SUNSHADE SYSTEM USING LINEAR ACTUATORS AND FREE-FLOATING CANOPY

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/087,536, filed Oct. 5, 2020, the entire content of which is herein incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002](NOT APPLICABLE)

BACKGROUND

[0003]The invention relates to a shade system for a marine vessel or the like and, more particularly, to a lower cost single stage automated shade system.

[0004]Existing shade systems with multiple linear actuators are not able to accommodate relative motion between the various actuators. As such, these systems tend to incorporate advanced electronic control systems (e.g., PCBs) to ensure that the actuators remain aligned. Furthermore, such systems tend to rely on PCBs or the like to detect obstructions through monitoring of current draw. These systems tend to be expensive and have multiple potential failure points that can affect system reliability.

[0005]During high-speed transport, shade systems are typically stowed to avoid damage to the shade system and also prevent wind effects on the vessel. External storage boots have been used to cover stowed shade systems. An external storage boot is a separate piece of fabric with attachment structures. These components are wrapped around slack canvas and secured for system transport. Issues with these systems include the external boot being lost, the need to store the boot when the system is being utilized, costs associated with additional components, and difficulty installing the external boot (requiring multi-person operation in many cases).

[0006]Roller assemblies are spring-loaded or gear-driven structures that spiral wind the canvas for storage during retraction of the system. These assemblies are labor intensive during manufacture and have multiple potential points of failure during usage. They also tend to be heavy, which can be problematic on small marine vessels with center of gravity concerns.

[0007]It may be desirable to attach tubular constructs of a shade system to various existing mounting structures on the vessel. Existing solutions have singular sizing constraints, which means that a specific product is required for each mounting configuration (e.g., different diameter tube, tubular vs flat, etc.). Existing solutions lack adjustability and often require significant effort be devoted to measuring and marking prior to installations. Moreover, installation of these systems is generally a multi-person job.

[0008]Existing shade systems typically include telescoping or scissor-style systems to extend and retract a canvas shade. Existing systems, however, only allow for canvas tensioning in two directions. Furthermore, these systems require fixed mounting locations. This creates difficulties for both OEM and A/M installations requiring precise tolerancing and acquisition of specific components.

[0009]It may be desirable to attach a shade system to existing structure(s) on a vessel such as T-tops, radar arches and the like. Current systems, however, are typically assembled to the existing structure via the use of various clamps and mounting hardware. This increases system cost and labor requirements and allows for systems to be installed such that the actuators are misaligned, which can degrade system performance.

SUMMARY

[0010]It would be desirable to provide an automated shade system that overcomes the drawbacks noted above with existing systems.

[0011]In some embodiments, the system of the described embodiments is comprised of two motor driven linear actuators, a free-floating canvas, specialized mounting componentry, a wire harness, and a singular switch to actuate the system. There is no circuit board or chip controlling the system. The system is able to slightly “rack” if the actuators deploy or retract at different speeds. The actuators are self-aligning at the full deployment position and full retraction position.

[0012]A specialized canvas assembly may contain features allowing the canvas to wrap around itself, securing the fabric for high speed transport. Specifically, the canvas may incorporate a linear portion of fabric that is able to compress into an “accordion” like structure. There is a separate portion of the canvas comprised of a loop possessing opposing male and female attachment structures (e.g., zippers, hook and loop fasteners, etc.). When the shade system is extended, the entire canvas is pulled taught against the framework members of the shade system. When the system is retracted, the loop section of the canvas is able to be pulled around the “accordion” section of the canvas and is secured by the attachment structures. This simulates a storage boot and allows for high speed transport of the system while preventing the canvas from flapping or catching wind.

[0013]An attachment device may be provided to attach tubular constructs of the shade system to various existing mounting structures on the vessel. In some embodiments, the attachment device is a clamp with a specialized “S” mounting structure, two clamping components, and hardware including bolts and nuts. The assembly allows for tubular structures (e.g., linear actuators) to be attached to other tubular structures (e.g., T-top frames) with a variety of tubing outer diameters/shapes and/or to attach the system to flat frameworks (e.g., hard tops).

[0014]In some embodiments, a telescoping awning system includes nested crossbars and a specialized canvas tensioning system to accommodate multiple overall system widths as determined by the actuator mounting location. The nested crossbars allow for the canvas support structure to adapt to variable mounting locations. The canvas tensioning system is comprised of webbing members rigidly affixed to the primary canvas and cam lock capable sliding members that ride on the actuator extension arms. The webbing is tightened through the cam lock sliders allowing for a canvas with a fixed primary width to adapt to multiple actuator mounting widths.

