commonly (or canopies) commonly include a support structure for a single unit (shade); awnings otherwise may be attached to buildings (windows and doors) for shade, rain protection, or general decorative purposes, and the canopy is frequently retractable or collapsable in an umbrella-like fashion. Prior technology stresses frames and means to anchor such devices.
U.S. Pat. No. 2,963,031 issued Dec. 6, 1960 and titled “Tension Canopy” describes and claims a tension spaced, diamond shaped web with pairs of support rods to support the web and to anchor and secure the web in position.
U.S. Pat. No. 6,179,513 issued Jan. 30, 2001 describes and claims a canopy tensioning rafter comprising an outer member and an inner member that telescopically slides within the outer member, and a clamp that secures the inner member of the rafter to the outer member that further comprises a handle with clamping jaws that secure the side edge of the canopy fabric. The extended canopy is supported at the corners of its outer edge by a pair of support arms. The tension rafter is adapted to securing an extendable/retractable canopy to the side of a trailer or motor home, but its use is not limited to vehicles.
U.S. Pat. No. 7,640,703 issued Jan. 5, 2010 and titled “Demountable and Reusable Canopy” discloses a canopy deck frame and solid panels that can be installed for an indefinite period, disassembled (demounted) and reinstalled for alternative uses, and U.S. Pat. No. 3,332,179 titled “Canopy Construction” and issued Jul. 25, 1967 describes and claims a cover assembly and underlying support and anchor frame. U.S. Pat. No. 8,191,561 issued Jun. 5, 2012 and titled “Umbrella with Integral Anchoring Structure” includes a central post with an anchoring assembly at its distal end to secure the post in sand or soil.

SUMMARY OF THE INVENTION

The purposes and goals of the invention include:

- a first purpose and goal of the invention is a canopy tensioner to be used in association with a louver assembly in which rotating an adjustment nut moves the canopy tensioner outward and generates tension on the fabric element of the shade canopy at right angle to the front and rear anchor extrusions to which the first and second members, respectively, of a pair of canopy tensioners are functionally attached;
- a second purpose and objective of the invention is a canopy tensioner to be employed in pairs associated with a louver shade assembly in which each member of a pair of canopy tensioners comprises a tensioner body comprises an arm connecting chase that slidably engages the threaded end of a rib arm unit (the distal end of either the short arm or long arm of the rib arm unit) thereby connecting the canopy tensioner to the rib arm unit and the first and second members of the pair canopy tensioners, respectively, are attached to the front and rear fabric anchor extrusions (keders) that are connected to and anchor, respectively, the front and rear edges of the fabric element of the canopy;
- a third purpose and goal of the invention is a canopy tensioner to be used in pairs as part of a shade canopy that consists of four major elements (a foundation frame, a rafter assembly, the shade assembly, and the canopy tensioner unit) wherein the body of the canopy tensioner is slidably attached to a rafter and wherein rotating a nut exerts tension on the fabric element of the shade canopy;
- a fourth purpose and goal of the invention is a canopy tensioner that connects the rafter assembly and the shade assembly and in which the rafter assembly is connected to headers that are supported by pairs of corner posts; and
- a fifth purpose and goal of the invention is a canopy tensioner in which the foundation anchor frame may be mounted on a deck, patio, or the ground.

These and other purposes and goals are satisfied by a canopy tensioner that is used with a louver assembly in which the canopy tensioner comprises a body with an arm connecting chase that is adapted to engage the threaded end of the long arm (or of the short arm) of a rib arm unit and in which the body of the canopy tensioner is adapted to be physically connected to the front (long arm) fabric anchor sleeve extrusion (keder) or to the rear (short arm) fabric anchor sleeve extrusion (keder), and in which the canopy tensioners are used in pairs as described above, and further in which tension on the fabric element of the shade canopy of the louver can be increased (or decreased) by rotating a tension adjusting nut that functionally engages the threaded end of the long arm (or the short arm) of the rib arm unit and that contacts and exerts outward force on the inner face of the canopy tensioner body and further in which the body of the canopy tensioner may further comprise a camber cable chase that traverses the body and that is positioned generally parallel to and below the arm connecting chase; further, these and other purposes and goals are satisfied by a canopy tensioner that is used with a shade assembly in which the canopy tensioner unit includes the canopy tensioner is a part of the fabric anchor assembly and the tensioning unit comprises a threaded metallic tensioning rod that functionally engages a threaded tensioning nut and the distal end of which has a connector eye, and the opposite (proximal) end slidably engages the tension rod chase that longitudinally traverses the tension chase block wherein the tension chase block is secured in the open core (lumen) of a rafter that is supported by headers that are connected to and supported by vertical, upright posts; a rotating nut threadedly engages the tension rod, and rotating the nut increases (or decreases) tension on the shade canopy (fabric element) by extending (or retracting) the tension rod and effectively changing the length of the rafter; the distal end of the rod is connected through an eye to the front (or rear) keder by a bolt.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A provides an overview of the louver assembly indicating major parts shade component, central axle tube, rod rib assembly, and carrier bracket.

FIG. 1B provides details common to front and rear fabric anchor extrusions.

FIG. 2A illustrates rod rib assemblies positioned on central axle tube, camber cable, and ridge tube.

FIG. 2B provides half section, cut away view of a rib hub.

FIG. 2C illustrates rod rib assembly including rib arm unit camber cable, and cable guide.

FIG. 3A illustrates canopy tensioner body.

FIG. 3B illustrates canopy tensioner assembly positioned on a rib arm.

FIG. 3C illustrates canopy tensioner with the camber cable attached by an integrated turnbuckle device.

FIG. 3D provides bottom view of shade canopy showing central axle tube, rod tip assembly positioning, and canopy tensioners.

FIG. 4A illustrates carrier bracket assembly with carrier unit.

FIG. 5A provides details of axle support ring and support chase.

FIG. 5B provides details of axle support ring in half-section view.

FIG. 6A illustrates wax piston assembly in relation to lift arms and rear fabric anchor extrusion.

FIG. 6B illustrates details of wax piston assembly.

FIG. 6C shows relative positions and structures of wax piston assembly, support arm, carrier bracket, and axle support ring.

FIG. 7A is a diagram of a decompressed, compression gas spring with the piston fully extended.

FIG. 7B is a diagram of a compressed (pressurized), compression gas spring with the piston fully retracted.

FIG. 8A illustrates a manual pitch adjustment system by which both shade canopy pitch and elevation are controlled by a pitch/elevation adjustment assembly using the modified mounting bracket.

FIG. 9A illustrates an alternative method of mounting the shade louver assembly using a wall mounted axle receiver.

FIG. 9B illustrates details of the wall mounted axle receiver.

FIG. 10A provides a schematic overview of the shade canopy showing the foundation frame, rafter assembly, and shade assembly.

FIG. 10B illustrates corner post with railing and railing connectors.

FIG. 10C shows assembled corner post with railing plate and standard desk properly positioned.

FIG. 10D shows disassembled parts of a double layer anchor.

FIG. 10E shows a fully assembled double layer anchor.

FIG. 10F illustrates a ground corner post.

FIG. 10G illustrates corner post/header connector assembly fully disassembled.

FIG. 10H illustrates corner post/header connector assembly partially assembled.

FIG. 10I shows corner post/header assembly with square tee-connector.

FIG. 10J illustrates corner post and header connector fully assembled.

FIG. 11A shows assembled corner post and header and cap structure.

FIG. 11B shows header mounting eye with fully assembled corner post-header.

FIG. 11C diagrams assembled corner post/header and pair of rafters with connecting rod.

FIG. 11D illustrates fully assembled corner post/header and a pair of rafters with connecting rod.

FIG. 12A illustrates shade assembly in relation to a corner post, header, and rafters, showing connection to keder.

FIG. 12B provides details of tensioning unit.

