SUPPORT BRACKET ASSEMBLY FOR POOL COVER BOX LID

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 63/643,830, filed May 7, 2024, entitled “SUPPORT BRACKET ARM ASSEMBLY FOR POOL COVER BOX LID,” which is incorporated herein by reference in its entirety.

BACKGROUND

Pool cover housings enclose and safeguard the internal components of a pool cover system. Specifically, a pool cover housing can include a lid that can cover the internal components stored in the housing. The lid can be removable to provide access to the components within the pool cover housing, for example for repairing and/or replacing the components contained therein. However, there are challenges in optimizing the connection between the lid and the pool cover housing.

BRIEF SUMMARY

One aspect of the disclosure provides for a pool cover assembly may include a cover housing configured to store a pool cover, where the cover housing may include a container and a lid, and a bracket arm assembly positioned in the cover housing. The bracket arm assembly also may include a base, a support arm associated with the base, and an adjustment fastener movably received in the base and positioned between the base and the support arm. The base of the bracket arm assembly may be removably coupled to the container and the lid is supported on the support arm. and the adjustment fastener may be displaceable into, or out of, a receiving element of the base for adjusting a relative angle between the support arm and the base.

Implementations may include one or more of the following features. The support arm may include a first end and a second end opposite the first end, the first end can be received in an interface volume defined by the base, the support arm can rest on a first protrusion along an intermediate portion of the support arm between the first end and the second end, and the support arm can rotate about a point of contact between the intermediate portion and the first protrusion. The support arm may include a center of gravity closer to the second end than the first end. The center of gravity may be between the point of contact and the second end. The intermediate portion may include a first projection defining a first projection recess that is shaped to receive the first protrusion such that the support arm is limited in linear translation relative to the base. The support arm may include a second projection adjacent the first end and the base may define a mating recess that is shaped to receive the second projection such that the support arm is limited in linear translation relative to the base. The interface of the first projection within the first projection recess and the second projection within the mating recess may limit angular rotation of the support arm relative to the base about the point of contact. The base may include a second protrusion and a third protrusion extending into the interface volume, and the first end may be received in the interface volume between the second protrusion and third protrusion such that the support arm is limited in linear translation relative to the base. Displacement of the adjustment fastener into, or out of, the receiving element may adjust an angle of the support arm relative to the base about the point of contact. The support arm may couple to the base free of fasteners. A first top surface of the spacer and a second top surface of the bracket arm may be substantially co-planar.

One aspect of the disclosure provides for a bracket arm assembly for use in a cover housing of a pool cover assembly. The bracket arm assembly may include a base, a support arm coupled to the base in a free-floating cantilevered configuration, and an adjustment fastener movably received in the base, where movement of the adjustment fastener within the base adjusts a relative angle between the support arm and the base.

Implementations may include one or more of the following features. The support arm may include a first end and a second end opposite the first end, the first end can be received in an interface volume defined by the base, the support arm can rest on a first protrusion along an intermediate portion of the support arm between the first end and the second end, and the support arm can rotate about a point of contact between the intermediate portion and the first protrusion. The intermediate portion may include a first projection defining a first projection recess that is shaped to receive the first protrusion such that the support arm is limited in linear translation relative to the base. The support arm may include a second projection adjacent the first end and the base may define a mating recess that is shaped to receive the second projection such that the support arm is limited in linear translation relative to the base. The interface of the first projection within the first projection recess and the second projection within the mating recess may limit angular rotation of the support arm relative to the base about the point of contact. The base may include a second protrusion and a third protrusion extending into the interface volume, and the first end may be received in the interface volume between the second protrusion and third protrusion such that the support arm is limited in linear translation relative to the base. Displacement of the adjustment fastener into, or out of, the receiving element may adjust an angle of the support arm relative to the base about the point of contact. The support arm may couple to the base free of fasteners.

