WO2001033000A1

WO2001033000A1 - Canopy shelter with integral lighting and octagon-shaped extrusion posts for support of the shelter

Info

Publication number: WO2001033000A1
Application number: PCT/US2000/028867
Authority: WO
Inventors: Stephen George Kieffer
Original assignee: Kieffer & Co., Inc.
Priority date: 1999-11-01
Filing date: 2000-10-31
Publication date: 2001-05-10
Also published as: CA2389254A1; AU1336101A

Abstract

The present invention is directed to a canopy shelter which includes first and second extrusion posts (14), a support beam (10) interconnecting the first and second posts (14), a plurality of rafters (8) mounted on the support beam (10) and at least one roof panel (6) connected to the rafters (8). The support beam (10) includes at least one lighting member (2) connected thereto for lighting an area located beneath the roof panel (6). The support beam (10) is positioned either beneath the center portion of the roof panel (6) or between the center portion and an edge portion of the roof panel (6), as desired.

Description

Canopy Shelter With Integral Lighting And Octagon-shaped Extrusion Posts for Support of the Shelter

The present application is based upon and claims priority upon provisional Application Serial No. 60/162,884, filed November 1, 1999.

The present invention is directed to a canopy shelter with integral lighting which includes prefabricated roof panels attached to purlins which are connectable to standardized prefabricated rafter sections, the rafter sections being cornectable to a structural beam with lighting members integrated into the beam so as to provide reflective lighting off the roof of the roof panels and/or downwardly diverted lighting from the beam. The light beam is connectable to structural post fabrications with integral lighting permeating light from opposite sides of the post wherein the posts are extrudible members of a substantially octagon-shaped section with formed hollow interior portions. The shelter is therefore designed for rapid, easy field assembly of the roof panels, rafters, light beam and post and insulation thereof without the necessity of heavy lifting equipment, fabrication equipment or complex tools while withstanding environmental loads, such as wind and snow.

BACKGROUND OF THE INVENTION

The present invention relates generally to permanently installable canopy shells which are capable of protecting people and/or equipment from environmental conditions such as rain and snow.

Common uses for permanent canopy shelters include shelters for bus stops, park and trail rest stations, automatic teller machines, and other fixed activities and services needing to protect people and equipment from the elements. Lighting is often needed for illumination of the activities conducted under the canopy shelter with improved night time safety. However, lighting is not always provided, thus necessitating additional field fabrications and electrical work. Such canopy shelters are normally either field fabricated, or large bulk units are required which are expensive to transport and require heavy lifting equipment or complex tools for assembly and insulation. In addition, moving such canopy shelters to a new location is often difficult or impossible.

Examples of previously utilized canopies are U.S. Patent 4,941,500 which discloses a knock down canopy shelter having a frame of telescopic poles and arch assemblies with the latter being joined at an apex of the shelter by insertion into a central connector. The canopy is fitted to the frame in a snug manner and straps are utilized to secure the corners of the canopy to each arch assembly in order to facilitate canopy attachment to the frame, the disclosure of which is herein incorporated by reference. Another known canopy design is that shown in U.S. Patent 928,495 which provides a canopy with means whereby the same may be raised and lowered to a desired elevation and means are also provided to secure the same to other structural elements, such as machines. The disclosure of U.S. patent 928,495 is also incorporated herein by reference.

SUMMARY OF THE INVENTION An object of the present invention is to provide a complete canopy shelter with lighting, the shelter being formed of light weight modular components including roof panels, rafters, support beams and posts and which are easily connected to one another in field assembly and installation. The integral lighting provides illumination of an area under the canopy as well as within an area extending beyond the footprint of the canopy shelter. The light weight modular design provides for compact economical shipment.

Further objects of the present invention are to provide roof panels formed of metal or polymeric roofing material, which simultaneously provide structural integration and which protect individuals from the elements. The roofing materials may consist of roof panels which are fabricated and attached to the metal purlins provided on the rafter so as to provide additional structural support. The number of purlins are variable, as are the number of rafter members utilized. Each group panel forms a portion of a completed roof. The type of metal used in the shape of the roofing can vary to meet engineering or aesthetic requirements. The purlins are pre-fabricated for attachment to the rafters and the roof panels are both light in weight and easily liftable onto the rafters.

