| WO/1997/032799 | REFUSE CONTAINER WITH WHEELS |
| JP2007084747 | HEAT-RESISTANT AND DIMENSIONALLY STABLE MONOMER-CAST NYLON MOLDED FORM |
| WO/1997/009181 | VEHICLE WHEEL FRAME |
| WHAT IS CLAIMED IS: 1. A wheel comprising: an inner assembly including a rim generally formed around a hub, the rim including a cross-section having a first side, a second side generally opposite the first side, a ground-facing surface, and a hub-facing surface; and an outer assembly comprising a material different from that of the inner assembly, the outer assembly mechanically coupled through the rim at the first and second sides of the rim, the outer assembly at least partially covering the ground- facing surface of the rim and extending below the hub-facing surface of the rim, the hub-facing surface of the rim being generally devoid of the material of the outer assembly. 2. The wheel of Claim 1 , wherein the hub-facing surface of the rim is substantially devoid of the material of the outer assembly. 3. The wheel of Claim 1 or 2, wherein the hub-facing surface of the rim is completely devoid of the material of the outer assembly. 4. The wheel of any of Claims! -3, wherein the inner assembly comprises high density polyethylene (HDPE) and the outer assembly comprises rubber or rubber-like material. 5. The wheel of Claim 4, wherein the rubber or rubber-like material comprises thermoplastic elastomer (TPE). 6. The wheel of Claim 4, wherein the rubber or rubber-like material comprises thermoplastic urethane (TPU). 7. The wheel of any of Claims 1-6, wherein the rim includes a plurality of apertures through the first side of the rim, and wherein the outer assembly overlaps the rim and extends through the plurality of apertures on the first side of the rim. 8. The wheel of any of Claims 1-7, wherein the rim includes a plurality of apertures through the second side of the rim. and wherein the outer assembly extends through the plurality of apertures on the second side of the rim, the outer assembly defining a plurality of buttons on an inner portion of the rim on the second side of the rim. 9. The wheel of any of Claims 1 -8, wherein the rim includes a first plurality of apertures through the first side of the rim and a second plurality of apertures through the second side of the rim, the first plurality of apertures radially offset from the second plurality of apertures. Knobbe, Martens. Olson & Bear, LLP -25- GEO Plastics GEOPL.024A 10 The wheel of any of Claims 1 -9, wherein the rim includes a flange proximate to the first side of the nm 11 The wheel of Claim 10, wherein the πm includes a plurality of πbs transverse to the flange 12 The wheel of Claim 1 1 , wherein the πm includes a plurality of partially annular πbs transverse to the flange and substantially orthogonal to the ribs 13 The wheel of Claim 11 or 12 wherein the outer assembly is mechanically coupled through the πm at the first side of the πm between at least some of said πbs 14 The wheel of Claim 13, wherein the outer assembly is mechanically coupled through the rim at the second side of the πm radially inward from said πbs. 15. The wheel of any of Claims 11 -14, wherein the at least some of the πbs have different radial thicknesses 16 The wheel of any of Claims 10-15, wherein the rim includes a first plurality of apertures through the flange and a second plurality of apertures through the second side of the πm, the first pluiahty of apertures radially offset from the second plurality of apertures 17 The wheel of any of Claims 10-16, wherein the flange includes a hp extending towards the first side of the rim, and wherein the outer assembly at least partially overlaps the hp 18 The wheel of any of Claims 1-17, wherein a radial width of the outer assembly at the second side of the nm is greater than a radial width of the outer assembly at the first side of the πm 19 Fhe wheel of any of Claims 1 -18, wherein a ratio of weight of the outer assembly to weight of the inner assembly is less than about 0 5 1 20 The wheel of any of Claims 1 -19, wherein a ratio of a radial width of the outer assembly on the second side of the πm to a radius of the wheel is between about 0 1 1 and about 0 4 1 21 The wheel of any of Claims 1-20, further comprising a hub assembly configured to secure the wheel on an axle 22 A method of manufactunng a wheel, the method comprising molding a first matenal into a first part of the wheel, the first part compnsmg a hub and a πm the nm including a cross-section having a first side, a second side generally opposite the first side, a ground-facing surface, and a hub-facing surface, Knobbe Martens Olson &. Bear LLP -26- GEO Plastics GEOPL 024A molding a second material into a second part of the wheel, wherein molding the second material comprises mechanically coupling the second part of the wheel through the nm at the first and second sides of the πm, wherein, after molding the second material, the second material at least partially covers the ground-facing surface of the nm, the second material extends below the hub-facmg surface of the πm, and the hub-facmg surface of the rim is generally devoid of the second materia] 23 The method of Claim 22, wherein molding the first material comprises injection molding the first material, wherein the first part is a unitary piece. 