One aspect of the disclosure provides for a method of assembling a pool cover assembly may include coupling a base of a bracket arm assembly to a container of a cover housing. The bracket arm assembly may include a support arm associated with the base, and an adjustment fastener received in the base between the base and the support arm. The support arm may support a lid of the cover housing such that the bracket arm assembly is positioned in the cover housing. The method also may include displacing the adjustment fastener relative to the base to adjust an angle of the support arm relative to the base.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

FIG. 1 illustrates an isometric view of an example pool, according to at least one example.

FIG. 2 illustrates a cross-sectional view of an example cover housing along Section A-A, according to at least one example.

FIG. 3A illustrates an isometric view of an example bracket arm assembly, according to at least one example.

FIG. 3B illustrates an exploded view of the example bracket arm assembly of FIG. 3A, according to at least one example.

FIG. 3C illustrates a cross-sectional view of the example bracket arm assembly of FIG. 3A along Section B-B, according to at least one example.

FIG. 4A illustrates an isometric view of an example bracket arm assembly, according to at least one example.

FIG. 4B illustrates an exploded view of the example bracket arm assembly of FIG. 4A, according to at least one example.

DETAILED DESCRIPTION

A pool may include a cover system and may further include a cover housing that stores certain components of the cover system, such as a pool cover, a roller tube that the pool cover is wrapped around, a motor that can roll and unroll the roller tube, or the like. The cover housing can include a container to store the components of the pool cover system, a lid covering the container, and a bracket arm assembly for coupling the lid to the container. The cover housing may be recessed in a deck surrounding swimming pool.

It may be beneficial for the top surface of the lid to be co-planar with the top surface of the surrounding deck to provide a more appealing appearance. Doing so may also reduce the likelihood of the lid introducing tripping hazard to users walking around the pool (e.g., from a portion of the lid extending above or below the top surface of the deck). As such, it may be beneficial for the angle of the lid to be adjustable relative to the container such that a desired angle can be found where the top surfaces of the lid and the surrounding deck are co-planar. Additionally, it can be beneficial to provide such an adjustment system that is simple to install and easy to use so that users without much technical experience can adjust the angle of the lid with less confusion and less risk of damaging the pool cover system.

The present disclosure provides a bracket arm assembly that can be coupled between a lid and a container of a pool cover housing. The bracket arm assembly may include a base that can be coupled to the container of the pool cover housing and a support arm that can support the lid of the pool cover housing. The bracket arm assembly may also include an adjustment fastener that may adjust an angle of the support arm relative to the base such that, by extension, the angle of the lid relative to the container and surrounding deck can be adjusted to a desired angle. Further, the support arm may be coupled to the base through a free-floating cantilevered configuration such that the support arm can be removed from the base (e.g., for repair and replacement of the internal components of the pool cover system stored in the container) in a more simplified manner (e.g., without having to use fasteners). As such, the support arm assembly of the present disclosure can be a simplified way of adjusting the angle of the lid of the pool cover housing to facilitate a physically seamless deck surrounding the pool.

FIG. 1 depicts a simplified view of an example pool 100 coupled to a deck 102. The pool 100 may be defined by a plurality of sides and corners and may define a pool volume 104 that receives water for users to swim in. The pool 100 may be a vinyl liner pool, a fiberglass pool, a gunite pool, or any other pool material. The deck 102 can be formed around a top-edge of the pool 100. As such, the pool 100 may be an in-ground pool. However, in other embodiments, the pool may be an above-ground pool.

The pool 100 may include a cover assembly 108 (e.g., a pool cover assembly, such as an automatic pool cover assembly or the like) coupled to a first end 115 of the pool 100. The cover assembly 108 may include a cover housing 110 that houses various components of the cover assembly 108, such as a roller tube for a cover 112 (e.g., a protective sheet that includes one or more of plastic, fabric, composite material, or the like) to wrap around, a motor that can be actuated to facilitate the cover 112 to cover and uncover the pool volume 104, and/or other components related to the cover assembly. The cover assembly 108 may include a leading edge bar 114 coupled to a distal end of the cover 112. In some embodiments, the distal end of the cover 112 may be wrapped (e.g., partially or entirely) about the leading edge bar 114 such that the leading edge bar 114 is partially or completely hidden from view (e.g., when a user is viewing the pool 100 while standing on the deck 102).