A further object of the present invention is to provide an extruded unequaled-sided octagon shape post used to provide structural strength substantially equivalent to that of a square-shaped posted cross section while providing the pleasing appearance of an eight-sided shape. A further object is to provide the post with corners which are formed with a slight radius to improve adhesion of paints to the surface which is often difficult to obtain at sharp corners and to further enhance the appearance of the post. While the extrusion is used as a structural element of aluminum fabrications, such are normally intended to be visible after completion of the fabrication.

A further object of the present invention is to provide a semi-octagon extrusion so as to permit two extrusion pieces to be connected by a flat aluminum sheet or a plate piece so as to provide a smooth outer surface.

An additional object of the present invention is to provide an extruded metal post with alternating sections of identical length but wherein portion as defining each diagonal corner are located at a position spaced one-sixth of the overall width of the shape inwardly from each corner.

A further object of the present invention is to provide a post designed as a component for use in the fabrication of an eight-sided shaped post having two extrusion pieces connected by flat sheets or plates.

BRIEF DESCRIPTION OF THE DRAWINGS

Various objects features and attendant advantages of the present invention can be more fully appreciated by reference to the attached figures, wherein:

Figure 1 is a perspective view of a canopy shelter in accordance with the present invention;

Figure 2 is a top, front and right side perspective view thereof showing a portion of the roof removed from the shelter;

Figure 3 is a bottom, front and right side perspective view thereof on an enlarged scale;

Figure 4 is a right side elevational view thereof;

Figure 5 is a left side elevational view thereof;

Figure 6 is a top plan view thereof;

Figure 7 is a bottom plan view thereof;

Figure 8 is a top and right side perspective view of a second embodiment thereof;

Figure 9 is a front elevational view thereof;

Figure 10 is a rear elevational view thereof;

Figure 11 is a right side elevational view thereof; Figure 12 is a left side elevational view thereof;

Figure 13 is a top plan view thereof;

Figure 14 is a bottom plan view thereof;

Figure 15 is a top and right front perspective view of a cross-sectional portion of the post which can be utilized in a first and second embodiments of the present invention discussed herein above.

Figure 16 is a right side elevational view thereof;

Figure 17 is a top plan view thereof;

Figure 18 is a bottom plan view thereof;

Figure 19 is a front elevational view thereof, the rear elevational view being a mirror image of the front view shown.

Figure 20 is a top, front and right side perspective view of a fourth embodiment of the present invention showing a portion of a extrudible post;

Figure 21 is a front elevational view thereof;

Figure 22 is a top plan view thereof;

Figure 23 is a bottom plan view thereof;

Figure 24 is a right side elevational view thereof;

Figure 25 is a left side elevational view thereof;

Figure 26 shows the embodiment of Figure 20 with all components thereof illustrated in an exploded manner;

Figure 27 is a front elevational view thereof when assembled;

Figure 28 is a top, front and right side perspective view thereof when assembled;

Figure 29 is a cross-sectional view of a portion of the embodiment shown in Figure 28; and

Figure 30 is a cross-sectional view showing an additional embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to Figures 1-14, there are shown a complete canopy shelter 1 with lighting members 2,2 composed of light weight modular components 4 as well as roof panels 6, rafters 8, support beam 10, purlins 12 and posts 14,14, which are easily connected to another during field assembly and installation. The integral lighting 2 provides illumination of the area under the canopy shelter as well as within an area extending around the footprint of the canopy shelter. The lightweight modular design provides for compact economical shipment.

With reference to the drawings, it is noted that the roof panels 6,6 comprise metal or a polymeric roofing material, for example, which simultaneously provides structural integration and protection from the elements, the panels being fabricated and attached to the metal purlins 12 which provide additional structural support for the roof. The number of purlins 12 utilized can vary and each roof panel 6 forms a portion of the completed roof. The material type and shape of the roofing can vary to meet engineering or aesthetic requirements. The purlins are prefabricated for attachment to the rafters 8,8 and the roof panels 6,6 are both light in weight and easily lifted onto the rafters 8 so as to be secured by conventional securing members such as bolts, screws or other members.

