DESCRIPTION CAM ACTION CASTER ASSEMBLY FOR RIDE-ON DEVICES

BACKGROUND ART

[0001] The present invention relates generally to caster assemblies. More particularly, in various embodiments, the present invention relates to caster assemblies for use with ride-on devices. Even more specifically, this invention, in particular embodiments, pertains to an adjustable cam action assembly for improved performance of recreational skate boards, caster boards, and the like. [0002] There are numerous ride-on devices in the marketplace. Ride-on devices take many forms and may be used for exercise, entertainment or both. They may have a non-descript, mostly functional aesthetic form, like a skateboard or scooter, or they may be made to look like a vehicle, an animal or a fictional character as with many preschool toys.

[0003] Conventional skate boards are generally supported by two-wheeled truck assemblies attached to the undersides of the boards. Such skate boards have long been popular, but are limited in the sense that the rider could realistically accelerate on a level or uphill surface only by removing one of his or her feet from the board and pushing off the ground. Typical such skate boards were also limited in the degree of steering that was possible, as where the turning radius reached a certain angle, the wheels would touch the board. [0004] There is a desire and need in the marketplace for ride-on products that can be propelled in a way that is more novel than simply pushing off, and that may provide sharper turns if desired.

[0005] Caster boards were subsequently developed to address the limitations of skate boards. U.S. Patent No. 7,195,259 provides certain examples of caster boards. Caster boards typically have comprised one or two boards, with at least one swivel caster wheel assembly in front and at least one in the rear of the caster board. The rider twists his or her body to the left and to the right to accelerate the caster board or to turn it within a relatively small turning radius. This is accomplished by having the wheels rotate around the wheel axis when the board is twisted in either direction, where the axis is angled with respect to the bottom of the caster board.

[0006] In prior art caster boards, the board rises and falls at a rate predetermined by angle of attachment of the axis as the wheel bracket rotates. The angle can be made steep or slight or somewhere in between by the angle of the connection of the axis. Therefore the ease of operation and speed are inversely proportional to each other within this design and both must be compromised, in typical prior art designs, to achieve a balance between them. Moreover, in common prior art caster boards, the angle of the axis cannot be adjusted by the rider, according to his skill level, chosen activity or preference. In contrast, many sport type ride-on devices, such as BMX bicycles and common skateboards, retain the interest of the user partly due to the fact they can be customized to affect performance via changeable parts such as sprockets, trucks and other paraphernalia.

[0007] Typical prior art caster boards with a fixed angle design are also limited in that propulsion is only unidirectional. This is because most caster boards use the lateral force against the supported weight and the rise of the board as the wheel caster rotates to propel the board. With the angled shaft design there is only one low point on the rotation of the wheel assembly. If the wheel assembly is rotated 180 degrees, the base of the ride-on device is at its highest point, no further rise is possible, and so it cannot be propelled in this direction.

[0008] Some ride-on devices have used a spring to work against the rotation of the wheel assembly along the wheel axis, thus creating a force that replaces the gravitational force used in other prior art devices. This method still provides forward motion resulting from side-to-side, or twisting, forces applied by the rider. However, this does not allow full rotation of the wheel assembly which limits the maneuverability of the ride-on device. Moreover, the spring has a set preload or tension so performance varies greatly with the weight of the rider. [0009] It is desirable therefore to provide a caster assembly that permits full rotation of the wheel for improved maneuverability. This improved performance may include sharper turns, bi-directional travel, and user- adjustable components for various preferences and/or skill levels as examples. Other needs and potential areas for benefit may be apparent to persons of skill in the art having studied this document.

DISCLOSURE OF PARTICULAR EMBODIMENTS OF THE INVENTION [0010] It is an object of some embodiments of this invention to provide a caster assembly for ride-on devices such as caster boards that uses a cam to permit bidirectional motion, improve performance, or both, for example, for riders of all sizes. Some embodiments may have other objects or benefits, some of which may be apparent from this document.