24 The method of Claim 22 or 23, wherein molding the second mateπal compπses injection molding the second material 25 The method of any of Claims 22-24, wherein molding the second mateπal comprises weaving molten second mateπal through the first side of the πm and forming a button proximate to the second side of the πm 26 A wheel compπsmg an inner piece comprising high density polyethylene (HDPE), and an outer piece mechanically coupied to the inner piece, the outer piece comprising thermoplastic elastomer (TPE) or thermoplastic urethane (TPU) 27 The wheel of Claim 26, wherein the inner piece compπses a nm and a hub, a cross-section of the πm having a first side, a second side opposite the first side, a ground- facing surface, and a hub-facmg surface, wherein the outei piece is mechanically coupled through the πm at the first and second sides of the πm, w herein the outer piece at least partially covers the ground-facing surface of the πm, wherein the outer piece extends below the hub-facmg surface of the nm, and wherein the hub-facmg surface of the nm is generally devoid of the TPE or TPU 28 The wheel of Claim 26 or 27, wherein a ratio of weight of the outer piece to weight of the inner piece is less than about 0 5 1 29 The wheel of any of Claims 26-28. wherein a ratio of weight of the outer piece to weight of the inner piece is between about 0 1 1 and about 0 4 1 30 An mjection-molded wheel compπsmg a plastic inner section, and an outer section comprising a different mateπal than the inner section, the outer section mechanically coupled to the inner section, wherein a ratio of weight of the outer section to weight of the inner section is less than about 0 5 1 Knobbe Martens, Olson & Beai LLP -27- GfIO Plastics GEOPL 024 A 31. The wheel of Claim 30, wherein a ratio of weight of the outer section to weight of the inner section is between about 0 1 1 and about 0.4 1 32 The wheel of Claim 30 or 31, wherein the inner piece comprises a πm and a hub, a cross-section of the πm having a first side, a second side generally opposite the first side, a ground-facmg surface, and a hub-facing surface, wherein the outer section is mechanically coupled through the πm at the first and second sides of the πm, wherein the outer section at least partially covers the ground-facmg surface of the πm, wherein the outer section extends below the hub-facing surface of the πm, and wherein the hub-facing surface of the πm is generally devoid of material of the outer section. 33 A wheel compnsing a hub, and a ran generally foπried around the hub, the πm compπsmg a plurality of generally hollow features, and a flange disposed radially outward of the generally hollow features 34 The wheel of Claim 33, wherein the flange is proximate to an mside of the πm 35 The wheel of Claim 33 or 34. wherein the flange compπses a hp extending towards a side of the πm 36 The wheel of Claim 35, wherein the πm further compπses a plurality of πblets disposed radially inward of the lip 37 The wheel oi any of Claims 33-36, wherein the πm further compnses a plurality of ribs generally transverse to the flange 38 The wheel of any of Claims 33-37, wherein the πm includes a cross-section having a first side, a second side generally opposite the first side, a ground-facing surface, and a hub-facing surface and wherein the wheel further compπses an outer assembly compnsing a material different from that of the inner assembly, the outer assembly mechanically coupled through the πm at the first and second sides of the rim, the outer assembly at least partially coveπng the ground-facing surface of the nm and extending below the hub- facing surface of the πm, the hub-facing surface of the πm being generally devoid of the material of the outer assembly Knobbe Mariens, Olson &. Bear LLP -28- GEO Plastics GEOPL 024A |
BACKGROUND Field
[0001] The present application generally relates to wheels, and, more particularly, to wheels including a tread. Description of the Related Ait
[0002] The use oi plastic wheels on a vaπety of products has dramatically increased m recent years One area where such plastic wheels have been widely employed is on wheeled refuse or garbage carts or bins of the type commonly employed by homeowners or commercial businesses for their trash and recyclables Some plastic wheels produce abundant noise when rolled along hard surfaces Additionally, some vaneties of plastic are prone to chipping, fracturing, and breakage when a product comprising the wheels is rolled along certain sui faces T his can especially be an issue when these wheels support heavier loads Such wheels may be prone to causing a disturbance and/or breaking Accordingly, various wheel assemblies have been devised m which a rubber or rubber-like material is chemically bonded or mechanically fastened to the plastic wheel
SUMMARY
[0003] In certain embodiments, a wheel comprises an inner assembly and an outer assembly The innci assembly includes a πm generally formed around a hub The πm includes a cross-section having a first side a second side generally opposite the first side a ground-facing surface and a hub-facing surface 1 he outer assembly comprises a material different from that of the innei assembly The outer assembly is mechanically coupled through the πm at the fust and second sides of the πm The outer assembly at least partially covers the ground-facing surface of the πm and extends below the hub-facmg surface of the πm The hub-facmg surface of the πm is generally devoid of the matenal of the outer assembly