The rafters 8 comprise prefabricated mounting units which support the roof panels 6,6 and attach to a laterally extending beam having lighting members positioned therein. The rafters 8 support the roof panel 6,6 and transfer environmental loads from the roof to the support beam 10. The rafters 8 include provisions for easy replacement and attachment of the roof panels, the rafters being of lightweight material for easy lifting onto the light beam position. Positioning of the rafters on the light beam can vary, as can the number of rafters utilized. As noted, the rafters comprises A-shaped frame members which are substantially identical in terms of size, shape and dimensioning.

The support beam 10 includes the above-noted lighting members and comprises a prefabricated metal unit includes structural support for the roof panel/rafter system and transfers environmental loads to the posts 14,14. A light beam 22 includes integral lighting which provide illumination in an upward direction for reflecting off the other side of the roof panels as well as light emitting downward from the beam 22. The light beam 22 includes connecting members for each attachment of the rafters thereto. The light beam 22 includes provision for rapid attachment and electrical connections to the posts utilizing conventional electrical wiring, sockets and related elements for electrical connection to a power supplier, such as an underground electrical outlet. The light beam is light in weight and is easily liftable onto the posts 14,14. A lighting lens 30 is located on the underside portion of the light beam and can vary in shape and composition to change the light diffusion pattern or provide appropriate space for commercial identification or advertising.

The posts 14,14 comprise prefabricated metal units which provide structural support for the light beam 22, rafters 24 and roof panel assembly. The posts 14,14 include integral lighting 26 within frames 28 which provides illumination of the area under the canopy as well as beyond the extent of the canopy shelter for safety and visibility and can also be used to display advertising or other information. The posts 14,14 include the provision for easy attachment and electrical connection of the light beam 22. In commercial applications, the lighting lens 30 can also provide space for illuminated advertising. Details of the design of the post can vary in order to accomplish variations in size and width of the panels incorporated into the post fabrication.

Important features of the canopy shelter include the modular design of all major fabricated components to provide for easy handling and installation, as well as condensed packing capabilities for shipment, integration of the lighting into the structural component and the provision for lighting under the canopy shelter as well as in the surrounding area. The use of exposed structural components creates a visually appealing canopy shelter and the modular design and ease of assembly of these components enables disassembly and reasonably or for repair of the canopy shelter when necessary.

As can be appreciated from the view shown in Figures 1 -7, the post can be positioned so as to be substantially aligned with the longitudinal axis of the roof. However, as described below, the spacing between the posts and the location of the posts with respect to the roof can vary depending upon the design required and the location selected for shelter.

The embodiment shown in Figures 8-1 1 shows the utilization of spacing between the posts 14,14. while being substantially centrally located underneath the roof 6 whereas the embodiment shown in Figures 12-14 properly demonstrate that the post can be longitudinally offset towards one edge of the roof so as to provide an overhang such as. for example, where space is necessary to permit a vehicle or other item to pass beneath the overhang portion of the roof in a convenient manner.

Considering next then the embodiment of the octopost extrusion shown in Figures 15- 19 which can be used for the posts 14,14 in Figures 1-14, it can be understood that the octagon shaped extrusion comprises an unequal sided octagon designed to provide structural strength which is substantially square-shaped in cross-section while providing a visually pleasing appearance of an eight-sided shape. Thus, the post 14 formed by use of this embodiment includes an aluminum extruded octopost 100 having sides 102 of shorter length, sides 104 of longer length and corner members 106 interconnecting sides 102 and 104. Corner members 106 are formed with flat radium edges to further enhance the appearance thereof and to improve adhesion of paint thereto when painting is necessary. The aluminum extrusion octopost 100 thus provides for prefabricated posts which are easily substitutable, can be mass produced, and can be easily assembled to transport to the field. It is further noted that the corner members 108 are also formed with a slight radius to enhance the appearance thereof. While aluminum extrusion is possible, it is fairly understood that other types of extrusions, including other metals and/or plastics, for example, can be utilized. More particularly, any type of extrudible material of sufficient strength and durability can be utilized to form the posts 14,14.