[0011] In accordance with some embodiments of the invention, a caster assembly includes a wheel bracket, a wheel attached to the wheel bracket, a shaft about which the wheel bracket is free to rotate, and a cam assembly, for example. In some embodiments, the caster assembly is attached to the underside of a caster board, for instance, where the shaft is fixed perpendicular to the board, and the cam assembly may comprise a cam track fixed to the board with the shaft at its center, for example, and a cam follower may be fixed to the wheel bracket in some embodiments. The cam track is geometrically formed to have a number of valleys and peaks along its circumference, in various embodiments. Oscillating lateral forces applied by the rider may cause the wheel bracket to rotate about the shaft and the cam follower to engage and track the valleys and peaks in the cam track, for example. The resulting forces may operate to cause the wheels to roll and maintain a generally forward motion in the caster board, without the need for further efforts by a rider. [0012] Through the use of various embodiments of the invention, forward motion may be easier to maintain than it is to initiate. Further, in a number of embodiments, the caster assembly further permits the rider to travel backwards as well as forwards. In different embodiments, the cam track may comprise a wide variety of configurations and some embodiments may be easily changeable by the rider to accommodate various user preferences and skill levels, for example. As used herein, "changeable", when referring to a part such as a cam track, means that the part can be removed and replaced without damaging the part using the skill and tools ordinarily found in homes of most riders of skateboards, caster boards, scooters, and the like.

[0013] In accordance with other embodiments of the caster assembly, the cam track may be attached to the wheel bracket and may actually rotate with the wheel bracket. In some such embodiments, the cam follower(s) is/are fixed to

the underside of the caster board, for example, and thus continue(s) to engage the cam track as it rotates around the shaft. In this manner, the caster assembly may allow for a variety of cam configurations where aesthetically desirable or functionally necessary, while still maintaining some or all of the improved capabilities of the previously disclosed embodiments. [0014] While many ride-on devices as contemplated by this invention may require more than one wheel to operate, only one propulsion caster assembly as described may be required. However, the various caster assemblies of the present invention may be used in a variety of combinations with a variety of ride- on devices. In some embodiments, the caster assembly may, in addition, comprise a blade instead of a wheel where the ride-on device is to be used on ice. Further, the caster assembly may conceivably be used with devices that are not intended to be ridden such as carts or wagons, as examples. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figs. IA and IB contain a side view and a front view of one embodiment of a caster board of the present invention having two caster assemblies of the present invention.

[0016] Fig. 2 is an end view (e.g., a front or back view) of one embodiment of a caster assembly of the present invention (no caster wheel attached). [0017] Fig. 3 is an exploded perspective view of the caster assembly of Fig.

2 (with a caster wheel included).

[0018] Figs. 4A to 4C contain side, perspective, and front views of a wheel, wheel bracket, and cam assembly used in one embodiment of the invention. [0019] Figs. 5A to 5C contain perspective side, angle, and front views of another embodiment of a caster assembly in accordance with the invention. [0020] Fig. 6 is a side view of another embodiment of a caster assembly in accordance with the present invention (without a wheel attached). [0021] Figs. 7A to 7C contain side, bottom, and end (front or back) views of one embodiment of a cam track used with a caster assembly of the present invention.

[0022] Figs. 8A and 8B contain back and front views of another embodiment of a caster assembly in accordance with the present invention.

[0023] Fig. 9 is an exploded perspective view of another embodiment of a caster assembly in accordance with the invention.

[0024] Fig. 10 is a perspective view of an embodiment of a scooter in accordance with the invention, having an embodiment of a caster assembly in accordance with the present invention.

[0025] Fig. 11 is a perspective view of another embodiment of a scooter in accordance with the invention, this embodiment having two caster assemblies of the present invention.

[0026] Fig. 12 contains a perspective view of still another embodiment of a ride-on device or scooter in accordance with the invention, having caster assemblies in accordance with the present invention.

[0027] Fig. 13 is a flow chart illustrating the steps of one embodiment of a method in accordance with the present invention.

BEST MODE FOR CARRYING OUT EXAMPLES OF THE INVENTION [0028] One embodiment of the invention is disclosed in Figs. IA and IB.

In this embodiment, a cam action caster assembly 10 is presented for use with a ride-on device 12 having at least one base 14. Each base 14 has a top side 16 for supporting the feet of a rider and a bottom side 18 to which the caster assembly 10 is attachable and is attached.