In use, the motor may extend the cover 112 to cover the pool volume 104. In particular, the motor may cause the leading edge bar 114 coupled to the cover 112 to move from a first position, where the leading edge bar 114 is proximate the first end 115 of the pool 100, toward a second position at a second end 116 of the pool 100 (e.g., along the Y-axis). In this first position, the cover 112 may be in a stored position in the cover housing 110 where the cover 112 is rolled around the roller tube within the cover housing 110. As the leading edge bar 114 moves toward the second end 116 of the pool 100, the leading edge bar 114 may pull the cover 112 from around the roller tube positioned in the cover housing 110 such that the cover 112 remains taut as the leading edge bar 114 moves toward the second end 116 (e.g., as depicted in FIG. 1). When the leading edge bar 114 reaches the second end 116 of the pool 100, the cover 112 may cover a top region of the pool 100. In this second position, the cover 112 may be in a deployed position. The motor may also be actuated to retract the cover 112 back to the stored position by causing the roller tube to roll the cover 112 around the roller tube and moving the leading edge bar 114 from the second end 116 of the pool 100 towards the first end 115 of the pool.

FIG. 2 depicts a simplified cross-sectional view of the cover housing 110 along Section A-A (e.g., as shown in FIG. 1). The cover housing 110 includes a lid 210 and a container 220. The lid 210 and container 220 can define, therebetween, an internal volume 212 that can house components of the cover assembly 108, such as a roller tube, motor, the cover 112, or the like. In some embodiments, the lid 210 may comprise the same material as the deck 102 surrounding the pool 100 such that the lid 210 generally blends into the surrounding deck 102. For example, the lid 210 may be level with the deck 102 (shown in FIG. 1) and may comprise the same material or a material that substantially resembles the deck material. The cover housing 110 may include a bracket arm assembly coupling the container to the lid.

The cover housing 110 may include a bracket arm assembly 230 coupling the container 220 to the lid 210. In particular, a base 234 of the bracket arm assembly 230 can be associated with the container 220 (e.g., via welding, brazing, soldering, gluing, fastening, integrally combined with, or the like) while the lid 210 may rest on top of a support arm 232 of the bracket arm assembly 230. In some embodiments, the lid 210 may also be coupled to the support arm 232 (e.g., via welding, brazing, soldering, gluing, fastening, or the like).

As noted above, it may be beneficial for the lid 210 to be angularly adjusted relative to the container 220. The bracket arm assembly 230 addresses this issue by including an adjustment system that allows for the support arm 232 to be angularly adjusted relative to the base 234. As the lid 210 rests on the support arm 232, angularly adjusting the support arm 232 also allows for the lid 210 to be angularly adjusted relative to the container 220. Further, as will be discussed further below, the support arm 232 can be easily installed and removed with the base 234. Accordingly, the bracket arm assembly 230 can provide a simple means of adjusting the angle of the lid 210 relative to the container 220 such that the lid 210 can be seamlessly integrated with the surrounding deck 102.

FIGS. 3A-3C depict detailed views of the bracket arm assembly 230. FIG. 3A depicts an isometric view of the bracket arm assembly 230. FIG. 3B depicts an exploded view of the bracket arm assembly 230. FIG. 3C depicts a cross-sectional view of the bracket arm assembly 230 along Section B-B (e.g., as shown in FIG. 3A). Turning to FIG. 3B, the base 234 may include a base body 320 with a coupling feature 330 at an end of the base body 320 and an receiving element 340 extending from the base body 320 from the base body 320. The base body 320, coupling feature 330, and receiving element 340 may be integrally formed with each other such that the base 234 is a monolithic structure. However, in other embodiments, one or more of the coupling feature or receiving element may be separate components coupled to the base body (e.g., via welding, brazing, soldering, gluing, fastening, or the like).