The next embodiment of the present invention is as shown in Figures 20-28 wherein an aluminum extrusion 200 is designed as a component for use in the fabrication of an eight- sided shape member consisting of two extrusion pieces 204, 204 connected by a flat aluminum sheet or plate piece 206 of varying dimension which are attached to the extrusion at each flange 208 thereof by completely overlapping the flange. Flange 208 is offset a distance equal to the thickness of the flat aluminum piece so as to result in a smooth surface eight-sided shape as illustrated. A completed fabrication provides the structural strength substantially equivalent to a rectangular shaped extrusion while providing a visually pleasing appearance of an eight-sided shape. The comer members 210 are formed so as to have a slightly radiussed edges 212 so as to improve the adhesion of paints to the surface thereof which is often difficult to obtain when sharp corners are utilized and, moreover, such further enhances the appearance of a semi-octopost extrusion resulting therefrom. As shown in the drawings, the sides 202 are of a shorter length than sides 204, the resulting combination is illustrated in the exploded view in Figure 26 and in the assembled view shown in Figures 27 and 28.

Considering next then the embodiment shown in Figure 29, such serves to illustrate an aluminum extrusion 300 having an unequal sided octagon shape assembly with alternating sections or sides 302 of identical lengths designed to provide structural strength equivalent to a radius corner shape 306 for comer members 308 while providing a visually pleasing appearance of an eight-sided shape. The dimensional rules provided for the maximum size of a diagonal comer allowed within normal economical and physical constraints for extruding aluminum shapes with varying wall thicknesses are applicable. The points defining each diagonal are, as shown in the Figure 29, placed one-sixth (1/6) of the overall width of the shape outward and inward from each comer. The wall thickness of a diagonal is 1.0 to 1.5 times the base wall thickness of the extrusion. The inside radius 306 of each corner is equal to the base wall thickness of the extrusion and the outside radius of each corner is 1.5 times the thickness of the base wall.

The corner members 308 are formed with the above-noted radiussed edges 306 to avoid stress cracking, to improve adhesion of paint to the surface which is otherwise difficult to gain using sharp comers, and further enhances the appearance thereof. The extrusion is used as a structural element of aluminum fabrications, for example, an normally is intended to be visible after completion of the fabrication. It is envisioned, however, that other metals and/or plastic or plastic like materials can be utilized to extrude this member. This extrusion may be directly substituted for a standard radius co er square extrusion of a similar base wall thickness and outside dimensions.

A yet further embodiment of the present invention is in the form of a semi-octagon extrusion shown in Figure 30 wherein an aluminum extrusion 400 is designed as a component for use in the fabrication of eight-sided shapes for use as posts which comprise two extrusion pieces 402 connected by a flat aluminum sheet or plate pieces of varying dimensions which are attached to the extrusion at each flange 412. These sheets are similar, for example, to the sheets 206 shown in Figure 26. The flange is, as shown, offset a distance equal to the thickness of the flat aluminum piece does result in a smooth surface eight-sided shape of the post to be constructed. As shown in Figure 30, this embodiment includes a long side 404, a short side 406, corner members 408 and radiussed edges 410 as well as flanges 412. The completed fabrication provides structural strength equivalence to a radiussed corner rectangular shape while providing a visually pleasing appearance of an eight-sided shape on the flat sheet with other thicknesses equal to or greater than the base wall thickness of the extrusion. The dimensional rules with respect to this embodiment provide for a maximum size diagonal comer to be permitted within normal economical and physical constraints for extruding aluminum shape for varying wall thicknesses. While aluminum is the preferred embodiment with respect to extrusion, it can be understood that other metals and/or plastics can be instead utilized. The points defining each diagonal are placed one-sixth ( 1 /6th) the overall width of the shape positioned inwardly from each comer, as illustrated. The wall thickness of the diagonal is 1.0 to 1.5 the base wall thickness of the extrusion. The inside radius of each comer is equal to the base wall of the extrusion and the outside radius of each comer is 1.5 the base wall thickness. The comer members are formed with a slight radius so as to improve adhesion of paints to the surface which is often difficult to obtain when utilizing a sharp comer and, moreover, further enhances the appearance thereof in the same manner as described in the previously mentioned embodiments.