[0004] In certain embodiments, a method of manufacturing a wheel comprises forming a first part of the wheel forming a second part of the wheel, and mechanically coupling the second part of the wheel to the first part of the wheel The second part of the wheel comprises a different matenal than the first part of the wheel The first part comprises
Knobbe Mai tens Olson & Bcai LLP - 1 ~ GFO PIaMn. s
GEOPL 024Λ a hub and a nm The nm includes a cross-section having a first side, a second side generally opposite the first side a giound-facmg surface, and a hub-facmg surface Mechanically coupling the second part of the wheel to the first part of the wheel includes weaving the material of the second part through the rim at the first and second sides of the nm After mechanically coupling the second part of the wheel to the first part of the wheel, the mateπal of the second part of the wheel at least partially covers the ground-facing surface of the nm, the mateπal of the second part of the wheel extends below the hub-facmg surface of the nm, and the hub-facmg surface of the nm is generally devoid of the matenal of the second part of the wheel
|0005] In certain embodiments, a method of manufacturing a wheel compπses molding a first mateπal into a fust part of the wheel and molding a second matenal into a second part of the wheel The first part compnses a hub and a nm The nm includes a cross- section having a first side, a second side generally opposite the first side, a ground-facing surface, and a hub-facmg surface Molding the second matenal compnses mechanically coupling the second part of the wheel through the nm at the first and second sides of the nm After molding the second matenal, the second matenal at least partially covers the ground- facing surface of the nm. the second material extends below the hub-facmg surface of the nm, and the hub-facmg surface of the nm is generally devoid of the second material
|0006] hi certain embodiments, a wheel compmes a hub and a nm generally formed around the hub The nm compπses a plurality of generally hollow features and a flange disposed radially outward of the generally hollow features
[0007] In certain embodiments, a wheel comprises an inner piece and an outer piece mechanically coupled to the inner piece The ouler piece compπses rubber or rubber- like mateπal The inner piece compnses a material that does not chemically bond to the rubber or rubber-hke matenal
[0008] In certain embodiments, a wheel comprises an inner piece and an outer piece mechanically coupled to the inner piece The inner piece comprises high density polyethylene (HDPE) The outer piece comprises a mateπal that does not chemically bond to HDPE
10009] In certain embodiments, a wheel compπses an inner piece and an outer piece mechanically coupled to the inner piece The mnei piece comprises acrylonitnle butadiene styrene (ABS) The outer piece compπses a material that does not chemically bond to ABS
Knobbe, Martens Olson &. Bear LLP -2- GCO Plastics
GEOPL 024A [0010] In certain embodiments, a wheel comprises an inner piece and an outer piece mechanically coupled to the inner piece. The outer piece comprises thermoplastic elastomer (TPE) or thermoplastic urethane (TPU). The inner piece comprises a material that does not chemically bond to TPE or TPU.
|0011] In certain embodiments, a wheel comprises an inner piece and an outer piece mechanically coupled to the inner piece. The inner piece comprises high density polyethylene (HDPE). The outer piece comprises thermoplastic elastomer (TPE) or thermoplastic urethane (TPU).
J0012] In certain embodiments, a wheel comprises an inner piece and an outer piece mechanically coupled to the inner piece. The inner piece comprises acrylonitrile butadiene styrene (ABS). The outer piece comprises thermoplastic elastomer (TPE) or thermoplastic urethane (TPU).
[0013] In certain embodiments, a wheel comprises an inner section and an outer section comprising a different material than the inner section. The outer section is mechanically coupled to the inner section. A ratio of weight of the outer section to weight of the inner section is less than about 0.5:1.
[0014] In certain embodiments, an injection-molded wheel comprises a plastic inner section and an outer section comprising a different material than the inner section. The outer section is mechanically coupled to the inner section. A ratio of weight of the outer section to weight of the inner section is less than about 0.4:1.
[0015] In certain embodiments, a wheel comprises an inner portion and an outer section comprising a different material than the inner section. The outer section is mechanically coupled to the inner portion. The inner portion comprises a rim and a hub. A cross-section of the rim has a first side and a second side generally opposite the first side. The second side is configured to face away from an axle. A ratio of a radial width of the outer portion on the second side of the rim to a radius of the wheel is between about 0.05:1 and about 0.5:1.