The coupling feature 330 may define an interface volume 331 sized and shaped to receive a mating assembly 350 of the support arm 232. In this manner, as described further below, the coupling feature 330 may facilitate the coupling between the support arm 232 and the base 234. The coupling feature 330 may include protrusions that extend into the interface volume 331 and that are configured to interface with portions of the mating assembly 350, as discussed further below. For example, the coupling feature 330 may include a first protrusion 332 extending along a Z-axis from the coupling feature 330 into the interface volume 331, a second protrusion 334 extending along an X-axis from the coupling feature 330 into the interface volume 331, and a third protrusion 336 extending along an X-axis from the coupling feature 330 into the interface volume 331. The second protrusion 334 may extend along a first direction into the interface volume 331 and the third protrusion 336 may extend along a second direction into the interface volume 331 opposite the first direction. As will be described below, the protrusions 332, 334, 336 may interface with portions of the mating assembly 350 (e.g., edges 358, 359 and second projection 354, as shown in FIG. 3B) to form an interference fit coupling the mating assembly 350 and the coupling feature 330. Additionally, also discussed further below, as shown in FIG. 3C, the coupling feature 330 may define a mating recess 333 sized and shaped to receive portions of the mating assembly 350 (e.g., third projection 356, as shown in FIG. 3C).

The receiving element 340 may define a fastener channel 341 configured to receive a fastening feature 312 of an adjustment fastener 310 (e.g., a screw, bolt, or the like). When the adjustment fastener 310 is received within the receiving element 340, the adjustment fastener 310 and the receiving element 340 may be, collectively, referred to as an adjustment assembly. The receiving element 340 may include a threaded section 342 sized and shaped to interface with threads of the fastening feature 312. In this manner, when the fastening feature 312 is received in the fastener channel 341, the threaded section 342 can interface with the threads of the fastening feature 312 such that the adjustment fastener 310 may rotate relative to the receiving element 340. Rotation of the threaded section 342 within the fastener channel 341 may result in the adjustment fastener 310 linearly translating toward or away from the base 234 along the fastener channel 341. As will be discussed below, a head 314 of the adjustment fastener 310 may abut against the support arm 232, for example, but not limited to against, a portion of the mating assembly 350, such that the linear translation of the adjustment fastener 310 relative to the base 234 may result in a change of angle of the support arm 232 relative to the base 234.

The base body 320 can define a number of openings sized and shaped to receive fasteners to associate, couple, or otherwise secure the base body 320 together with the container 220, in aspects in which the base body 320 is not integral with the container 220. For example, the base body 320 can define a first base opening 321, a second base opening 323, a third base opening 325, a fourth base opening 327, and a fifth base opening 329. The base openings 323, 325, 327, 329 can receive a fastener to stabilize the base 234 on an X-Z plane to about a Z-axis while the first base opening 321 can receive fastener to stabilize the base 234 on an X-Z plane about an X-axis. Though five base openings are depicted, more or fewer may be used without departing from the scope of the present disclosure. For example, the base body may not define the first opening. In another example, the base body may not define one of the second or third base openings, or one of the fourth or fifth base openings. In this manner, fastening the base 234 to the container 220 with at least one fastener in the first base opening 321, the second base opening 323 and/or the third base opening 325, and the fourth opening base and/or the fifth base opening 329 can result in a secure coupling between the base 234 and the container 220 even if the wall of the container 220 that the base 234 is coupled on is uneven. In some embodiments, the base body 320 may be associated with, coupled to, or otherwise secured together with the container 220 by other means, for example but not limited to adhesives, magnets, other mechanical fasteners, hook and loop fasteners, or any other suitable means.

The base 234 can include a shroud 322 that extends from the base body 320 along a Y-axis at least partially around the first base opening 321 such that, when a fastener is received in the first base opening 321, the shroud 322 may reduce the risk that the fastener contacts internal components housed in the container 220. For example, shroud 322 may provide a buffer between the cover 112 stored in the container 220 and the fastener received in the first base opening 321 to minimize the risk that the fastener cuts the cover 112. However, in other embodiments, the base may not include a shroud.