Claims

Claim:

1. A canopy shelter, which comprises: first and second extrusion posts formed by extrusion of a metal, plastic or other extrudible material; a support beam interconnecting said first and second posts; a plurality of rafters mounted on said support beam; and at least one roof panel connected to said rafters.

2. The canopy shelter as claimed in claim 1, wherein said support beam comprises at least one lighting member connected thereto for lighting an area beneath said at least one roof panel.

3. The canopy shelter as claimed in claim 1, wherein said support beam is positioned beneath a substantially central portion of said at least one roof panel.

4. The canopy shelter as claimed in claim 1, wherein said support beam is located between a point positioned beneath a central portion of said at least one roof panel and a position located beneath an edge portion of said at least one roof panel.

5. The canopy shelter as claimed in claim 1, wherein each of said rafters comprise substantially A-shaped rafters that are integrally formed as a single piece.

6. The canopy shelter as claimed in claim 1, wherein at least one of said posts includes a lighting member mounted thereto.

7. The canopy shelter as claimed in claim 1, which comprises a plurality of purlins which connect at least one of said roof panels to at least one of said plurality of rafters.

8. The canopy shelter as claimed in claim 1, wherein said rafters comprise substantially A-frame shaped rafters.

9. The canopy shelter as claimed in claim 2, wherein said at least lighting member on said support beam provides light in a direction both above and below the support beam.

10. The canopy shelter as claimed in claim 1, wherein a lighting member is positioned on at least one of said posts so as to provide illumination of an area beneath said at least one roof panel.

1 1. The canopy shelter as claimed in claim 1 , wherein said lighting member comprises a lighting lens.

12. The canopy shelter as claimed in claim 10, wherein said lighting member comprises a lighting lens.

13. The canopy shelter as claimed in claim 1, wherein said posts are of a modular shape so as to be interchangeable with one another.

14. The canopy shelter as claimed in claim 1, wherein each of said posts comprise at least one unequally sided, substantially octagon-shaped post as viewed in cross-section.

15. The canopy shelter as claimed in claim 1 wherein at least one of said posts comprise at least one unequally sided, substantially octagon-shaped post as viewed in cross- section.

16. The canopy shelter as claimed in claim 14, wherein said octagon shaped posts comprise metal extrusion posts of a one piece construction.

17. The canopy shelter as claimed in claim 14, wherein said posts are of a one-piece construction having radiussed edges.

18. The canopy shelter as claimed in claim 16, wherein said metal posts comprises metal extruded posts.

19. A post for supporting a canopy shelter, which comprises: a one-piece extruded post of a substantially octagon shape in cross-section having a plurality of side members and a plurality of substantially straight corner members which respectively interconnect adjacent side members of said plurality of side members.

20. A post as claimed in claim 19, wherein an interior portion of said post forms a hollow chamber.

21. A canopy shelter as claimed in claim 15, wherein an interior portion of said post forms a hollow chamber.

22. A post as claimed in claim 19, where an external edge interconnects the side member to the corner members and said external edge has a radiussed edge.

23. A post as claimed in claim 19, wherein said post comprises an extruded metal post having an interior portion forming a hollow chamber.

24. A post for supporting a canopy, which comprises: a post of a substantially octagon shape in cross-section, said post comprising first and second extrusion pieces and first and second sheet metal which interconnect opposite sides of said first and second extrusion pieces, respectively.

25. A post disclaimed in claim 24, wherein each of said first and second extrusion pieces comprise a flange member lying in a plane offset from a plane of the opposite sides, respectively, of the post, said first and second sheet members lying in the plane of said opposite sides so as to form a smooth outer surface of the post.

26. The post as claimed in claim 25, wherein said post is substantially rectangularly shaped in cross-section.

27. The post as claimed in claim 24, wherein corners of the post are provided which interconnect adjacent sides of said extrusion pieces, each of said comers having radiussed edges.

28. The post as claimed in claim 24, wherein the post has diagonally opposite comers with radiussed edges which are positioned inwardly substantially one-sixth of an overall width dimension of the side walls thereof.