[0015]In some embodiments, a telescoping shade system installs the stationary components of the actuators directly within the tubular framework of a T-top structure. The system allows for reduced cost by removing external mounting features, and direct integration into the T-top frame improves the retention and sturdiness of the system.

[0016]The shade system may be a telescoping linear actuator system with two linear actuators attached via an extensible crossbar such that the attachment points of the crossbar are able to pivot, allowing for relative motion between the two actuators. Furthermore, swivel eye ends on the actuators are frictionally attached via controlled crimp features that allow for rotary motion only when the actuators reach their end of travel. The actuators possess current limiting devices that limit the total load output capability of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]These and other aspects and advantages will be described in detail with reference to the accompanying drawings, in which:

[0018]FIG. 1 shows the shade system in a deployed position;

[0019]FIG. 2 shows the shade system in a retracted position;

[0020]FIG. 3 is a close-up view of the rings and strap configuration connecting the canvas to the actuators;

[0021]FIGS. 4-6 show an embodiment including an integrated boot;

[0022]FIGS. 7-10 show mounting clips for attaching tubular constructs to a mounting structure;

[0023]FIGS. 11 and 12 show a variable width telescoping awning system with provisions for tensioning the canvas;

[0024]FIG. 13 shows an exemplary shade system integrated into a T-top structure;

[0025]FIGS. 14 and 15 show an extensible crossbar with swivel eye ends; and

[0026]FIG. 16 is a close-up view of an actuator swivel eye end.

DETAILED DESCRIPTION

[0027]With reference to FIGS. 1 and 2, a shade system 10 is configured as a single stage automated shade system intended to target lower-cost boats in the recreational marine industry. The system 10 includes a first linear actuator 12 attachable to a structure S (e.g., a T-top, radar arch, etc.). A second linear actuator 14 is spaced from the first linear actuator 12 and is similarly attachable to the structure S. In some embodiments, the first and second linear actuators 12, 14 are motor driven and are displaceable between a retracted position (FIG. 2) and an extended position (FIG. 1). The shade system 10 also includes a stationary crossbar 11 connected between a proximal end of linear actuators 12, 14 and a driven crossbar 13 connected between a distal end of linear actuators 12, 14. See FIG. 4.

[0028]A canvas 16 is connected between the first and second linear actuators 12, 14. The canvas 16 is fixed to distal ends and to proximal ends of the first and second linear actuators 12, 14 and is free-floating between the distal and proximal ends. Using ring connectors as shown in FIG. 3, the canvas 16 is configured to retract into the accordion configuration shown in FIG. 2 when the first and second linear actuators 12, 14 are displaced from the extended position to the retracted position.

[0029]In some embodiments, the motor driven first and second linear actuators 12, 14 are operable via a single switch. There is no circuit board or chip controlling the system. Rather, the system is able to slightly “rack” if the actuators 12, 14 deploy or retract at different speeds. The actuators 12, 14 are self-aligning at the fully extended position and the fully retracted position.

[0030]With continued reference to FIG. 3, in some embodiments, the canvas 16 is connected to the actuators 12, 14 via a ring 18 including a clip 20 through which an adjustable strap 22 is secured. The strap 22 is sewn or otherwise connected to the canvas and subsequently extends through the clip 20. The clip 20 includes a cam lock portion that enables the strap 22 to tension the canvas 16. The rings 18 fit loosely over the actuators 12, 14 so that the canvas is free-floating between the distal and proximal ends of the actuators 12, 14.

[0031]With reference to FIGS. 4-6, the canvas 16 may be provided with features allowing a portion of the canvas 16 to wrap around itself, securing the fabric for high-speed transport. In this context, the canvas 16 may be provided with a shade section 16a and a cover section 16b connected to the shade section 16a. Cover section 16b is a circular piece of canvas fabric for loosely encompassing the stationary crossbar 11. In the extended position as shown in FIG. 4, the cover section 16b may be extended over the cabin area or the like and contribute to the shading function of the canvas 16. In the extended position, the stationary crossbar 11 engages an exterior end of the cover section 16b to pull the canvas taut. When the canvas 16 is retracted into the accordion configuration (see FIGS. 2 and 5), the cover section 16b is not part of the accordion configuration and can be pulled around the accordion configuration of the canvas 16 and secured by suitable attachment structures or connectors 24. In the retracted position, the cover section 16b may be pulled so that the stationary crossbar 11 engages an interior end of the cover section to allow the exterior end of the cover section to wrap around the accordion configuration. The cover section 16b may be provided with the connectors 24 at ends thereof. Exemplary connectors 24 may include a zipper as shown in FIG. 5, a hook and loop fastener, snaps, etc. As shown in FIG. 6, the connectors 24 are provided at both interior and exterior ends of the cover section 16b, and when the canvas 16 is retracted into the accordion configuration, the cover section 16b is looped over the accordion-configured shade section 16a to engage the connectors 24. The cover section 16b simulates a storage boot and allows for high-speed transport of the system while preventing the canvas from flapping or catching wind.

