HDPE Canopy Weight Case With Integrated Hinges
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Solution Overview
Problem
Existing portable weights for stabilizing instant pop-up canopies and gazebos are either prone to leakage, require multiple units for sufficient weight, or are difficult to attach and remove, and often damage the structures they are intended to secure due to their design and materials.
Innovation Solution
A blow-molded dual-walled hollow plastic weight case made from High-Density Polyethylene (HDPE) with integrally molded hinges and flexible latches, allowing easy attachment and removal around the canopy leg, and the option to hang from the frame, preventing dislodgment under windy conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If sewn thick polyester fabric bags with compartments filled with sand, gravel, or rock are used, then sufficient weight can be achieved, but the weights are prone to leakage when torn, zippers break, or hook and loop closures fill with debris
Solution Approach 1:
The patent uses a flexible polyester fabric bag to contain the weighting material (sand, gravel, or rock). The flexible shell design allows the bag to conform to the canopy leg while providing containment. The fabric is chosen to be durable yet flexible, balancing the need for structural integrity with the need for adaptability to different leg shapes and sizes.
Solution Approach 2:
The patent employs inexpensive materials such as polyester fabric, sand, gravel, or rock that can be easily replaced if damaged. The weighting system is designed as a disposable or easily replaceable component, where if the fabric bag tears or the weighting material is lost, the entire weight can be quickly replaced without affecting the canopy structure or requiring complex repairs.
2Ease of operation
If plastic coated concrete or metal discs with an open ended slot are used, then easy attachment can be achieved, but they are limited in size and do not provide sufficient weight required to prevent wind uplift
Solution Approach 1:
The weighting system is divided into two separate components: the fabric bag containing the weighting material and the canopy leg. This segmentation allows the weight to be adjusted independently by adding or removing weighting material from the bag, while the attachment mechanism (hook and loop fastener) remains separate and can be applied to various leg configurations. The slot in the footplate is utilized as a separate attachment point that works with the flexible bag design.
Solution Approach 2:
The patent changes the key parameter of weight by varying the amount and type of weighting material (sand, gravel, or rock) placed in the fabric bag. This allows the same bag design to provide different weight levels depending on the event conditions, such as stronger winds requiring heavier weighting. The flexible design accommodates a range of weight parameters without requiring different structural designs.
3Reliability
If multiple amounts of weights are required on each leg to achieve optimum stability, then sufficient stabilization can be achieved, but the device complexity and time to attach increase
Solution Approach 1:
The fabric bag weight design serves multiple functions: it provides stabilization weight, can be attached to various leg configurations (straddling the leg or using the footplate slot), and can be adjusted in weight by adding or removing material. This multi-functionality reduces the need for multiple different weight types or multiple separate weights per leg, as a single versatile bag design can handle various stabilization requirements.
4Weight of stationary object
If home-made weights of plastic pipe filled with sand or concrete are used, then sufficient weight can be achieved, but fabrication is time-consuming and require some degree of knowledge of construction
Solution Approach 1:
The patent uses inexpensive, easily acquired materials such as polyester fabric, sand, gravel, or rock that do not require specialized construction knowledge to assemble. The fabric bag can be sewn or purchased pre-made, and the weighting material can be simply poured in and sealed, eliminating the need for complex fabrication processes like concrete mixing or pipe assembly that require construction expertise and specialized equipment.
5Reliability
If duct-tape or tie-wraps are used to attach home-made weights, then secure attachment can be achieved, but they are often difficult to remove after use
Solution Approach 1:
The patent replaces the mechanical attachment system of duct-tape or tie-wraps with a hook and loop fastener system (such as Velcro). This substitution maintains secure attachment during use while allowing easy removal by simply pulling the tab of the loop fastener, which releases the hook elements. The mechanical advantage of the hook and loop system provides both secure attachment and easy release, eliminating the difficulty of removing duct-tape or tight tie-wraps after use.
Data Source
AI summary
A method of applying weights to the legs of instant pop-up canopies and the like is disclosed. The weights help prevent uplift under windy conditions. Each weight case is comprised of two half-round hollow cases. The case halves are joined by hinges on one edge and latches on the opposite edge. Each case half has a full length inner V-groove, which when closed, create a throughbore for the canopy legs. Each case half top is fitted with a filler hole and cap. The hollow cases can be filled with a variety of weight material. The weighted case is wrapped around the lower leg of the canopy and latched shut to secure the weight around the canopy leg. The weight case rests on the flanged footplate of each leg. Four to six weight cases are required for each application.