[0029] Referring now to Figs. 2 and 3, in the embodiment illustrated, the caster assembly 10 includes a wheel 20 supported by a wheel bracket 22. The wheel 20 is attached so as to rotate freely along its entire circumference. Wheel 20 may be rotatably attached to and supported by an axle and bearings (not shown), for example, such as two sets of ball bearings, for instance. In this embodiment, the wheel bracket 22 is rotatably connected to a shaft 24 that is fixed perpendicular to the bottom side 18 of the base 14. In this manner the wheel 20 and the wheel bracket 22 are free to rotate around the shaft 24 and about an axis generally forming a right angle with respect to the base 14. The benefits of this axis of rotation will be discussed below. In the embodiment illustrated, in addition to being free to rotate, wheel bracket 22 is also free to translate (e.g., up and down) along shaft 24 for a certain distance. Figs. 2 and 3 show different alternatives for the top of shaft 24, for example, where shaft 24 attaches to board 14 shown in Fig. 1.

[0030] In some embodiments, friction on the shaft 24 may be reduced, for example, by the use of shaft radial bearings 26 engaging both wheel bracket 22 and shaft 24. Bearings 26 may be secured to wheel bracket 22 by a bushing 28 having a flange or lip 30 on one side (e.g., on the top) and an external snap ring 32 on the other side (e.g., the bottom), for example. Once so secured, the bushing 28 may then slide on shaft 24, for instance.

[0031] Referring to Fig. 1, in the embodiment illustrated, cam track 34 is attached to bottom side 18 of base 14 with shaft 24 at its center. In various embodiments, cam track 34 is shaped such that it has at least on valley 36 and one peak 38 (e.g.,, when viewed when device 12 is upside down, see, e.g.,, Figs. 6 and 7A). Particular embodiments of cam track 34, including the embodiments shown, have precisely two valleys 36 and two peaks 38. In the embodiment shown, the two lowest points or valleys 36 of cam track 34 face to the left and to the right of the ride-on device 12 with respect to a direction in which device 12 is normally ridden, for example, the long axis or long horizontal dimension of device 12. Likewise, the two highest points or peaks 38 of the cam track 34 face forward and to the back of the ride-on device 12 with respect to the normal direction of motion or the long axis (i.e., referred to herein as the "direction of movement"). In other embodiments, the valleys 36 of the cam track 34 may be in front of and behind shaft 24 or at other locations along cam track 34. [0032] In the embodiment shown, a cam follower is attached to the wheel bracket 22 by cam bolts 42. In some embodiments, the cam follower comprises roller followers or cam track radial bearings 40. The cam track bearings 40 may be secured to the wheel bracket 22 so as to be parallel to each other and to the wheel 20 at all times, in some embodiments. In other embodiments, the cam track bearings 40 may be perpendicular to, or at another angle to wheel 20, for example, rotated around cam track 34 with valleys 36, for instance. The cam track bearings 40 are also equidistant from the center of the wheel bracket 22 at a distance equal to the radius of the cam track 34 in the embodiment shown. Upon rotation of wheel bracket 22, each of the cam track bearings 40 engages cam track 34. In the embodiment shown, as the cam track bearings 40 engage and trace cam track 34 from a low point 36 to a high point 38, a distance between the wheel 20 and the base 14 subsequently increases. Likewise, as the cam track

34 is followed by cam track bearing 40 from the high point 38 back to the low point 36, the distance between the wheel 20 and the base 14 decreases. As such, the more pronounced the difference between the valleys 36 and peaks 38 of the geometry of the cam track 34, the greater the effect on the distance between the wheel 20 and the base 14, with results that will become apparent below. [0033] In some embodiments of the caster assembly 10, for example, a helical spring 44 (e.g., shown in Fig. 3) is positioned over the end of shaft 24 and may be secured in place by subsequently threading a shaft bolt 46 into the end, for instance. As the wheel bracket 22 rotates around cam track 34, in this embodiment spring 44 is compressed by wheel bracket 22 traveling (i.e., translating) down or away from bottom side 18 of base 14. In this embodiment, spring 44 acts to keep wheel 20 and wheel bracket 22 from rotating freely (i.e., around shaft 24) when wheel 20 is not making contact with a riding surface, such as during an airborne maneuver, for example.