EXAMPLES

Louver Assembly

The louver assembly 101 comprises four major elements, components, and parts as illustrated in FIG. 1A and FIG. 1B. The louver assembly 101 comprises a shade canopy 102, a rotatable central axle tube 112, rod rib assembly 201.
The shade canopy 102 includes a fabric element 103 and the front 110 and rear 111 fabric anchor extrusions. The fabric element 103 is described as having a length 104 and a width (some times designated as depth) 105, as well as having a bottom surface 106 and a top surface 107. The fabric element 103 is also characterized by a front edge 108 and a back edge 109.
The fabric anchor extrusions provide the structural element for connecting the shade canopy 102 to the rod rib assembly 201 and further provide the connection surface for attachment of the pitch control devices (wax piston assembly, compression spring, and manual pull system) to the shade canopy. Aluminum fabric anchor extrusions are extruded into rectangular, commonly flattened, rectangular tube. Both of the fabric anchor extrusions, front 110 and rear 111, are equal in length to the length 104 of the fabric element 103. Although not an absolute limitation, maximum length rarely exceeds 24 to 30 feet (7.3 to 9.4 m).
The dimensions of the fabric anchor extrusion vary as a function of the length of the extrusion, the unit weight of the fabric from which the fabric element 103 is made, and potentially to specific environmental conditions to which the louver assembly may be exposed.
When the fabric anchor extrusion is extruded as a flattened tube, dimensions of the aluminum extrusion, by way of example, not limitation, are as follows: wall thickness 0.125 to 0.250 inch, height 0.25 to 0.50 inch, and width 1.5 to 4.0 inch (3.2 to 6.4 mm; 0.64 to 1.3 cm, and 3.8 to 10.2 cm, respectively). One skilled in the art recognizes that the material from which the fabric anchor extrusion is fabricated could be round, oval, or rectangular in cross-section and could be from a variety of metal, plastic, or composite materials, all of which are herein anticipated.
In one configuration, each fabric anchor extrusion 110 and 111 is positioned in a sleeve 114 formed respectively along the front edge 108 and back edge 109 of the fabric element 103, as illustrated in FIG. 1B. The sleeve 114 is formed by folding (or wrapping) the fabric around the fabric anchor extrusion, thereby forming a seam 115 along the length of the sleeve 114. The seam may be secured by various means known to those skilled in the art, heat or RF welding, stitching, or various adhesives, preferably, with man-made fabrics, joining the material along the seam line adjacent to the edge of the fabric anchor extrusion. Note, the width 105 of the fabric as illustrated and defined excludes the material required to form the sleeve and seam 114 and 115. In practice, this would be 6 inches (15 cm) or less.
The cross section shape (configuration) and means by which the fabric element 103 and fabric anchor extrusion are connected may assume a variety of forms, as one skilled in the art recognizes, including a specific form recognized as the keder anchor extrusion. Such variations do not alter the scope or intent of the invention and are anticipated by the appended claims.
By way of example, but not an absolute limitation, the width 105 of the fabric element 103 varies from 1 to 4 feet, preferably 2 to 3.5 feet (0.3 to 1.3 m, preferably 0.6 to 1.0 m), and the length 104 varies from 4 to 24 feet (1.1 to 8 m), or longer. The fabric element 103 is generally manufactured from various synthetic fibers, such as but not limited to, vinyl coated polyesters, and rarely may be manufactured from natural fibers (cotton). As one skilled in the art understands, the fabric may be dyed, woven, or otherwise decorated, and may be treated to display certain surface characteristics and to resist/withstand specific climatic conditions, such as excessive moisture, heat, and degeneration caused by ultra violet radiation.

Central Axle Tube and Rod Rib Assembly

Although structurally separately identifiable, functionally, as illustrated in FIGS. 2A, B, and C, the rotatable central axle tube 112 and the rod rib assembly 201 constitute a functional element. The rotatable central axle tube 112 is the structural/functional backbone of the louver assembly 101, and is most commonly manufactured from 1.75 or 2 inch (4.5 or 5.0 cm) diameter, preferably anodized, aluminum tube. Such material is readily available through commercial aluminum suppliers. The overall length 216 of the rotatable central axle tube 112 varies as a direct function of the size (width) of the window, or group of windows to be protected (shaded) by the louver assembly 101. The length 216 of the rotatable central axle tube 112 is approximately 6 inches (15 cm) shorter than the length 104 fabric element 103 and the ridge tube 113. Byway of example, not limitation, the length 104 of the fabric element 103 varies from 4 feet (1.2 m) to over 24 feet (7.3 m).
The rod rib assembly 201 comprises a rib arm unit 217 and the rib hub 202. The rib arm unit 217 is divided into a short arm section 204 and a long arm section 203.
One member of a minimum of one pair of rod rib assemblies 201 is positioned at the first end 116A of the rotatable central axle tube 112 and the second member is positioned at the second end 116B of the rotatable central axle tube 112. Depending on the overall length 216 of the rotatable central axle tube, additional rod rib assemblies may be spaced along the rotatable central axle tube. (See FIG. 2A.) For each rod rib assembly, the corresponding rib arm unit 217 traverses the rotatable central axle tube 112 along a common diameter line 124 such that when the rib arm units 217 are properly positioned they are parallel to each other and to any other arm positioned on the same rotatable central axle tube. They are in the same horizontal plane extending from the common diameter line 124 and extend on both sides of the central axle tube 112 at right angle to the longitudinal dimension 216 of the central axle.
Each arm rib unit 217 is positioned as a result of traversing the rotatable central axle tube 112 such that the rib arm unit 217 is divided into a long arm segment 203 and a short arm segment 204. The long arm segment 203 terminates in the distal end 205 of the rib arm unit 217, and the short arm segment 204 of the rib arm unit 217 terminates in the proximal end 206 of the rib arm unit 217. Equal segments of the distal 205 and proximal 206 ends of the rib arm units are threaded for a common length 215, varying from 2 to 6 inches (5 to 15 cm).
FIG. 2A provides an example in which three rib arm units 217A, B, and C are positioned at the first end 116A, the second end 116B, and at the mid-point of the central axle tube 116C. Rib arm units 217A and 217B are positioned flush at the first 116A and second 116B ends of the central axle tube 112. Rib arm units 217 are generally spaced 4 to 6 feet (1.2 to 1.8 m) apart. If the length 104 of the fabric element 103 is greater than 6 feet (2 m,) and up to approximately 12 feet (4 m), a third rib arm unit 127C (FIG. 2A) is positioned at the mid-point of the central axle tube, equal distance from the first 217A and second 217B rib arm units. Thus, the distance is equal between any two, adjacent rib arm units 217A, 217B, and 217C, in this example, is 6 feet (2 m). If the overall length exceeds 12 feet (4 m), for example 24 feet (7.3 m), the third rib arm unit would be positioned at the mid-point 12 feet (3.7 m) from either end rib arm unit, and two additional rib arm units (not illustrated) would be positioned at a point equal distance from the first end rib arm unit and the middle rib arm unit and equal distance from the second end rib arm unit and the middle rib arm unit, a total of five rib arm units, each equal distance from any immediately adjacent rib-arm unit (6 feet or 2 m) distances within the suggested range of 4 to 6 feet (1.2 to 2.0 m).
As illustrated in FIG. 2A, the rib arm units 217A, 217B, and 217C traverse the diameter of the rotatable central axle tube 112 and are positioned such that the length of the long arm 208 is twice (or more) the length of the short arm 209. This results in approximately 70 percent of the weight of the shade canopy 102 being positioned on the long arm side of the rotatable central axle tube 112. The relative proportion of weight distribution above 50 percent may be varied without altering the scope and intent of the invention, and such variation is anticipated by the invention.
The long 203 and short 204 arms of the rib arm unit 217 is fabricated preferably from stainless steel rod, varying in diameter, by way of example, not of limitation, from about 0.25 to 0.75 inch (0.63 to 1.9 cm). One skilled in the art recognizes that the long 203 and short 204 arms may be fabricated from a variety of other materials, including, but not limited to plastics and composites, and material may be square, round, or oval in cross-section with accommodation for threaded ends, and solid or hollow. Length of the long arm 208 and the short arm 209 varies with the specific width 105 of the shade canopy 102.
The rib hub 202 of each rod rib assembly 201 functions as a clamp to support the rib arm unit 217 when it is in position, traversing the central axle tube 112 and to engage and secure the central axle 112 in relation to the arm units 217. The rib hub 202 also supports the ridge tube 113. The ridge tube 113 is positioned in the in the ridge tube cradle 220 at the top edge 230A of the rib hub 202, and the ridge tube 113 extends the length 104 of the fabric element 103 parallel to the rotatable central axle tube 112. Functionally, the ridge tube supports the fabric element 103 of the canopy 102 and allows spacing for proper positioning of axle support ring element 501. The rib hub 202 of the rod rib assembly 201 may be manufactured in mirror image, half sections 225, and half sections are connected to form the rib hub 202.
A half section 225 of the rib hub 202 as illustrated in FIG. 2B comprises the half body element 228. The half body element 228 includes a first end 223A and a second end 223B. The hub clamp chase 218 extends from the first end 223A to the second end 223B of the half body element 228. The diameter 218A of the hub clamp chase 218 is nominally equal to (slightly less than) the diameter of the stainless steel rib arm units 217.
The hub axle lumen 222 (FIG. 2C) traverses the center 229 of the rib hub 202 at a right angle to the arm unit 217. The hub axle lumen 222 is defined and limited by lumen walls 226. The ridge tube cradle 220 a semi-circular notch, adapted to receiving and positioning the 0.75 inch (1.9 cm) diameter ridge tube, is formed at the top center 230A of the rib hub 202.
The two half sections 225 of the rib hub are securely connected by bolts 224 traversing the two half units at four points to form the rib hub 202, clamp and secure the rib arm units 217 in position to ensure proper spacing of the long 203 and short 204 arms, and secure the rotatable central axle tube 112 in relation to the rib arm unit 217 and the ridge tube 113. The rib hub 202 engages the rotatable central axle tube 112, and the rotatable central axle tube 112 rotates within and is supported by the axle support ring 501 in response to force transmitted by either the piston pressure assembly 601 or the compression gas spring 701. The rod rib assembly 201 rotates with the rotatable central axle tube 112.
FIG. 2C illustrates the rod rib assembly 201 with half sections 225 of the rib hub 202 connected by bolts 224 at four points. The rib arm unit 217 is positioned in the arm unit clamp chase 218, extending through the rib hub 202 from the first end 223A of the rib arm unit 217 to the second end 223B. The rotatable central axle tube 112 is positioned in the hub axle lumen 222, and is secured friction tight against the lumen walls 226. The ridge tube 113 is positioned in the ridge tube cradle 220 and extends at right angle to the rib unit 217 and parallel to the central axle tube 112.