[0032]The integrated boot canvas via the cover section 16b is a low-cost lightweight method of storing canvas when the shade system is not in use. The integral nature of the cover section 16b ensures that the boot functionality cannot be misplaced. Furthermore, the system is easily deployed by a single individual.

[0033]FIGS. 7-10 show an exemplary clip 26 for attaching tubular constructs to an existing mounting structure. The clip 26 is provided with an S-shaped mounting structure, two clamping components, and hardware including bolts and nuts. The clip 26 allows for tubular structures (e.g., linear actuators) to be attached to other tubular structures (e.g., T-top frames) with a variety of tubing outer diameters or shapes and/or to attach the shade system to flat frameworks (e.g., hard tops).

[0034]The clips 26 allow for a single product to cover nearly any conceivable installation scenario. Additionally, the system inherently includes adjustability to allow for rapid installation. The clips 26 are also readily installed by a single person, as the S-shape of the clip 26 allows for the top clamping component to balance on an upper tubular structure without user support. The clips 26 can accommodate any size and shape of canopy frame. FIG. 10 shows the clips supporting one of the linear actuators 12, 14 of the shade system 10.

[0035]FIGS. 11 and 12 show a variation including a variable width telescoping awning system with a specialized canvas tensioning system. The telescoping awning system includes nested crossbars 28 and a specialized canvas tensioning system to accommodate multiple overall system widths as determined by actuator mounting locations allowing for four directions of canvas tension. The nested crossbars 28 allow for the canvas support structure to adapt to variable mounting locations.

[0036]The canvas tensioning system is comprised of webbing members 30 rigidly affixed to the canvas 16 and cam lock capable sliding members 32 that ride on extension arms of the actuators 12, 14. The cam lock sliding members 32 slide on the actuators 12, 14 with a small amount of clearance to allow for the sliding action. The webbing 30 is tightened through the cam lock sliding members 32, allowing for a canvas with a fixed primary width to adapt to multiple actuator mounting widths.

[0037]The configuration shown in FIGS. 11 and 12 allows for reduced complexity by providing a single part to accommodate multiple installations. The adjustability of the system reduces the need for precise tolerancing and allows for the system to operate with less electrical power. The cam lock sliding members 32 allow for four direction tensioning of canvas and hands-free stowage of the system during retraction.

[0038]FIG. 13 shows a variation with the shade system incorporated into the tubular framework TF of a T-top structure TS. The actuators 12′, 14′ include a stationary component and a movable component. The stationary components of the actuators 12′, 14′ are installed directly within the tubular framework TF of the T-top structure TS. The illustrated system allows for reduced cost by removing external mounting features. Additionally, the direct integration into the T-top structure TS improves retention and sturdiness of the system.

[0039]FIGS. 14-16 show a self-aligning load limiting linear actuator system. The linear actuators in this embodiment are attached via an extensible crossbar 34 such that the attachment points of the crossbar 34 are able to pivot, allowing for relative motion between the two actuators. Canvas 16 is generally attached to and travels with extensible crossbar 34, but is spaced from the extensible crossbar in FIGS. 14 and 15 for clarity. Swivel eye ends 36 on the actuators are frictionally attached via controlled crimp features that allow for rotary motion only when the actuators reach their end of travel. The swivel eye ends 36 are capable of rotation if needed. During normal operation, the friction between the swivel eye ends 36 and the extensible crossbar 34 is greater than the friction between the lead screw and nut. At end of travel, the lead screw and nut become locked together, but the motor is still attempting to rotate. In this instance, the swivel eye ends 36 become stationary, and the tube is able to begin rotating. The benefit is that the motor does not go into a stall condition. In this context, the actuators possess current limiting devices that limit the total load output capability of the system.

[0040]The construction allows for linear actuator systems to operate without the need for PCB control. This vastly simplifies the system and reduces costs. The friction eye end mechanisms allow for linear load control via mechanical means. This increases safety by allowing for inherent current limiting and by limiting linear load capability in the event that something becomes entangled in the system during switch operated movement.

[0041]While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.