[0034] Fig. 4A to 4C illustrate another embodiment of a caster assembly having a cam. Other embodiments of the caster assembly 10 of the present invention can be viewed in Figs. 5A to 6. Figs. 7A to 7C demonstrate an embodiment of the cam track 34 specifically. Although not shown in Fig. 7B, in a number of embodiments, cam track 34 may contain holes for fasteners to secure cam track 34 to base 14, for example (e.g., as shown in Fig. 3). [0035] With one or more caster assemblies 10 as described mounted to a ride-on device 12, in this example, a caster board, motion may be started with a push by the rider. The supported weight on cam bearings 40 causes them to seek the valleys 36 of the cam track 34. As a sufficient twisting and/or side-to-side force is applied, e.g., swizzling, the cam bearings 40 overcome this tendency in proportion to the twisting and/or the side to side force applied. As a result, the cam bearings 40 travel from the valley 36 of the cam track 34 toward the peak 38 of same.

[0036] With the cam action of this embodiment of the invention, as described, the rise and fall of the base 14 is not limited to a predetermined rate by the axis angle of attachment as the wheel bracket 22 rotates. Using a cam allows more control over the rise and fall of the device, and therefore more control over performance when compared to an angled caster without a cam. By

its shape, the cam track 34 can cause the base 14 to rise and fall modestly at first and accelerate the angle of action as the caster assembly 10 rotates further around the cam track 34 and its axis. This means that a cam track 34 can make the ride-on device 12 easy to set into beginning motion, yet still offer the potential for greater speed within a single configuration. Therefore a cam track 34 effectively reduces the opposition of these two characteristics of performance in a ride-on device 12 using such a caster assembly 10. Using a cam, such as cam track, allows more control over the rise and fall of the device as the caster rotates, in comparison with an angle caster without a cam, for example. [0037] For example, a cam track 34 having a steeper angular incline with respect to the base 14 may raise the base 14 higher and more quickly, and permit the rider to move the device at greater speeds when side to side force is applied, and may make the device more stable at high speeds, with the caveat that such an angle may make the ride-on device 12 more difficult to set in motion and turn at low speed. A cam track 34 with a flatter angular incline with respect to the base 14 will facilitate easier starts and enable turns and tricks such as a 180 or 360 degree spin, for example, at low speeds. However, a flatter angular incline will decrease the ability to accelerate to higher speeds.

[0038] A cam track 34 having a wider radius also allow greater speeds with a lower profile cam track. As such, some embodiments of the invention offer a variety of configurations of cam tracks 34 that may easily be changeable by the rider, for example, to adjust the performance of the ride-on device 12 to match skill level, chosen activity, or preference. In some embodiments, a cam track 34 may be changeable simply be detaching it from the base 14 using conventional fasteners and may be interchangeable with other shape or height cam tracks 34, for example. Where a wider radius for the cam track 34 is desired, other components may also be detachable and interchangeable.

[0039] In various embodiments of ride-on devices 12, the most stable positions of the device 12 are where the caster 10 (e.g., cam bearings 40) is at its low points 36 (e.g., low point when viewed with device 12 upside down). This is because gravity always causes the device 12 to seek its lowest point. The higher the base 14 is pushed by the rotation of the caster 10, the more it gravitates toward a lower position. With the cam track 34 of certain embodiments,

including the embodiments shown, complementing low positions 36 are available in both the forward and back positions of cam track 34 relative to the normal direction of forward motion of ride-on device 12. This makes reversing the direction of ride-on device 12 (going backwards) a more stable activity than was possible previously, e.g., with angle-axis caster devices. This opens up a variety of tricks that can be better executed by various embodiments of the invention. [0040] In another embodiment of the invention, a specialty "trick track" cam track 34 with smaller valleys 36 every ninety degrees rather than merely in the front and rear of the ride-on device 12 can be attached to the caster assembly 10 by the rider, for example. This will make the ride-on device 12 more stable north, south, east and west (i.e., sideways as well as forwards and backwards) and able to propel itself in each of these directions. This opens up more possibilities for dancing or freestyle activities, for example.