The support arm 232 may include the mating assembly 350, as noted above, and a support feature 360. The mating assembly 350 and support feature 360 may be integrally formed together such that the support arm 232 is a monolithic structure. However, in other embodiments, the mating assembly and support feature may be separate components that are coupled together (e.g., via welding, brazing, soldering, gluing, fastening, or the like). A top surface of the support feature 360 is configured to support the lid 210 or other components (e.g., the arm extension 420 coupled to support openings 361, as shown in FIG. 4A, below).

The mating assembly 350 may mate with, or otherwise engage, the coupling feature 330 to securely maintain the position of the support arm 232 relative to the base 234 in a free-floating cantilever configuration. For example, as depicted in FIG. 3C, the mating assembly 350 may include a first projection 352, a second projection 354, and/or a third projection 356. The first projection 352 may define a first projection recess 351 on a bottom surface of the first ident 352 and the second projection may define a second projection recess 353 on a bottom surface of the second projection 354. The first projection recess 351 may be sized and shaped to receive the head 314 of the adjustment fastener 310. The second projection recess 353 may be sized and shaped to receive an end region of the first protrusion 332. However, in other embodiments, the support arm may not include one or more of the recesses, such as no first recess or the like. The third projection 356 may be sized and shaped to be received in the mating recess 333 of the coupling feature 330.

The support arm 232 may be coupled to the base 234 through the interface between the first protrusion 332 and the second projection 354 within the second projection recess 353, and the interface between the third projection 356 and the coupling feature 330 within the mating recess 333. The support arm 232 may include a center of gravity to the right of the interface between the first protrusion 332 and the second projection 354 along the Y-axis as shown in FIG. 3C such that, when the support arm 232 rests on the first protrusion 332, the support arm 232 is disposed to freely rotate in a clockwise direction about the X-axis at the point of contact between the first protrusion 332 and the second projection 354. The support arm 232 may be limited from rotating in this clockwise direction by the interface between the third projection 356 and the coupling feature 330 within the mating recess 333. This cantilevered configuration may support a downward force placed on the support arm 232 (e.g., along the supporting feature 360 from the weight of the lid 210) without movement of the support arm 232 in a clockwise direction. The stability of the cantilevered configuration (and, as discussed below, the angular orientation of the support arm 232 relative to the base 234) may also be increased by the interface between the head 314 of the adjustment fastener 310 and the first projection 352.

When the support arm 232 is assembled together with the base 234, the support arm 232 may be limited from moving along a Y-axis due to the interface between the mating assembly 350 and coupling feature 330. Specifically, as depicted in FIG. 3C, the curved cross-sectional shape of the first protrusion 332 can engage the curved cross-sectional shape of the second projection recess 353 such that the first protrusion 332 and the second projection 354 are in an interference fit within the second projection recess 353. Additionally, the curved cross-sectional shape of the third projection 356 can engage the curved cross-sectional shape of the mating recess 333 such that the third projection 356 and the coupling feature 330 are in an interference fit within the mating recess 333. Accordingly, the interference fit between the above-noted features of the mating assembly 350 and coupling feature 330 may limit the support arm 232 from linearly translating along a Y-axis when the support arm 232 is in the free-floating cantilever configuration. In other embodiments, the cross-sectional shape of the first protrusion, third projection, and recesses may not be curved. Instead, the cross-sectional shapes of one or more of these features may be angular (e.g., rectangular, triangular, or the like).