First Best Mode: Canopy Tensioner

As illustrated by FIGS. 3A, B, C, and D, a canopy tensioner 301 provides the basic structure for connecting the shade element 102 with the rib arm unit 217 and thus with the rod rib assembly 201. The basic structure of canopy tensioner 301 is illustrated in FIG. 3A. The canopy tensioner 301 comprises a tensioner body 302 with a width 303A, a height 303B, a length 303C; an arm connector chase 305 traverses the length 303B of the tensioner body 302, and a camber cable chase 306 also traverses the length 303B of the tensioner body 302 parallel to and below the support arm chase 305.
The arm connecting chase 305 is adapted to engage the threaded end 215 of long arm 203 or of the short arm 204 of the rib arm unit 217. Each tensioner is connected by bolts or similar means to a fabric anchor extrusion 110 or 111. Thus, each rod rib assembly is connected to the shade canopy by a pair of identical tensioners 301. One member of the pair of tensioners is secured to the front fabric anchor extrusion, and the second member of the pair of tensioners is anchored to the rear fabric anchor extrusion. Thus, the shade canopy 102 is physically connected to the rod rib assembly 201.
One skilled in the art recognizes that fabric anchor extrusions may assume may forms, including by way of specific example, but not limitation, the keder fabric anchor extrusion, and a canopy tensioner can be connected to any of these types of fabric anchor extrusion. Such variations are assumed by and included in the designation fabric anchor extrusion as used herein. As illustrated, the body 302 of the canopy tensioner 301 is connected to the front and rear fabric anchor extrusions 110 and 111 by a pair of bolts 308A and 308B with nuts. Other connector means could be used, including, but not limited to rivets and adhesive means and materials.
The threaded ends 215 of the long and short arms 203 and 204 respectively of the rib hub assembly 201 are positioned in the arm connector chase 305 and traverse the length 303C of the canopy tensioner body 302. A tension adjustment nut 307 is threaded on each arm 203 and 204 such that the tension adjustment nut 307 contacts the inner face 304 of the canopy tensioner body 302 such that rotating the nut increases tension on the front and rear fabric anchor extrusions 110 and 111, thereby stretching the fabric element 103 of the shade canopy 102. Rotating the tension nut clock-wise (as illustrated in FIG. 3B) causes the tension adjusting nut 307 to exert force on the canopy tensioner 301 moving it as appropriate towards the distal 205 or proximal 206 end. Movement is transferred to the front and rear fabric anchor extrusions, and as a result of such movement, tension is exerted on the fabric element. One of average skill in the art recognizes that reversing threading would reverse the direction of rotation of the tension nut required to generate the desired tension. Such modification is anticipated by the invention and does not alter the scope or intention of the invention.

Camber Cable Guide System

The camber cable guide system comprises at least two camber cable guide units 316, and in practice, the number of camber cable guide units generally equals the number of rib arm units 217 with one camber cable guide unit 316 connected to each rib arm unit 217. As illustrated in FIG. 2C, each camber cable guide unit 316 comprises a camber cable 312, a camber cable guide 313, and the camber cable guide 313 comprises a head 318 with an eye 319 and a threaded neck element 313A, and a camber cable guide chase 315 at the bottom center 230B of the rib hub 202. The camber cable guide 313 is positioned and pressed and held frictionally tight in the camber cable guide chase 315.
As illustrated in FIG. 2A and FIG. 2B, a camber cable 312 extends the full length of each rib arm unit 217A, B, and C, the length of which effectively equals the width 105 of the fabric element 103 as illustrated in FIG. 2A. The camber cable may be fabricated from woven wire (a wire subject to minimum stretching) or from a thin metal rod, such as a 0.25 inch (0.63 cm) stainless steel rod), by way of example, but not limitation.
Tension on the arms 203 and 204 of the rod rib assembly 201 can be adjusted by the camber cable guide system 316 as illustrated in FIG. 2A and further explained in FIG. 2C, FIG. 3B, and FIG. 3D.
Each end of the camber cable 312 is secured to a canopy tensioner 301 directly, as illustrated in FIG. 3B or indirectly as illustrated by FIG. 3C by a turnbuckle cable attachment device 320. The camber cable 312 is passed through the eye 319 in the head 318 of camber cable guide 313. A nut 314 engages the threaded neck element 313A, and the distal segment 313B of the threaded neck element is positioned in the camber cable guide chase 315. The first face 314A of the nut 314 contacts the bottom surface 230B of the rib hub 202, and rotating the nut 314 extends (or retracts) the distal segment 313B of the camber cable guide 313, thereby changing tension on the long and short arms 203 and 204 to the ends of which the canopy tensioners are attached and anchored by attachment respectively to the front 110 and rear 111 fabric anchor extrusions.
The first end 324 of the camber cable 312 is secured directly to the camber cable anchor point 317 of the camber cable chase 306 of a canopy tensioner 301 positioned on the front fabric anchor extrusion 110, as shown in FIGS. 3B and 3D. As illustrated in FIG. 3C, optionally, the second end 325 of the camber cable 312 may be connected indirectly to the camber cable chase 306 of the canopy tensioner 301 attached to the rear fabric anchor extrusion 111. An integrated turnbuckle cable connector device 320 is secured to the camber cable chase 306 positioned on the rear fabric anchor extrusion 111; a terminal stay 321 on the proximal end 322 of the turnbuckle cable connector 320 prevents the turnbuckle cable connector from being pulled free of the canopy tensioner 301. The distal end 323 of the turnbuckle cable connector 320 is swaged to the second end 325 of the camber cable 312.
As one skilled in the art understands, the body 329 of the turnbuckle connector rotates on the threaded, proximal end 327 of the turnbuckle shaft, thereby increasing (or optionally decreasing) tension on the camber cable that is transferred through the canopy tensioners to the long 203 and short 204 arms. It is further understood that the connections of the camber cable to the canopy tensioners may be reversed without extending or modifying the scope and intent of the invention and such modifications are anticipated.
FIG. 3D illustrates the connections and relations among parts of the camber cable guide system 316: the connection of the camber cable 312 to the tensioners 301, bolted or otherwise connected to the front 110 and rear 111 fabric anchor extrusions, as well as the central axle tube 112 in relation to the rib hub 202, long 203 and short 204 arms, and the shade canopy 102. The fabric element 103 is suspended by a ridge tube 113; other than the front and rear fabric anchor extrusions, 110 and 111, respectively, the ridge tube 113 is supported by the ridge tube cradle 220 provides the only direct support of the fabric element 103.
The canopy tensioner 301 may be fabricated from metals and artificial materials. Preferably, the canopy tensioner is manufactured by injection molding from a plastic material, such as, but not limited to fiberglass filled nylon.
The dimensions of the canopy tensioner 301 are important only to the extent of adequate arm length to form the support arm chase 305 and camber cable chase 306 and adequate strength to allow secure connection to the fabric anchor extrusions and tolerate pressure exerted by rotation of the tension adjustment nut 307. Thus, the width 303A may vary, but is not limited to from 1 to 3 inches (2.5 to 7.5 cm), the height from 0.75 to 1.5 inch (1.9 to 3.8 cm), and the length also from 0.75 to 1.5 inch (1.9 to 3.8 cm). The respective diameter of the support arm chase 305 and camber cable chase 306 are nominally the same as or slightly greater than the diameters of the threaded ends 215 of the long and short arms (203 and 204, respectively) and of the camber cable.
The camber cable guide system 316 equalizes tension on the rib arm units 217 such that they are subject only to compression loading. A camber cable extends the full length of each rib arm unit 217, which length is effectively the width 105 of the fabric element 103, FIG. 2A. The camber cable 312 is anchored to the canopy tensioners 301 positioned at and connected to the distal 205 and proximal 206 ends of the rib arm unit 217. The fabric element 103 is tightened by extending the canopy tensioners 301. The desired degree of tightness may cause undesired, upward deflection of the ends of the rib arm units 217. Extension of the camber cable guide 313 eliminates this upward deflection and equalizes tension such that they are subject only to compressive loading. In addition, the effective length of the camber cable 312 can be changed by adjustment of the integrated turnbuckle cable attachment device 320.