[0041] Another significant advantage of some embodiments of the invention resides in the integrity of the attachment of the caster assembly 10 to bottom side 18 of base 14. Cam track 34 allows a vertical attachment as opposed to an angled attachment. Therefore less bending moment is exerted on the connection point when a downward force is applied (such as the weight of the rider, particularly during some sort of landing as from a trick). Because of the bending moment an angle creates, an angled attachment actually acts as a lever to increase force on the single attachment point of the caster. Conversely, the disclosed cam track 34 serves as an additional support for the caster assembly 10, in some embodiments. This relieves stress placed upon the connection point when a downward force is applied by distributing the force over a wider area. [0042] Referring now to Figs. 8A and 8B, in another embodiment of the invention, the caster assembly 10 further includes pivot hinge 48 on wheel bracket 22 such that wheel bracket 22 no longer needs to travel up and down shaft 24. A helical, or other shape spring may be affixed to the pivot hinge 48, in this embodiment, for the same reason that the helical spring 44 was positioned over the shaft 24 in other embodiments.

[0043] In another embodiment of the invention, as displayed in Fig. 9, cam track 34 is attached to, or is integral with, wheel bracket 22 and rotates with wheel bracket 22. In this embodiment, cam follower or cam bearing 40 is fixed

(from rotating about shaft 24, although cam bearings 40 are free to rotate about their own axes) to the bottom side 18 of the base 14, and engages cam track 34 as it rotates around shaft 24. In other embodiments, shaft 24 may rotate with cam track 34. In this manner, caster assembly 10 allows for a variety of cam configurations where aesthetically desirable or functionally necessary, while still maintaining, in some embodiments, some or all of the improved capabilities of the previously disclosed embodiments.

[0044] In the particular embodiment of the invention specifically illustrated in Figs. IA and IB, the ride-on device 12 is a caster board having two bases 14 connected to each other with a connecting element 50 and having one caster assembly 10 attached to the bottom side 18 of each base 14. In various embodiments, boards 14 may be adapted to support a riders feet. For example, boards may be of sufficient strength to support a rider and may be made of a material having a relatively high coefficient of friction with the sole of a typical shoe that may be worn when riding a ride-on device of the embodiment. Caster assembly 10 may also work with numerous other embodiments of ride-on devices 12.

[0045] Fig. 10 illustrates a ride-on device 12, which is a scooter, having a front board 14a and a rear board 14b with a connecting element 50 having elastic properties connected between the two boards 14a, and 14b. In this embodiment, the front board 14a is rotatably attached to a steering column 52 having a wheel bracket 22 such that the wheel 20 is able to pivot about the axis of the steering column 52. A cam action caster assembly 10 is attached to the underside 18 of the rear board 14b, in the embodiment shown, and permits the rider to sustain a forward motion in the ride-on device 12 without taking his or her feet off of the boards 14a and 14b (e.g., by swizzling or pushing rear board 14b from side to side).

[0046] Fig. 12 shows a ride-on device 12 having one board 14 with two cam action caster assemblies 10 attached to either end of a rear portion of the underside of the board 14. In the rear center portion of the underside of the board 14 there is attached a fixed third wheel 20 to provide support during riding maneuvers conventionally known as "wheelies." The front end of the board 14 is rotatably attached to a steering column 52 having a wheel bracket 22 such that a

front wheel 20 is able to pivot about the axis of the steering column 52. The cam action caster assemblies 10 permit the rider to sustain a forward motion in the ride-on device 12 without taking his or her feet off of the board 14. [0047] Fig. 11 illustrates a ride-on device 12 having a left member 15 and a right member 15, each member 15 having a foot platform 54 to support a rider. In particular, one of skill in the art will recognize that each platform 54 should have sufficient surface area and structural rigidity so as to support a rider's feet during use of the device 12. The members 15 are each attached to a bracket 56, in this embodiment, the attachments being pins or hinges 48 that permit the members 15 to pivot to the left and to the right while steering column 52 remains at the same nearly-vertical angle. There is also a support element 58, in this embodiment, pivotably attached on one end to a central portion of the left member 15 and on the other end to a central portion of the right member 15. The bracket 56 also is attached (rotatably) to a steering column 52, in this embodiment, and a wheel 20 that is able to rotate about the axis of the steering column 52. There are two cam action caster assemblies 10, in this embodiment, one attached to the underside of each foot platform 54, to permit the rider to sustain a forward motion in the ride-on device 12 without taking his or her feet off of the platforms 54.