[0016] hi certain embodiments, a wheel comprises an inner portion and an outer section comprising a different material than the inner section. The outer section is mechanically coupled to the inner portion. The inner portion comprises a rim and a hub. A cross-section of the rim has a first side and a second side generally opposite the first side. The second side is configured to face away from an axle. Weight of the outer portion divided
Knobbe, Mariens : Olson & Bear. LLP -3- GEO Plastics
GEOPL.024A by radius of the wheel is between about 0 5 lb/ft (approximately 740 g/m) and about 1.5 lb/ft (appioximately 2,200 g/m).
[0017] Li certain embodiments, an inject ion-molded wheel compπses a plastic inner portion and an outer section comprising a different material than the inner section The outer section is mechanically coupled to the inner portion The inner portion compπses a πm and a hub A cross-section of the πm has a first side and a second side generally opposite the first side The second side is configured to face away from an axle A ratio of a radial width of the outer portion on the second side of the rim to a radius of the wheel is between about 0 1 1 and about 0 3 1 Weight of the outer portion divided by radius of the wheel is between about 0 5 lb/ft (approximately 1 ,200 g/m) and about 1 5 lb/ft (approximately 1 ,500 g/m)
|0018] For purposes of summarizing the invention and the advantages achieved ovei the pπor art, certain objects and advantages of the invention have been descπbed herein above Of course, it is to be understood that not necessarily all such objects or advantages may be achieved m accordance with any particular embodiment of the invention Thus, for example, those skilled in the art will recognize that the invention may be embodied or earned out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving other objects or advantages as may be taught or suggested herein
[0019] All of these embodiments are intended to be within the scope of the invention herein disclosed These and other embodiments will become readily apparent to those skilled in the art from the following detailed descπption of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed
BRIEF DESCRIPTION OF THE DRAWINGS
|0020] These and other features, aspects, and advantages of the invention disclosed herein are descπbed below with reference to the drawings of certain embodiments, which are intended to illustrate and not to limit the invention
|0021] Figure I is a top/front/side perspective view of a refuse cart including a wheel assembly according to an example embodiment of the present disclosure mounted thereto
|0022] Figure 2A is a top/iront^side perspective view of an example embodiment of a wheel
Knobbe Mdiiens Olson & Bear, LLP -4- GEO Plastics
GEOPL 024A [0023] Figure 2B is an exploded perspective view of the wheel of Figure 2A
|0024] Figure 2C is a cross-sectional view of the wheel of Figure 2B taken along the line 2C-2C of Figure 2B
[0025] Figure 3A is a front elevational view of an example embodiment of an inner portion of a wheel
[0026] Figure 3B is a front elevational \ iew of a wheel
[0027] Figure 4A is a back elevational view of an example embodiment of an inner portion of a wheel
[0028] Figure 4B is a back elevational view of an example embodiment of an outer portion of a wheel
|0029] Figure 4C is a back elevational view of a wheel
[0030] Figure 5A is a back/top perspective view of a portion of an example embodiment of an inner portion of a wheel
[0031] Figure 5B is a back/top view of a portion of a wheel
[0032] Figure 6A is a front/top perspectne view of a portion of an example embodiment of an inner portion of a wheel
[0033] Figure 6B is a front/top perspective view of a portion of another example embodiment of an inner portion of a wheel
[0034] Figure 6C is a front/top perspective view of portion of an example embodiment of a wheel
[0035) Figure 7A is a cross-sectional view of the wheel of Figure 5B taken along the line IA-I A of Figure 5B
[0036] Figure 7B is a cross-sectional view of the wheel of Figure 5B taken along the line 7B-7B oi Figure 5B
[0037] Figure 1C is a cross-sectional \ iew of the wheel of Figure 5B taken along the line 7C-7C of Figure 5B
[0038] Figuie 8A is a cross-sectional view of another embodiment of a wheel
[0039] Figuie SB is another cross-sectional \iew of the wheel of Figure 8A
[0040] Figure 8C is still another cross-sectional view of the wheel of Figure 8A
[0041] Figure 9A illustrates a cross-section of an example embodiment of a portion of a method of manufacturing a wheel
Knobbc Mailcns Ohon &. Bear LLP -5- GEO Plasiits
GEOPL 024A |0042] Figure 9B illustrates a cross-section of another example embodiment of a portion of a method of manufacturing a wheel
[0043] Figure 9C is an elevational view of the portion of the method of Figure 9B [0044] Figure 9D is an elevational view of the portion of another method of manufacturing a wheel
DETAILED DESCRIPTION
[0045] Although certain embodiments and examples are disclosed below, it will be understood by those in the art that the invention extends beyond the specifically disclosed embodiments and/or uses of the invention and obvious modifications and equivalents thereof Thus, it is intended that the scope of the invention herem disclosed should not be limited by the particular disclosed embodiments described below