Carrier Bracket Assembly

FIG. 4A illustrates the complete carrier bracket assembly 401 including the mounting bracket 402 and carrier unit 403.
The carrier bracket assembly 401, FIG. 4A, comprises two major elements: a mounting bracket 402 and a carrier unit 403. The carrier unit 403 comprises a base flange plate 404 and a support arm 405. The distal end 406 of the support arm 405 is adapted, as the connector tongue, to engage and support the axle support ring element 501.
The support arm 405 and base flange plate 404 are comprise a single unit, commonly manufactured from die-cast aluminum processes. As illustrated in FIG. 4A, the support arm 405 extends outwardly and upward at a shallow angle from the base flange plate 404.
In a common configuration, the mounting bracket 402 is physically attached to the face of the building, thereby serving as the actual connection of the entire louver shade assembly with the building. Further, the mounting bracket 402 physically engages the base flange plate 404, thereby connecting the carrier bracket and building.

Axle Support Ring Element

FIGS. 5A and 5B provide details of the axle support ring element 501. The axle support ring element 501 comprises two segments, the connector tongue chase body 502 and the axle tube chase support 503. Commonly the axle ring support element 501 is injection molded in individual, complimentary half sections 515 from, by way of example, not limitation, a blend of fiberglass and nylon.
The connector tongue chase body 502 comprises connected structural elements as follows: a first face wall 504A and a second face wall 504B and a first side wall 505A and a second side wall 505B. The receptacle tongue chase 508 is defined and limited by the inner surfaces 509A and 509B of the first and second face walls 504A and 504B and by the inner surfaces 510A and 510B of the first and second side walls 505A and 505B, respectively. The receptacle tongue chase has a height 511, a width 512, and a length 513, the dimensions of which are nominally the same as the dimensions of the connector tongue 405A.
The central axle tube chase support 503 segment is defined by the first and second faces of the central axle tube chase support walls 506A and 506B, respectively. The chase lumen 520 is defined and limited by the inner surface 518 of the first and second central axle tube chase walls 506A and 506B and the circular support wall 507. The diameter 519 of the lumen 520 is nominally equal to the diameter of the rotatable central axle tube is generally, but not limited to, 1 to 3 inches (2.5 to 7.5 cm).
The connector tongue 405A is positioned in and engages the connector tongue chase 508, thereby connecting the axle support ring element 501 to the support arm. The half-sections 515 of the axle support ring element 501 are physically connected, thereby securely clamping the connector tongue 405 in the connector tongue chase.
The connector tongue chase body 502 further comprises a lift arm anchor point 514 that traverses the first and second faces 504A and 504B, respectively.

Control of Shade Canopy Pitch

The pitch of the shade canopy can be altered by controlled rotation of the rotatable central axle tube. Pitch is described as the slope downward of the front edge (and concurrent slope upward of the back edge) of the shade canopy from horizontal. Increasing pitch increases shading by the shade canopy. This, for convenience, is referred to as the shade orientation of the canopy. The normal (default) position of the shade canopy is generally defined as horizontal orientation; however it may also be defined as the pitched or shade configuration.
The shade canopy may be rotated by elevating the rear fabric anchor extrusion, thereby increasing the pitch and increasing shading and cooling. Optimum pitch considers exposure (east and west versus south) and latitude and regional daily and seasonal temperature patterns.
Thermally induced, automatic modification of the pitch is achieved by the use of a compression gas spring or a combination of a compression gas spring and wax piston assembly to stabilize the pitch of the shade canopy or to rotate the shade canopy by elevating the rear fabric anchor extrusion.