[0048] In many embodiments, a ride-on device may be human powered

(e.g., by swizzling), but in other embodiments, a ride-on device may be powered, for example, with an electric motor, an internal combustion engine, a sail (e.g., wind power), or the like. Some embodiments may have a battery, which may be used to power an electric motor, lights, controls, or a combination thereof, for instance.

[0049] Referring to Fig. 13, the present invention includes methods of obtaining and/or providing a device, article, or multiple articles, for example, (e.g., act 61) which may certain characteristics described above, for instance. Various methods include acts such as obtaining, providing, manufacturing, making, forming, or assembling, one or more of the devices, caster assemblies, caster boards, scooters, or parts thereof described herein.

[0050] In some embodiments, for example, a method includes an act of obtaining or providing multiple articles (e.g., act 61), wherein each article has at

least a first wheel having a first wheel center, a second wheel having a second wheel center, and a first wheel bracket supporting the first wheel and allowing free rotation of the first wheel, for example. In some such embodiments, each article further includes a first shaft supporting the first wheel bracket and permitting rotation of the first wheel bracket around the first shaft, and a first cam functional to cause the first wheel bracket to translate along the first shaft as the first wheel bracket rotates around the first shaft.

[0051] In some such embodiments, the act of obtaining or providing multiple of the articles (e.g., act 61) may further include obtaining or providing multiple articles wherein the first shaft is oriented at a substantially right angle to a line extending through the first wheel center and the second wheel center, for example . Further, in some embodiments, the act of obtaining or providing multiple of the articles (e.g., act 61) may further include obtaining or providing multiple articles having a second wheel bracket supporting the second wheel and allowing free rotation of the second wheel. In particular such embodiments, each article may include a second shaft supporting the second wheel bracket and permitting rotation of the second wheel bracket around the second shaft. In this embodiment, each article may have a second cam functional to cause the second wheel bracket to translate along the second shaft as the second wheel bracket rotates around the second shaft, for instance.

[0052] In a number of such embodiments, the act of obtaining or providing multiple of the articles (e.g., act 61) further includes obtaining or providing multiple articles wherein the second shaft is oriented at a substantially right angle to the line extending through the first wheel center and the second wheel center.

[0053] In some embodiments, the act of obtaining or providing multiple of the articles (e.g., act 61) further includes obtaining or providing multiple articles each having a first board wherein the first shaft is attached to the first board, having a second board wherein the second shaft is attached to the second board, having a connecting element connecting the first board to the second board, or a combination thereof, as examples.

[0054] Various methods of the invention may also included an act of obtaining or providing multiple articles (e.g., act 61) wherein the first cam has

precisely two peaks and two valleys. Further, in different embodiments, certain methods of the invention may include an act of advertising (e.g., act 62), for instance, that the articles can be ridden both frontwards and backwards and/or that the caster boards can be propelled by swizzling, as examples. Such advertising (e.g., act 62) may be conducted through commercials, through the media, on packaging for the articles, through mailings, or through the Internet, as examples. As used herein, "advertising" is performed or paid for by a manufacturer, distributor, or retailer of at least hundreds of copies of a product. Still further, In any one of the foregoing methods, the act of obtaining or providing multiple of the articles (e.g., act 61) may further include obtaining or providing multiple articles wherein the first cam is a cam track and the article further includes a first cam follower engaging the first cam.

[0055] A number of embodiments of the present invention have been presented herein. However, the invention may be used in the context of a device that is not ridden, such as a cart or wagon. In other embodiments, the invention could provide for a caster assembly using blades for use on ice rather than wheels. This disclosure is not intended to limit the invention in any way to the particular embodiments described, understanding that there are numerous alternative constructions. The invention is intended to cover the full scope of the subject matter as presented in the following claims.