|0046] Certain embodiments described herein include treads that are coupled to plastic inner portions of wheels The tread may reduce noise produced during rolling and protect the plastic inner portion from damage In some embodiments, the tread is mechanically coupled to the inner portion on an inside and an outside of the wheel such that foreign matter cannot easily become lodged between the tread and the innei portion and such that tampering with eithei side of the wheel does not lead to easy disassembly of the tread from the inner portion A mechanical coupling allows, but does not require, the wheel to comprise mateπals that do not chemically bond to each other or that poorly chemically bond to each other Accordingly, embodiments described herein may increase the number of possible mateπals available to be used for the parts of the wheel which may optionally bring about numerous advantages
[0047] For example, increasing the number of possible mateπals for the parts of the wheel may reduce the costs of manufactuπng the wheel by permitting the use of less expensive mateπals (e g use of HDPF rather than polypropylene) For another example, increasing the number of possible materials for the parts of the wheel may increase the ability of the manufacturer to more freely select certain mateπals that are adapted for use in specific parts of the wheel (e g use of HDPE for the inner portion based on its high tensile strength, hardness and/or operable temperature range) For yet another example, increasing the number of possible materials for the parts of the wheel may increase the ability to select certain mateπals for certain parts of the wheel that are adapted for use under certain
Knobbe Martens Olson & Bear Ll P -6- GEO Plastics
GEOPL 024A conditions, which can allow a manufacturer to customize wheels for certain customers and/or products (e g , use of HDPE for wheels to be used in cold climates)
[0048] Certain embodiments described herein may allow for the aesthetic visual appearance of a thick tread using a relatively small amount of tread mateπal Reduction of the amount of rubber or rubber-like material may reduce the costs of manufacturing the wheel while still remaining functionally practical In some wheels, the tread mateπal is more expensive than the inner portion mateπal (e g , TPE may be more expensive than HDPE and polypropylene) Some wheel uses only need a modest amount of tread to reduce noise and/or protect the inner portion, but consumers may prefer the appearance of thicker tread Accordingly certain embodiments described herein may permit reducing the thickness of the lrcad that contacts the ground, while slill being thick enough to remain functional, but increase the apparent thickness of the tread by extending the tread iadially mward along an outer side of the wheel, thereby still remaining aesthetically pleasing In some embodiments, this duality (reduced tread amount but thick tread appearance) may be expressed as a ratio between the weight of the mner portion to the weight of the outer portion a ratio of the radius oi the outer portion to the radius of the wheel, the radius of the outer portion divided by the radius of the wheel, combinations thereol, and the like
10049] The wheels and wheel assemblies described herein can be used in connection with numerous wheeled devices Figure 1 illustrates an example embodiment of a refuse cart 100 comprising plurality of wheels 1 10 mounted on an axle 150 at the lowei end of the cart body 102 Each of the wheels 1 10 includes a tread that is coupled to an inner portion, as described m further detail in the present disclosure Λ hinged hd 104 optionally can be provided, and the cart 100 can be tilted or tipped about the wheels 1 10 using handle 106 so as to enable rolling of the cart 100 for the transport of refuse, for example between a location for filling the cart 100 and a location for pickup by a refuse disposal company The low er end of the cart body 102 optionally includes a wheel well or recess area 108 configured to leceive wheels 1 10, for example to protect the wheels 110 and as a cosmetic structure. The w heels 1 10 may be secured on the axle 150 by a hub assembly 1 12 Each wheel 1 10 may be spaced from the cart 100 by a spacer which may be integrated with the wheel 1 10 or a hub assembly fhe axle 150 may extend partially into a wheel 1 10 (e g , as illustrated in Figuie 1) or hilly through a wheel 110, depending on the mechanism for securing the wheel 3 10 to the axle 150 T he wheels 1 10 described herein may also be suitable for use with many other wheeled products, including without limitation wagons, wheeled food and beverage coolers,
Knobbt Martens Olson & Bear LLP -7- GEO Plastics
GEOPL 0244 barbecues, wheeled toys, small refuse containers, dolhes hand trucks, medical devices (e g hospital beds, intravenous fluid holders), and the like