Turning to FIG. 3B, the support arm 232 may be limited from moving about a Z-axis (or along an X-axis) by an interference fit between the protrusions 334, 336 and the mating assembly 350. In particular, the mating assembly 350 may include a first edge 358 and a second edge 359 opposite the first edge 358. When assembled, the first edge 358 may interface with the second protrusion 334 and the second edge 359 may interface with the third protrusion 336 such that the mating assembly 350 is received between the two protrusions 334, 336 in an interference fit. This interference fit may limit movement of the support arm 232 about a Z-axis or along an X-axis relative to the base 234. However, in other embodiments, the base may not include a second protrusion and/or third protrusion. Instead, the movement of the support arm about a Z-axis or along an X-axis relative to the base may be limited by the engagement of the mating assembly within the portions of the coupling feature defining the interface volume.

The protrusions 336, 337 may include a curved shape to allow for the edges 358, 359 to more easily be received between the protrusions 336, 337. In this manner, the curved protrusions 336, 337 may allow for an easier assembly process. However, in other embodiments, the protrusions may include other shapes, such as being angular, rectangular, or the like.

The support arm 232 may be assembled to the base 234 by inserting the third projection 356 into the interface volume 331 at an insertion angle that allows the third projection 356 to pass the first protrusion 332 (e.g., at a transverse angle relative to the X-Y plane). Once the third projection 356 is inserted past the first protrusion 332 within the interface volume 331, the support arm 232 can be rotated in a clockwise direction until the third indent 356 is received within the mating recess 333 and the first protrusion 332 is received within the second projection recess 353, as shown in FIG. 3A and 3C. Accordingly, the support arm 232 may be easily assembled to the base 234.

As the support arm 232 is coupled to the base 234 without requiring any other forms of coupling mechanisms (e.g., via welding, brazing, soldering, gluing, fastening, or the like) between the support arm 232 and the base 234, the support arm 232 and the base 234 are in a free-floating cantilevered configuration. As noted above, such a configuration is beneficial to improve the ease of coupling the support arm 232 and the base 234 (e.g., without coupling the support arm 232 and the base 234 using additional coupling mechanisms). This increased simplicity reduces the risk of errors during assembly of the bracket arm assembly 230. For example, this increased simplicity reduces the technical expertise and tools required to assemble the bracket arm assembly 230 (e.g., by a user of the pool 100, inexperienced pool technicians installing the pool 100, or the like) that may otherwise be required if the support arm 232 and base 234 were coupled together through additional coupling mechanisms. However, in some embodiments, such additionally coupling mechanisms may be used to provide further stability between the support arm and the base.

With reference to FIG. 3C, the angle of the support arm 232 relative to the base 234 may be adjusted by the adjustment assembly (e.g., the linear translation of the adjustment fastener 310 within the fastener channel 341 of the receiving element 340). As discussed above, angular adjustment of the support arm 232 relative to the base 234 may be beneficial to adjust the support arm 232 to a desired angle relative to the base 234 such that the lid 210 later positioned on the support arm 232 may be angularly adjusted relative to the container 220 and the surrounding deck 102. This angular adjustment may be performed while the support arm 232 and the base 234 are coupled together in the free-floating cantilevered configuration such that the arm 232 and the base 234 may be angularly adjusted without the support arm 232 and the base 234 decoupling from each other. However, as noted below, the adjustment fastener 310 may translate within the fastener channel 341 without being coupled to the support arm 232 such that the support arm 232 may be coupled to the base 234 and adjustment fastener 310 at a desired angle. The lid 210 may then be positioned on the support arm 232 at a desired angle relative to the container 220 and the surrounding deck 102. However, in other embodiments, the support arm and base may be angularly adjusted with the lid positioned on the support arm.

In particular, the support arm 232 may rotate in a counterclockwise direction about the X-axis at the point of contact between the first protrusion 332 and the second projection 354 when the adjustment fastener 310 linearly translates away from the receiving element 340 (e.g., when the receiving elements 340 linearly translates toward the support arm 232) within the fastener channel 341 (e.g., through rotation of the fastening feature 312 relative to the threaded section 342) such that the head 314 in the first projection recess 351 pushes the support arm 232. As the support arm 232 is naturally predisposed to rotate in a clockwise direction about the X-axis at the point of contact between the first protrusion 332 and the second projection 354 (e.g., as a result of the location of the center of gravity of the support arm 232 being to the right of this point of contact, as noted above), movement of the adjustment fastener 310 away from the support arm 232 will naturally rotate or tilt the support arm 232 in this clockwise direction. As such, the support arm 232 may rotate or tilt in a clockwise direction about the X-axis at the point of contact between the first protrusion 332 and the second projection 354 when the adjustment fastener 310 linearly translates further inside the receiving element 340 (e.g., when the receiving elements 340 linearly translates away from the support arm 232) within the fastener channel 341 (e.g., through rotation of the fastening feature 312 relative to the threaded section 342).