Wax Piston Assembly

The wax piston assembly 601, FIGS. 6A and 602B, is the mechanism by which the orientation of the shade component is changed from the default, horizontal orientation to provide greater shading and related cooling. The wax piston assembly 601 comprises two lift arms 602A and 602B, a wax cylinder unit 604, a piston support block 610, and a lift arm block 617 the top surface of which 617A contacts the fabric anchor extrusion 111.
Both the first 602A and second 602B lift arms have a proximal end 603A and a distal end 603B. The lift arm block 617 is pivotally attached at the distal ends 603B to both lift arms 602A and 602B by attachment pin 616. The piston support block 610 is pivotally attached to the proximal ends 603A of the first 602A and second 602B lift arms at attachment points 614A and 614B by the connecting lugs 613A and 613B. This pivotally secures the piston support block 610 between the two lift arms 602A and 602B. The first 613A and second 613B piston block connection lugs are functionally part of the piston support block 610. Practically, the lugs 613A and 613B may be threaded respectively into the first 610A and second 610B side face and aligned with the corresponding attachment points 614A and 614B. The lugs traverse the respective lift arms and are secured with bolts or comparable means known to those skilled in the art, thereby securing the piston support block 610 between the two lift arms, 602A and 602B.
The wax cylinder unit 604 is connected to the piston support block 610. The threaded piston adjuster 612 at the proximal end 603A of the wax cylinder unit 604 engages the corresponding, threaded piston chase 612A. Thus, the wax cylinder unit 604 through connection with piston support block 610 is physically connected to the first 602A and second 602B lift arms. Details of the piston support block 610 and wax piston unit 604 are illustrated in FIG. 6B. The wax piston unit comprises a cylinder 609 with a piston 611 functionally connected to it and to the piston adjuster 612 extending from the threaded piston connection channel 612A at the distil end 605A of the piston support block 610.
The upper surface 618 of the lift arm block 617 contacts the bottom side 111A of the rear fabric extrusion 111. The cylinder 609 contains a heat reactive, wax material that expands with increasing temperature, and in response to increasing temperature, the wax expands exerting a force on the piston 611. The piston is mechanically and functionally connected to both the cylinder 609 and to the threaded piston adjuster 612 that is connected to piston support block 610.
Structurally and functionally, the wax piston assembly 601 is connected to the mounting bracket 402. The cylinder 609, as illustrated in FIG. 6C, is connected by the upper flange stay pin 425A that traverses the mounting bracket 402 and engages the cylinder attachment point 608. One skilled in the art recognizes that the cylinder 609 may be connected by an axle or pin located separately from the upper flange stay pin 425A without changing the scope or intention of the invention, and such modifications are anticipated and included as part of the invention.
The wax piston assembly 601 is connected to the carrier support arm 405 (FIG. 6C) indirectly as follows. The piston support block 610 is directly connected to lift arms 602A and 602B by the piston support block connecting lugs 613A and 613B. The lift arms 602A and 602B are connected the support arm 405 by lift arm anchor pin 606. Thus, the wax cylinder unit 604 is connected directly to the carrier bracket 402 through connection of the cylinder 609 through attachment point 608 by upper flange stay pin 425A. The wax cylinder unit 604 is connected by linkage of the threaded piston adjuster 612 linkage with piston support block 610 and the piston support block 610 being pivotally connected through piston support block connecting lugs 613A and 613B with corresponding lift arms 602A and 602B, and connection of lift arms by connection with the carrier bracket support arms 405. The carrier support arm 405 is attached to carrier bracket base flange 404, which is structurally and functionally connected to the wall mounting bracket 402.
The wax piston assembly 601 and its support as described above explain how the pitch of the shade component 102 is adjusted in response to increases in temperature. The upper surface 618 of the lift arm block 617 contacts the bottom side 111A of the rear fabric anchor extrusion 111. The cylinder 609 contains a thermal reactive wax material that expands in response to increases in temperature, thereby exerting a force on the piston 611. The force is transferred to piston support block 610 causing it to rotate on lugs 613A and 613B. The rotation in response to the force is transferred to the lift arms 602A and 602B causing the support arms to rise, exerting an upward force on back edge fabric anchor extrusion 111 causing it to rise, there by rotating the shade component 102 downward, or lowering its pitch and, thus, increase shading of an adjacent surface (window).
One skilled in the art understands that the response of the wax piston assembly to temperature change can be controlled by the threaded piston adjuster 612 that effectively determines the temperature required to generate force on the second fabric extrusion 111. Also, one skilled in the art recognizes that without affecting or increasing the scope or intent of the invention, the horizontal default orientation of the shade canopy assumed in the preceding examples can be modified by mechanically adjusting the height or angle of attachment of the lift arms or angle of attachment of cylinder 609 to the carrier bracket, and all such simple alterations are assumed by this specification.
Because up to 75 percent of the weight of the louver assembly is centered on the long arm side of the central axle 112, the shade component 102 does not rotate back to the default position when the wax cylinder is cooled. A compression gas spring 701 (FIG. 7A) provides the force to return the shade component to its default position, as force from the cylinder is reduced in response to cooling.
The wax piston assembly 601 is uni-directional in function. As temperatures increase, the wax expands to exert pressure on the piston ultimately to force the rear anchor extrusion 111 upward, or increase the pitch of the shade canopy 102. When the temperature decreases adequately, the wax cools and contracts, and the pressure decreases, but does not generate a force to pull the rear anchor fabric extrusion 111 down and rotate the shade canopy 102 back to its default, horizontal position. The force is supplied by a compression gas spring assembly 701, as illustrated by FIG. 7A and FIG. 7B.

Compression Gas Spring

The compression gas spring 701 FIGS. 7A and 7B comprises three basic parts: a cylinder (or tube) 702, a piston 703, and a piston arm 704. The proximal end 706 of the piston arm 704 is secured to the bottom surface 711A of the piston 703, and the piston arm 704 traverses the bottom cap of 712B of the cylinder 702, with the distal end 704 of the piston arm 704 extending beyond the bottom cap 712B. The distal end 705 of the piston arm 704 terminates in the piston arm connector 713. The volume of the cylinder starting at the upper surface 711B of the to the top cap 712A comprises the compression chamber 707. The volume of the cylinder below the piston comprises a lubricant sink 710. With no external, upward force applied to the piston arm arrow 709, the piston is positioned in and lubricated by oil in the lubricant sink 710.
Upward, compressing force, arrow 709, on the piston arm 705 drives the piston upward, compressing the gas (commonly nitrogen gas) in the compression chamber 707; compare the relative position of the piston 703 in FIG. 7A versus FIG. 7B and the volume (reflected by the area) of the compression chamber 707 in FIGS. 7A and 7B. The compressed gas as illustrated in FIG. 7B is a source of potential (stored) energy. When the compression force, arrow 709, is terminated, stored energy represented by the compressed gas in the compression chamber 707 drives the piston downward, opposite to the direction of the arrow 709.
In one mode, the shade canopy is maintained in a horizontal orientation. The shade canopy may be temporarily rotated to an increased pitch orientation, for example, in response to an accumulation of snow, or other material or debris or comparable conditions under which temporary rotation may be favorable, if not necessary to remove the material. When the conditions subside (the snow melts or is removed), the shade canopy rotates back to is default, horizontal orientation.
The compression gas spring 701 FIG. 7A may function in connection with the wax piston assembly 601 (see FIG. 6A). In this case the force to rotate the shade canopy downward (elevate the rear the second fabric anchor extrusion 111) is generated through heat acting on the wax piston assembly 601 as previously described.
When the rear fabric anchor extrusion 111 moves upward in response to force transmitted through the wax piston assembly 601, the piston connecting cable 714 pulls the piston arm 704 upward thereby driving the piston 703 upward, thereby compressing the gas in the compression chamber 707. So long as the upward force transmitted by the piston pressure assembly 601 is maintained, the shade canopy 102 remains in its rotated orientation. Only in the absence of upward force transmitted through the piston pressure assembly 601 does the compression gas spring 701 affect the orientation of the shade assembly 102. The force (energy) of the compressed gas forces the piston 703 downward; the connecting cable 714 transmits this to the rear fabric anchor extrusion causing it to be lowered from its elevated orientation, and the shade canopy 102 to rotate to its default, horizontal orientation.
FIG. 8A illustrates the invention in which both pitch of the shade canopy and elevation of the modified mounting bracket can be manually controlled. In this configuration, the dove-tail mounting plate 430 is secured to the building/window frame as previously described. The modified carrier bracket 426 is further adapted to include a lift cable chase 835. Details of several modifications to create the lift cable are illustrated in FIG. 8B and discussed below.
For most installations, the louver shade assembly 101 is mounted on and secured to the face of a building 937A with the shade canopy 102 extending over a window 937B, and the central axle tube 112 positioned below the top line 937C of the window 937B. FIG. 9A illustrates a modification to this installation secured directly on the face of a wall.
The opposing faces of a vertical wall element 901A and 901B support the entire window structure 937B and 937C (glass, actual window frame, and related structures or hardware as understood by one skilled in the art). The wall elements 901A and 901B functionally provide the full support functions of the carrier bracket assembly 401. A wall mounted axle receiver 902 comprises a modification of the axle support ring 501. The members of a pair of wall mounted axle receivers 902A and 902B are secured on opposing faces of the wall elements 901A and 901B, most commonly in a recessed chamber 903 in each wall element.
The rod rib assemblies 201 positioned at the first and second ends 116A and 116B of the central axle tube 112 are moved inward to allow the first 116A and second 116B ends of the central tube axle 112 to engage the chase lumen 520 of each corresponding wall mounted axle receiver 902A and 902B.
The wall mounted axle receiver 902 functionally replaces the support axle ring 501. The wall mounted axle receiver 902 comprises a body plate 904 with a chase lumen 520 with a diameter 519. The interior surface 905 comprises a flange or alternatively a friction-reducing coating, such as, but not limited to nylon. The first 116A and second 116B ends of the central axle tube 112 rotatably engage the corresponding chase lumen 520 of one member of the pair of wall mounted axle receivers 902A or 902B. The members of the pair of wall mounting receivers 902A and 902B are anchored to the wall element, usually in a recessed chamber 903 in each wall element 901A and 901B, thereby supporting the central axle tube 112, shade canopy 102, and rod rib assembly 201. Anchor points 905 are manufactured in the body plate 904 adapted to the use of appropriate anchoring hardware as understood by one of average skill in the art. In addition, adjustable standoff lugs 906 extend from the inner face 907 of the body plate 904 to provide adjustment for proper spacing and clearance of the shade canopy from the building structures 437A.