|0050) In wheels comprising a tread that is chemically bonded to a plastic inner portion, the types of materials that may be used for both the wheel and the tread are limited to those materials that can chemically bond to each other For example, if the tread compπses thermoplastic elastomer, the plastic inner portion is geneially limited to polypropylene because a large number of TPEs contain some polypropylene, thereby providing a basis for a suitable chemical bond In certain embodiments of wheels comprising a tread that is mechanically bonded to a plastic inner portion the tread may become unfastened from the plastic inner portion due to wear, lateral forces, tampering etc For example, if the tread is radially coupled to the plastic inner portion as descπbed in U S Patent Nos 4,444,435 to Honsa and 4,567,633 to Corkery, lateral forces on the uheel may cause the tread to become dislodged from the connection point or to teai proximate to the connection point Additionally, foreign material may become lodged betw een the tread and the plastic inner portion, which may cause uneven tread wear and/or poor performance Certain embodiments described herein may avoid the disadvantages of previous mechanical couplings by reducing the likelihood of becoming unfastened For example, fastening the tread to the outer side of a plastic portion can make a wheel attached to a cart less prone to tampering (e g because a force roughly parallel to the plane of the wheel would ha\e to be manipulated to cause even slight partial separation of the wheel parts) Certain embodiments descπbed herein may include parts that are both chemically and mechanically bonded to each other, which may avoid the disadvantages of previous chemical couplings and previous mechanical couplings
|0051] Figure 2A illustrates an example embodiment of a wheel 200 The wheel 200 compπses a first or inner section (or first or outer assembly, part, piece section etc ) 210 and a second or outer section (or second or ouler assembly part, piece, section etc ) 220 The outer section 220 is mechanically coupled to the inner section 210 In certain embodiments, the outer section 220 may also be chemically bonded to the inner section 210 The outer section 220 may reduce noise produced duπng rolling of the wheel 200 In some embodiments, the outer section 220 is mechanically coupled to the inner section 210 on the inside (e g the side facing the axle) and the outside (e g , the side facing away from the axle) such that foreign matter or tools cannot easily become lodged or inserted between the outer section 220 and the inner section 210 In some embodiments, the outer section 220 is mechanically coupled to the inner section 210 on the mside and the outside such that
Knobbc Martens Olson & Bear LLP -8- GEO PidstiLs
GEOPL 024 \ tampering with either side of the wheel 200 does not lead to easy disassembly of the outer section 220 from the inner section 210 In certain embodiments, mechanical coupling produces opportunities to utilize mateπals that may not or may poorly chemically bond to each other Some such materials may have reduced cost and/or better physical properties (e.g , wear, abrasion resistance, extreme temperature peiformance, response to impact, memory after impact, etc ) versus standard materials with bonding charactenstics
[0052] In the illustrated embodiment, the wheel 200 comprises a plurality of spokes 232 extending radially outward from an axle-beaπng portion 234 In some embodiments, the axle-bearing portion 234 is configured to interact with an axle 150 For example, certain such embodiments may be mounted on the end on an axle 150 by a hub member or push-on fastener (e g , a pawl nut) In some embodiments, the axle-bearmg portion 234 is configured to receive a through-boie sleeve that allow the wheel 200 to be mounted on the end on an axle 150 by a hub member or push-on fastener (e g , a pawl nut) In certain such embodiments, the sleeve may include an integrated spacer configured to space the inner side of the wheel 200 from, for example, the recess area ] 08 of a cart 100 Separate spacers are also possible
[0053] In certain alternative embodiments the axle-beaπng portion 234 is configured to receive a sleeve or hub assembly that is configured to interact with an axle ] 50 (e g , snap onto an end of an axle 150) For example, co-owned U S. Patent No 7,377,597, entitled "Wheel Assembly Having Wheel-Mounting Sleeve and Retainer, " U. S Patent No. 6,375,274, entitled ' Plastic Wheel Assembly and Mounting Sleeve Therefor. " and U. S Patent Application No 1 1/944,322, entitled "Wheel and Hub Assembly," filed November 21, 2007, each descπbe example embodiments of sleeves that could be inserted into the axle- beaπng portion 234 of the wheel 200 Each of the ioregoing references is incorporated by reference herein in its entirety hi certain such embodiments, the sleeve may include an integrated spacer configured to space the inner side oi the wheel 200 from, for example, the recess area 108 of a cart 100 Separate spacers arc also possible Other sleeves, hub assemblies, devices, and methods of mechanically coupling the wheel 200 to an axle 150 are also possible
[0054] Ln some embodiments, the axle-beaπng portion 234 is centeied within the inner portion 210 such that a wheel into which an axle 150 is inserted into the axle-beanng portion 234 (e g , into a hub assembly at least partially disposed within the axle-beanng portion 234) can uniformly rotate around the axle 150 An appropπate axle-beaπng portion
Knobbe Martens, Olson &. Bear LLP -9- GEO Plastics
G EOPL 024A 234 and/or sleeve or hub assembly may be selected based on, for example, anticipated use conditions or type of axle 150 (e.g., chamfered or non-chamfered).