The cantilevered configuration may define a maximum distance of rotation or tilting in both the clockwise and counterclockwise direction. For example, the support arm 232 may be limited in counterclockwise rotation when the support arm 232 rotates in the counterclockwise direction so much that: the adjustment fastener 310 exits the fastener channel 341 and the fastener feature 312 disengages (e.g., no longer interacts with) from the threaded section 342, therefore, preventing the adjustment fastener 310 from being able to further push the support arm 232 in the counterclockwise direction; or where the support arm 232 rotates so far that the third projection 356 disengages from the mating recess 333 and the second projection 354 disengages from the first protrusion 332, and an end 357 of the mating assembly 350 contacts a first surface 335 of the coupling feature 330 and the second projection 354 contacts a second surface 337. The support arm 232 may be limited in clockwise rotation when the support arm 232 rotates in the clockwise direction so much that the support arm 232 is no longer supported by the adjustment fastener 310 (e.g., when the adjustment fastener 310 linearly translates away from the first projection 352 so much that the head 314 disengages from the first projection 352 and is spaced from the support arm 232). In this position, the support arm 232 rests only on the free-floating cantilevered configuration between the second projection 354 and first protrusion 332, and the third projection 356 against the coupling feature 330 within the mating recess 333. The support arm 232 may have an adjustable angular range, relative to the X-Y plane, of between about 2° and 10°, between about 3° and 9°, between about 4° and 8°, between about 5° and 7°, or about 6°.

The free-floating cantilevered configuration provides good structural stability to handle high loads positioned on the support arm 232. For example, the bracket arm assembly 230 may support a heavy lid 210 positioned on the support arm 232, such as a stone lid 210 that matches a surrounding stone deck 102. Additionally or alternatively, the bracket arm assembly 230 may support other components positioned on the 210, such as furniture, appliances, or the like. For example, the bracket arm assembly 230 without an extension (e.g., such as an arm extension 420, as shown in FIGS. 4A and 4B, having a 13-inch length) may support, between about 15 lbs. and about 750 lbs., between about 15 lbs. and about 895 lbs., between about 525 lbs. and about 750 lbs., between about 525 lbs. and about 895 lbs., or the like, prior to failure. These supported loads are an improvement compared to conventional bracket systems (e.g., bracket systems including fasteners coupling the support arm and base together) as, through a similar load testing performed on the conventional bracket system of placing a progressively heavier loads, the conventional bracket systems may fail (e.g., undergo permanent damage) at lower weights. Accordingly, the bracket system 230, including the free-floating cantilevered configuration of the support arm 232 with the base 234, provides a load performance improvement compared to conventional bracket systems.

In some embodiments, the bracket arm assembly 230 may include components that increase an effective length of the support arm 232. For example, FIGS. 4A and 4B depict a bracket arm assembly 430 including a spacer 410, and arm extension 420 coupled to the support arm 232 and base 234. Securement components 440 (as shown in FIG. 4B), such as fasteners or the like, may couple the arm extension 420 to a distal end of the support arm 232 (e.g., the end of the support arm 232 opposite the mating assembly 350). The arm extension 420 increases a length of the bracket arm assembly 430 along a Y-axis compared to the bracket arm assembly 230. In this manner, larger and/or more objects can be positioned on the bracket arm assembly 430, such as a larger lid (e.g., lid 210, as shown in FIG. 2).