Second Best Mode Canopy Tensioner

Increasingly, families are turning to home decks and patios for relaxation, entertainment, and recreation. Shade, to reduced glare, protection from harmful levels of sun exposure, and to cool an area, is an important aspect of any deck or patio design and use. Residential buildings-single family homes, multifamily condominium facilities, and apartment complexes frequently include a deck (or patio) as part of the structure. In some instances, the deck may be covered, but frequently it is not. Deck (or patio) areas around swimming pool areas are recognized as part of a landscape plan, and the need for shade is generally obvious. Many decks and patio in gardens and pool side settings are free-standing with respect to the residential structure and frequently are part of the pool installation. Most include a covered or shaded area.
The shade canopy 1000 illustrated in FIG. 10A comprises four major elements—the foundation anchor frame 1001, the rafter assembly 1101, the shade assembly 1201, and the tensioning unit 1209. Each of these elements comprises two or more units or parts, and the elements are physically/mechanically, as well as functionally connected to form the shade canopy. The tensioning unit 1209 connects the shade assembly 1201 to the support and rafter assembly 1101 and effectively includes parts of both the shade assembly 1201 and the rafter assembly 1101.
FIG. 10A provides a general over view of the shade canopy 1000. Relationships among the elements and structural details are provided in the following figures. In FIG. 10A, the shade fabric 1202 is cut away 1202A to provide a view of the parts of the foundation anchor frame 1001, the support and tensioning frame 1101, the shade element 1201, and general positioning of the pairs tensioning unit 1209 at opposite ends of each rafter 1102.
The foundation anchor frame 1001 comprises two pairs of vertical support corner posts 1002A and 1002B and a pair of headers 1021A and 1021B, the front and rear headers, respectively. The members of the first pair of support corner posts 1002A are the front corner posts which are shorter than the members of the second pair 1002B, the back corner posts. The front corner posts 1002A, by way of example, not of limitation, range in length (height) 1003A from 7 to 9 feet (approximately 2 to 3 m), and the length (height) 1003B of the back corner posts 1002B ranges from 8 to 10 feet (approximately 2.5 to 3.5 m). Corner posts are frequently fabricated from 2.75×2.75 inch (7×7 cm) aluminum tube that is readily available from a wide variety of manufacturers (such as Alcoa Co.). As used above, the back corner posts generally are closest to the building (when the deck is attached to a structure) and the front corner posts on the exterior edge of the deck.
The foundation anchor frame 1001 further comprises fixtures to attach/secure the corner posts to the deck or ground surface. The members of the pair of front corner posts 1002A may be secured to the deck surface by either of at least two types of connector devices. Commonly, the deck includes a front (and side) rails for safety as well as for aesthetic purposes. The front corner posts 1002A may be connected to the deck rail 1005 or surface of the deck 1007 with a rail anchor 1001A assembly comprising a railing plate 1004 with railing plate fasteners (screws) 1004A and a standard deck plate 1006, FIGS. 10B and 10C.
A railing plate 1004 is secured by screws 1004A to the deck rail 1005. A standard deck plate 1006 is positioned on the deck floor 1007 and aligned with the railing plate 1004 such that the front corner post 1002A is positioned in the lumen 1004B of the railing plate 1004 and extends downward through the lumen 1006C of the standard deck plate 1006, and the front corner posts 1002A extend upward at a right angle to both the deck floor 1007 and the deck railing 1005. The first edge 1004C defining and limiting the lumen 1004B of the railing plate 1004 is aligned flush with the first face 1005A of the railing 1005, and the first edge 1006D defining the lumen 1006C of the standard deck plate 1006 is aligned with the corresponding first edge of the lumen of the railing plate 1004C plate, such that the lumen of the deck plate 1004B is aligned with the lumen 1006C of the standard deck plate 1006 and both are aligned with the first face 1005A of the deck railing 1005.
The deck railing 1005 may include both a front rail and an end or side rail or rails. In such cases, three corner posts can be mounted as described above, with the provision that two are the length of the front corner posts 1002A and the third is the length of the back corner posts 1002B; the third corner post is a back corner post 1002B connected to the side or end rail.
Commonly, with shade canopy installations on decks with railings, only three of the corner posts, the two front corner posts 1002A and one of the two back corner posts 1002B can be secured using the rail deck anchor assembly 1001A. A free standing anchor is used to secure the final (back) corner post 1002B. The double layer anchor 1008 is such a free standing anchor and is appropriate to securely anchor the second, back anchor post 1002B to the deck or patio floor 1007. It may also be employed to anchor both back corner posts 1002B to the deck or patio floor 1007. This double layer anchor 1008 provides support that otherwise is provided to the corner posts by connection of the deck railing plate 1004 with the deck railing 1005.
Although other alternatives may be available, as one skilled in the art recognizes, for relatively small shade canopies, all four corner posts may be anchored to the deck or patio floor using double plate anchors 1008.
The double layer anchor 1008 comprises identical first 1009A and second 1009B double layer anchor plates; both anchor plates 1009A and 1009B comprise a lumen 1009C with dimensions to allow a front or back corner post 1002A or 1002B to traverse the plate. The outside dimensions of the corner posts are nominally equal to the dimension of the lumen 1009C, thereby ensuring a snug fit of the post in the lumen 1009C.
Effectively, the double layer anchor 1008 is assembled on the corner (generally back) post 1002B. The first double layer anchor plate 1009A is positioned on the corner post by sliding the corner post 1002A/B through the lumen 1009C of the corner post 1002A/B a distance from the distal end of the corner post 1002A/B slightly greater than the length of a spacer 1011.
A square tube tee-connector 1010 is positioned in the lumen 1016 of the spacer 1011. Note, generally the spacer in fabricated from the same material as the four corner posts 1002A/B; the square tube, tee-connector 1010 is held in the lumen 1016 of the spacer 1011 by the first and second double layer anchor plates 1009A and 1009B (FIG. 10D).
Two, opposing, connector chases 1014B traverse the length 1012 of the square tube, tee-connector 1010. These connector chases 1014B are aligned with the connector bore 1014A in the first double layer anchor plate 1009A. The second double layer anchor plate 1009B is positioned on the corner post 1002A/B parallel to the first double layer anchor plate 1009A, and connecting screws (or comparable fasteners) 1013 are inserted through each first connector bores 1014A in the first double layer anchor plate 1009A, traverse the corresponding connector chase 1014B and extend outward through the aligned second connector bores 1014C in the second double layer anchor plate 1009B. The corner post 1002A/B is raised to a vertical position and the screws 1013 tightened into the deck or patio floor 1007 to secure the corner post 1002A/B in a true vertical and parallel relationship with the two adjacent corner posts. As one skilled in the art recognizes, stability of the corner posts 1002A/B is increased with the length 1012 of the spacer 1011 and square tube, tee-connectors 110, and by the length 1017 of the double layer anchor plates 1009A and 1009B.
FIG. 10F illustrates an alternative to either the rail anchor 1001A or the double layer anchor 1008, the sleeve anchor, used mostly for lawn installations. The sleeve anchor 1018 comprises a corner post sleeve 1019 for each of from one to four corner posts. In practice, but not as an absolute requirement, if this alternative is elected, generally all four corner posts are secured by sleeve anchors 1018.
The alternative is relative simple, but care must be exercised in positioning the corner post sleeves 1019 for each corner post utilizing the sleeve anchor 1018 option.
The standard deck plate 1006 is secured to the deck floor 1007 by screws 1006A, FIG. 10B. First spacer elements 1006B are positioned on each of the four screws 1006A to separate (elevate) the standard deck plate 1006 from the deck floor 1007. As shown for the front corner post in FIG. 10B, the front corner post 1002A traverses the deck plate 1006 by its lumen 1006C. The same is true for the rear corner posts, not illustrated.
Each member of each pair of corner posts 1002A and 1002B is positioned in a corner post sleeve 1019. The dimensions of the lumen 1019A of the corner post sleeve 1019 are slightly larger than the corresponding outside dimension of the corner posts, thereby allowing the corner posts to be inserted into and held securely by the corner post sleeve 1019. The corner post sleeves 1019 are a uniform length 1020 for each hole 1019A in which a corner post sleeve 1019 is positioned; this varies by way of example, not of limitation, from 2.5 to 3.0 feet (0.7 to 1.0 m). Holes are excavated at each corner of the shade canopy 1000. Generally, there is no deck or patio floor, although the shade canopy may extend beyond the perimeter of a floor or deck surface 1007. A corner post sleeve 1019 is positioned in each hole 1019A such that the top edge 1021 of the corner post sleeve 1019 is level with the adjacent soil surface. The corresponding front 1002A or back 1002B corner post is inserted into the lumen 119A of the corner post sleeve 1019 the full length 1020 of the sleeve 1019. Each corner post 1002A or 1002B should be vertical and horizontally aligned at right angles to adjacent corner posts 1002A or 1002B and braced in that position as one of average skill in the art understands. The hole 1019A is back-filled with concrete to anchor and secure the corner post sleeve 1019 in position. As with the rail anchor 1001A and the double layer anchor 1008, the back corner posts 1002B are longer than the front corner posts 1002A. The overall length of the front and back corner posts should be adjusted uniformly to compensate for the depth 1020 each corner post is buried with the corner cost sleeve. The line between the top of the front corner posts 1002A and between the back corner posts 1002B should be effectively level to a horizontal plane.
Regardless of the method of anchoring or securing the corner posts 1002A and 1002B, the foundation anchor frame 1001 further comprises a front header 121A and a back header 121B. The front and back headers 1021A and 1021B, respectively, are manufactured from rectangular tube material 1×2 inches (2.5×5.0 cm) and may vary in length 1030 by way of example, not of limitation, from less than six feet to up to 24 feet (2 to 7 m). For headers longer than 12 feet (3.5 m), rectangular tube material 1×3 inches (2.5×7.5 cm) is preferred. The length of the header 1030 (FIG. 10A) is equal to the distance between a pair of front 1002A or back 1002B corner posts.