|0055] Figure 2B is an exploded perspective view of the wheel 200 of Figure 2A. The wheel 200 comprises a first assembly 210 and a second assembly 220. The second assembly 220 comprises a material different from that of the first assembly 210. The first assembly 210 comprises a rim 212 and a hub 214. As illustrated in Figure 2C, a cross-section of the rim 212 has a first side 212a, a second side 212b generally opposite the first side 212a, a ground-facing surface 212c, and a hub-facing surface 212d. The second assembly 220 generally forms a ground-contacting surface of the wheel 200. The second assembly 220 is mechanically coupled through the rim 232 at the first and second sides 212a, 212b of the rim. The second assembly 220 a! least partially covers the ground-facing surface 212c of the rim 212. The second assembly 220 extends below (e.g., radially inward of) the hub-facing surface 212d of the rim 212. The hub-facing surface 212d of the rim 212 is at least partially devoid (e.g., generally devoid (e.g., more uncovered than covered), substantially devoid (e.g., almost completely devoid), completely devoid) of the material of the second assembly 220.
[0056] In some embodiments, the inner part 210 of the wheel 200 may be injection-molded, blow molded, rotational molded, compression molded, etc. In certain embodiments in which the wheel 200 is injection-molded, injection-molding includes coupling a male mold and a female mold, and injecting molten material therebetween. After the material has sufficiently hardened, the inner part 210 may be removed from one or more of the molds, or the inner part 210 may be moved to a different mold. In some embodiments, the inner part 210 and the outer part 220 may be made in the same mold and machine without movement of the inner part 210. In certain embodiments, the rim 212 and the hub 214 are integrally formed during the injection molding process to form a unitary piece, hi some embodiments, the hub 214 comprises corrugated surfaces and/or generally hollow features 260 that can reduce the amount of material used in creation of the inner part 210, but also provide strength by creating certain shapes (e.g., as illustrated in Figure 2C). hi some embodiments, optional features of the rim 212 (e.g., generally hollow features, apertures, ribs, flanges, etc.) are formed during the injection molding process. In embodiments in which the generally hollow features 260 are formed during the injection molding process, the generally hollow features 260 may be "cored out " from the inside of the wheel 200 and/or the outside of the wheel 200. hi some embodiments, the inner part 210 comprises a first material such as
Knobbe, Martens, Olson & Bear. LLP -10- GEO Plastics
GEOPL.024A plastic (e g , polypropylene, HDPE, ABS, etc ) or metal. In some emironments (e g , cold weather), HDPE exhibits better performance than polypropylene
|0057] The outer part 220 is mechanically coupled to the inner part 210 through the πm 212 In some embodiments, the outer part 220 may be mjection-molded, compression molded, etc As descπbed above, injection-molding involves formation of an element between a male mold and a female mold hi certain such embodiments, the inner part 210 is placed between the male mold and the female mold, and the outer part 220 fills the spaces between the male mold, the female mold, and the inner part 210 In embodiments in which the inner part 210 is also injection-molded, the material of the inner part 210 preferably cools enough that the material of the outer part 220 does not mix therewith In some embodiments, molding the outer part 220 can occur in the same mold as molding the inner part 210 oi can occur m a different mold In some embodiments, molding the outer part 220 can occur on the same machine as molding the inner part 210 or can occur on a different machine In some embodiments, molding the outer part 220 can use the same platens as molding the inner part 2] 0 or can use different platens In certain embodiments, tread lines 224 or other features of the outer part 220 may be integrally foπned during the molding process In some embodiments- the outer part 220 comprises a second material such as rubber or a rubber-like material {e g , TPE, TPU) In embodiments in which the first assembly 210 comprises polypropylene and the second material comprises TPE or TPU, the second assembly 220 may be both chemically and mechanically coupled to the first assembly 210 Other combinations of materials may also produce a combination chemical-mechanical bond In certain embodiments, cooling of the material of the outer part 220 may form a tight fit around the inner part 210 In certain embodiments in which the outer portion 220 comprises TPE or TPU, it may be advantageous to reduce the amount of the second material used for example to reduce costs of manufacturing the wheel 200 Example structures that can reduce the second mateπal used in the outer part 220 but that enjoy the appearance of a wide tread 220 are desciibed below The thickness of the outer part 220 between the ground-facmg surface 232c of the inner part 210 may be selected based factors such as, but not limited to intended use, mateπal cost, and shape of the ran 212