As a thickness of the arm extension 420 increases a height of the bracket arm assembly 430, an object resting on the arm extension 420 at one end and along a support arm 232 on another end may result in the object being tilted, such as the lid 210 being tilted relative to the surrounding deck 102. To address this issue, the bracket arm assembly 430 may include a spacer 410 coupled to the support arm 232 and base 234 opposite the arm extension 420. The top surface of the spacer 410 and the top surface of the arm extension 420 may be substantially co-planar along the X-Y plane such that an object may be positioned on the spacer 410 and arm extension 420 without being tilted. In other words, the top surfaces of the spacer 410 and arm extension 420 may be substantially parallel (e.g., the degree of rotation of the top surfaces of each of the spacer 410 and arm extension 420 relative to the X-Y plane may be within about a 20% deviation of each other, such as about a 10% deviation, such as about a 5% deviation, or being completely the same) and aligned along an X-Y plane (the offset distance along a Z-axis between each of the top surfaces may be less than about 0.5 mm, less than about 0.4 mm, less than about 0.3 mm, less than about 0.2 mm, less than about 0.1 mm, or no offset).

The spacer 410 may include a spacer body 412, a first spacer arm 414 extending from the spacer body 412, and a second spacer arm 416 extending from the spacer body 412. The spacer body 412 may rest on top of the coupling feature 330 of the base 234 while each of the spacer arms 414, 416 can be positioned underneath opposite sides of the support arm 232. In this manner, the spacer 410 may be coupled to the support arm 232 and base 234 without additional connection mechanisms (e.g., via welding, brazing, soldering, gluing, fastening, or the like), thus simplifying the assembly process of the bracket arm assembly 430. However, additional connection mechanisms may couple the spacer to the support arm and base to increase the stability of the spacer.

The bracket arm assembly 430 may include securement components 440 coupled on the arm extension 420. In some embodiments, the securement components 440 may include an adhesive or other type of anti-slip material such that an object positioned on the securement components 440 may be more securely held in place on the arm extension 420. However, in other embodiments, the bracket arm assembly may not include the securement components.

The bracket arm assembly 430 is shown to be capable of supporting different loads along the arm extension 420 and support arm 232. For example, the bracket arm assembly 430 including a twenty-five inch (25″) arm extension 420 may support between about 15 lbs. and about 400 lbs., between about 375 lbs. and about 425 lbs., between about 375 lbs. and about 575 lbs., between about 375 lbs. and about 595 lbs., or the like, for example, prior to failure. The bracket arm assembly 430 including a seventeen inch (17″) arm extension 420 may support between about 15 lbs. and about 400 lbs., between about 375 lbs. and about 425 lbs., between about 375 lbs. and about 575 lbs., between about 375 lbs. and about 595 lbs., or the like, for example, prior to failure. These supported loads are an improvement compared to conventional bracket systems (e.g., bracket systems including fasteners coupling the support arm and base together) as, through a similar load testing performed on the conventional bracket system of placing a progressively heavier load, the conventional bracket systems may fail (e.g., undergo permanent damage) at lower weights. Accordingly, the bracket system 430, including the free-floating cantilevered configuration of the support arm 232 and arm extension 420 with the base 234, provides a load performance improvement compared to conventional bracket systems.

The components of the bracket arm assembly 230, 430 can be made of metals (e.g., steel, aluminum, or the like), plastics, or the like. These components may be made from any suitable manufacturing process, such as stamping, additive manufacturing, or the like.

The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the disclosure as set forth in the claims.

Other variations are within the spirit of the present disclosure. Thus, while the disclosed techniques are susceptible to various modifications and alternative constructions, certain illustrated examples thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the disclosure to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions and equivalents falling within the spirit and scope of the disclosure, as defined in the appended claims.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosed examples (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (e.g., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate examples of the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is otherwise understood within the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain examples require at least one of X, at least one of Y, or at least one of Z to each be present.

Preferred examples of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. Variations of those preferred examples may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the disclosure to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.