A header chase connector (rectangular tee-connector) 1022 is positioned in the lumen 1027 of each end of the front 1021A and back 1021B header. The rectangular tee-connector is available in two or more sizes to accommodate different dimensions of the front and back headers 1021A and 1021B, respectively. The outside dimensions of the header chase connector 1022, height 1028 and width 1029 are nominally equal to the corresponding dimensions of the lumen 1027 of the header 1021A and 1021B. The length 1030 of the header chase connector 1022 varies from 2 to 6 inches (5 to 15 cm). Each member of a parallel pair of threaded connector bolt chases 1022A traverses the length 1030 of the header chase connector 1022.
Each corner post/header connector assembly 1023 comprises a corner post cap 1024 with a corner post mounting eye 1025. The corner post mounting eye 1025 is attached to the corner post cap 1024 by a mounting eye bolt 1025A. Members of a pair of cap connector bolts 1024A traverse the corner post cap 1024, are aligned with one member of the pair of parallel cap bolt chases 1023E in the connector corner post chase block (square tee-connector) 1023A, and engage the threaded chase 1023E securing the corner post cap 1024 to the connector corner post chase block (square tee-connector) 1023A.
When the connector corner post chase block (square tee-connector) 1023A is positioned in the lumen 1026 of a corner post 1002A or 1002B each member of the pair of head connector bolts chase block chases 1023D is aligned with a corresponding header connector bolt chase 1022A. Each member of a pair of header connector bolts 1022B traverses a corner post 1002A or 1002B, and the aligned header connector bolt chase block chase 1023D, and engages the threaded header connector bolt chase 1022A. Tightening each header connector bolt 1022B secures the header 1021A or 1021B to the corresponding corner post 1002A or 1002B, and secures the corner post chase block 1025A in the lumen 1026 of the corner post 1002A or 1002B. The edge 1031 of the corner post cap 1024 is flush with the sides of the corner post 1002A or 1002B and the corner post cap 1024 rests on the end of the corner post 1002A or 1002B.
The rafter assembly 1101 (FIG. 10A and FIGS. 11A, B, C and D) comprise at least two, but more commonly four, or more rafters 1102A/B, depending on the length 1028 of the headers. The rafters 1102A/B are fabricated from 1×2 inch (2.5×5.0 cm) rectangular tube, preferably aluminum. For rafters longer than 12 feet (4 m) or for installations in which the shade fabric 1202 may be exposed to heavy loads of snow, or similar stresses, rafters 1×3 inch (2.5×7.5 cm) are preferred. Rafters are spaced 2 to 6 feet, preferably approximately 4 feet (0.75 to 2, preferably about 1.3 m) apart and span the distance between the front and back header 1021A and 1021B, respectively and extend as an over-hang 0.5 to 1.5 feet (15 to 45 cm) or more beyond the edge of each header 1021A/B.
The rafters 1102 are connected to the front and back headers 1021A/B, respectively, by a pair of metallic connector rods 1111A/B. The metallic connector rods 1111A/B extend the full length of the front and back header 1021A/B. The front metallic connector rod 1111A passes through the lumen 1025B of the rafter mounting eye 1025 connected to each corner post/header connector assembly 1023 and passes through the lumen 1125B of the eye of the header mounting eye 1125 (functionally the same as the rafter mounting eye, but positioned on the rafters, not on the corner post cap 1024. Each header mounting eye 1125 is connected by a header bolt 1125A that secures the header mounting eye 1125 to the top surface 1107 of a rafter 1102.
Each rafter 1102 has a thickness (height) 1128 and a width 1129. The thickness, (height) by way of illustration, not limitation, varies from 2 to 3 inches (5.0 to 7.5 cm) and the width 1 inch (2.5 cm). Rafters are fabricated preferably from aluminum tubing. A connector rod chase 1110 is positioned at a common distance 1109 from each end of each rafter 1102. This common distance 1109 is the same as the length 1109 of the over-hang of the rafter from the front and back headers 1021A and 1021B, respectively, and is at the vertical (thickness or height) mid-point 1130 of the rafter.
Generally, rafters are spaced 2 to 4-6 feet (0.71 to 1.7 m) apart. Rarely is the distance between the pair of front 1002A or the pair of back 1002B corner posts, or the length of the header 1030, less than 6 feet 2 m); thus, in addition to rafters 1102 positioned on the header and contacting the edge 1031 of the respective corner post caps 1024, a shade canopy 1000 with a header of 6 feet (2 m) in width would have a rafter at each corner post and one in the middle, 3 feet (1 m) from the two end rafters, and a shade with a header over 8 feet (2.4 m) would have at least three rafters, with the middle (third) rafter positioned 4 feet (1.2 m) from either corner post rafters. A shade with a header width of 12 feet (3.7 m) would have four rafters two end rafters and two additional rafters one spaced 4 feet (1.2 m) from one end rafter and the other spaced the same distance from the second end, with 4 feet (1.2 m) separating the two additional rafters along the headers. For any installation, a minimum of two rafters is required.
A header mounting eye 1125 is bolted to the header for each rafter, except for the two rafters positioned at the corner posts wherein a corner post mounting eye 1025 is secured to the corner post cap 1024 and serves the same function as the header mounting eye 1125.
The metallic connector rod 1111 traverses the lumen of a corner post mounting eye 1025, continues through the connector rod chase 1110 of a rafter, extends to a second header mounting eye 1125 and continues ultimately to the rafter mounting eye at the second front (or back) corner post cap. Each end of a metallic connector rod 1111 is secured by a cap or comparable means to prevent lateral movement of the metallic connecting rod 1111. Note, the rafters are connected to the header by the metallic connector rod 1111; a after can be moved laterally along the header (usually limited on one side by a header mounting eye 1125 as illustrated in FIG. 12B, for example; however, one skilled in the art understands that the several header mounting eyes 1125 may be spaced such that rafters are equally spaced between the header mounting eyes 1125, or in the alternative so that a header mounting eye 1125 is positioned against a rafter. It is understood that a header mounting eye may also be positioned against a rafter 1102. In an additional alternative, pairs of header mounting eyes 1125 may be positioned on opposite sides of each rafter to minimize lateral movement of the rafters. Exercise of these options is a matter of design and specific installation objectives and limitations and all such alternatives are anticipated by the invention.
The shade element 1201 comprises the shade fabric 1202, front and back keder rails 1204A and 1204B, respectively, (FIG. 10A) and the shade anchor assembly 1205, FIGS. 12A and B. The front 1204A and back 1204B keder rails are attached to the front and back edges 1207A and 1207B, respectively, of the shade fabric 1202. The length of the keder rail 1206 is the same as the width 1208 of the shade fabric, which length is greater than the length of the header 1030, including the corner posts 1002A/B to which the header is connected. The keder rail is commonly fabricated as an aluminum extrusion. One skilled in the art recognizes that the term keder rail as used herein is used in a general sense and encompasses a wide array of extrusions that may be utilized to anchor and secure the front 1207A and back 1207B edges of shade fabric 1202, all of which extrusions are anticipated herein.
With the shade fabric 1202 secured along its front edge 1207A and its back edge 1207B by the corresponding front 1204A and back 1204B keder rails, fabric anchor assembly 1205 connects the shade assembly 1201 to the support frame 1101.
A fabric anchor assembly 1205 is positioned at the front and back ends 1102A and 1102B of each rafter 1102. The fabric anchor assembly 1205 comprises a tensioning unit 1209 wherein said tensioning unit 1209 comprises a threaded, metallic tension rod 1210 and a threaded tensioning nut 1211. The distal end 1212 of the threaded, metallic tension rod 1210 comprises a shade bolt connector eye 1213A and the proximal end 12138 is adapted to slidably engage a first or second tension rod chase 1216A/B. The threaded tensioning nut 1211 engages the threaded, metallic tension rod 1210, and rotating the tensioning nut 1211 moves it along the threaded, metallic tension rod, thereby extending the threaded, metallic tensioning rod 1210 outward, with respect to the end of the rafter 1102
A tension rod chase block 1214 is positioned in the lumen 1104 of each end of each rafter 1102. The outside dimensions of the tension rod chase block 1214 are nominally the same as the as the dimensions describing and limiting the lumen 1104 of the rafters 1102. The minimum length of the tension rod chase block 1215 equals the distance 1109 from the end of a rafter to the point at which the connector rod 1111 traverses the rafter and prevents she tension rod chase block being inserted too far into the lumen 1104 of the rafter 1102. The length of the tension rod chase block 1215 may be increased without altering or expanding the scope or purpose of the invention and such increase is anticipated. Bolt 1219 secures the tension rod chase block 1214 in position in the rafter 1102.
A first 1216A and a second 1216B tension rod chase traverses the length 1215 of the tension rod chase block 1214. The diameter of each tension rod chase 1216A/B is nominally equal to the diameter of the threaded, metallic, tension rod 1210, such that the threaded, metallic tension rod 1210 fits snugly in the chase 1216A/B but can slidably move through the tension rod chase 1216A/B. The first 1216A and the second 1216B tension rod chase are positioned respectively at a common distance from the top 1218A of the tension rod chase block 1214 and the bottom 1218B of the tension rod chase block 1214 such that the rafters may be inverted and either tension rod chase may be designated and function as the top chase. This spacing of the tension rod chases 1216A and 1216B also allows a bolt 1219 to traverse the rafter and to secure the tension rod chase block 1214 in the lumen 1104.
The shade assembly 1201 element is connected to the shade anchor assembly 1205 by one end of a keder connector bolt 1220, that engages and is secured to the keder bolt connector eye 1213. The opposite end of the keder connector bolt 1220, traverses the keder rail from its under side 1221 via keder connector hole 1223 that traverses the keder rail and is secured by a cap nut 1222.
The face 1211A of a tensioning nut 1211 is separated from the face 1214A of the tension rod face block 1214 by a smooth surfaced face plate 1211B. When the tensioning nut 1211 is rotated in a direction, usually clock-wise, so as to exert pressure (force) on the face 1214A of the tension rod face block 1214, the threaded, metallic tension rod 1210 is forced outward and tension is exerted on the shade fabric, pulling it to a uniformly taut condition. Rotating the tensioning nut 1211 in the opposite direction releases the tension and introduces slack to the shad fabric. As one skilled in the art recognizes and understands, to achieve the uniformly, smooth, taut surface of the fabric shade, each wing nut must be individually adjusted.
These and other modifications and variations of the present invention may be practiced by those skilled in the art, without departing from spirit and scope of the present invention. In addition, it is understood that the aspects of the various embodiments may be interchanged in whole or in part; those skilled in the art will appreciate that the foregoing descriptions are by way of example and are as limitations in any way. Therefore, the spirit and scope of the appended claims should not be limited to the descriptions of the preferred versions contained therein.

Claims

I claim:

1. A canopy tensioner adapted for use with a louver assembly, wherein said canopy tensioner is a member of at least one pair of identical canopy tensioners, and wherein said canopy tensioner comprises a tensioner body, wherein said tensioner body comprises an arm connecting chase that traverses the longitudinal dimension of said tensioner body and further wherein a threaded end of a rib arm unit slidably engages said arm connecting chase, and further wherein a threaded adjustment nut functionally engages said threaded end of said rib arm unit, and further, wherein said adjustment nut contacts the inner face of said tensioner body and wherein said said tensioner body is physically secured to an anchor sleeve extrusion; and finally, wherein said canopy tensioner comprises a camber cable chase, wherein said camber cable chase traverses said body of said canopy tensioner and is parallel to and positioned below said arm connecting chase.

2. A shade canopy tensioning device comprising a threaded, metallic rod and a tensioning nut, wherein the distal end of said threaded, metallic tensioning rod comprises a keder bolt connector eye, and wherein said shade canopy device further comprises a tension rod chase block, wherein said tension rod chase block comprises a first and a second tension rod chase, wherein said first and said second tension rod chases traverse the length of said tension rod chase block, and further wherein the proximal end of said threaded, metallic tensioning rod is adapted slidably to engage a tensioning rod chase; and further wherein said shade canopy tensioning device comprises a keder connector bolt, and wherein tensioning nut threadedly engages said threaded, metallic tensioning rod, and wherein said threaded, metallic tensioning rod slidably engages and is positioned in said first tensioning rod chase, and wherein said keder connector bolt mechanically engages and is connected to said keder bolt connector eye.

3. The shade canopy tensioning device of claim 2 wherein a tensioning rod chase block is positioned in the lumen of each end of at least two rafters, wherein the outside dimensions of said tension rod chase block are functionally equal to the inside dimensions of said lumen of each of said at least two rafters, such that said tension rod chase block is held securely in said lumen of each of said at least two rafters and further wherein a the members of a pair of bolt traverse each of said at least two rafters to further secure said tension rod chase block in said lumen; and further wherein a the members of a pair of metallic, rafter connector rods traverse and connect said at least two rafters and wherein said at least two rafters are connected to and supported by a front and a back header.

4. The shade canopy tensioning element of claim 3, wherein the front header is connected to and supported by a pair of front corner posts and wherein the back headed is supported by a pair of back corner posts.

5. The shade canopy tensioning element of claim 4, wherein the front corner posts and anchored by a rail anchor.

6. The shade canopy tensioning element of claim 5, wherein at least on of the back corner posts is anchored by a double layer anchor.

7. The shade canopy tensioning element of claim 5, wherein the corner posts are anchored by a sleeve anchor.