J0058] In the embodiment illustrated in Figure 2A. the outer part 220 comprises a ledged end proximate to or adjacent to a πm of the inner part 210 A ledged end may help to reduce (e g prevent) tampering and/or help to reduce (e g , prevent) foreign objects from being lodged (e g , wedged) between the inner part 210 and the outer part 220 In some
Knobbe Martens Olson & Bear, LLP -1 1 - GEO Plastics
GEOPL 024A embodiments, such a foreign object could weaken the bond between the inner part 210 and the outer part 220 A ledged end ol the outer part 220 is also possible in embodiments in which the inner part 210 does not comprise a ran (e g , terminating at a width t 0 or t,) In certain alternative embodiments, the outer part 220 comprises a tapered end proximate to or adjacent to a ran of the inner part 210 A tapered end may reduce the amount of the second material used A tapered end of the outer part 220 is also possible in embodiments in which the inner part 210 docs not comprise a rim (e g , terminating at a width t n or t,) Combinations of ends of the outer part 220 are also possible (e g , a tapered end on the inside of the wheel 200 and a ledged end on the outside of the wheel 200, a tapered end on the outside of the wheel 200 and a ledged end on the inside of the wheel 200)
[0059] In some embodiments, the rim 212 of the inner section 210 compπses features that allow the second section 220 to be mechanically coupled to the first section 210 tor example, m the embodiment illustrated m Figure 3A, the nm 212 comprises a fiist plurality of apertures 216 through the first side 212a of the πm 212, a second plurality of apertures 218 through the second side 212b of the πm 212, a flange 219 proximate to the first side 212a of the πm 212, and a plurality of πbs 217 transverse (e g . orthogonal, generally perpendicular) to the flange 219 The apertures 216 may have any quantity, position, spacing, and shape that can effect an acceptable fit of the outer section 220 to the first side 212a of the πm 212, and the apertures 218 may have any quantity position, spacing, and shape that can effect an acceptable fit of the outer section 220 to the second side 212b ol the nm 212 In certain embodiments, the πm 212 comprises fewer apertures 218 than apertures 216 In some embodiments, the first plurality of apertures 216 is radially offset from the second plurality of apertures 218 The πbs 217 may have different radial and annular thicknesses (e g alternating tall and wide πbs and short and thin πbs) In embodiments comprising a flange 219 and nbs 217. the πbs 217 may reduce distortion of the flange 219 and the flange 219 may add support (o and reduce deflection of, the nbs 217 Referring again to Figure 2C. in some embodiments, the flange 219 includes a lip 213 extending towards (lie first side 212a of the nm 212 In some embodiments, the lip 213 may reduce roll-off ol the second section 220 dunng lateral shifting that may occur with non-mechanically or solely chemically bonded outer sections
[0060] If a wheel is dropped on a hard object or subjected to a static or dynamic heavy load, the impact point may be prone to deflection (i e , movement from an original position due to stress) If the πm includes hollow features, for example, the impact point
Kiiobbc Martens Olson & Bear LLP -12- GEO Plasties
GEOPL 024 A could collapse into the spaces such that the wheel may lose its roundness, particularly if the rim 212 comprises generally hollou features 260 Increasing the amount of material m and to the surfaces of the hollow features 260 may add weight to the wheel and increase costs without reducing deflection In some embodiments, a flange 219 that is disposed radially outward of the generally hollow features 260 can reinforce the rim 212, thereby adding strength to the wheel 200 and reducing (e g , minimizing, eliminating) deflection and maintaining the roundness of the wheel 200 In some embodiments, a flange 219 that is disposed radially outward of the generally holfow features 260 can utilize Jess material than would be used by increasing the amount of material in and around the surfaces of the hollow features 260 The flange 219 may also reinforce the rim 232 of wheels 200 in which the rim 212 does not comprise the generally hollow features 260 Li certain embodiments, the ran 212 comprises a plurality of πbs 217 generally transverse to the flange 219 In certain embodiments, the flange 219 further comprises a hp 213 extending towards a side (e g , the inside, as illustrated m Figure 2A, ihe outside) of the ran 212 hi certain such embodiments, the rim 202 may comprise ribs 217 or other πbs or πblets disposed below (i e , radially inward of) the hp 213 to add structural support to the lip 213 (Figure 4A) In certain embodiments, the flange 219, the lip 213, and/or nblets thereunder can reduce (e g , minimize, eliminate) deflection of the wheel 200, which can reduce deformation under impact and heavy loads, leading to a wheel 200 that can remain a truer circular shape over a long term The material used for the flange 219, the hp 213, and/or the nblets thereunder, may also serve a mechanical coupling function as descπbed herein
[0061] Figure 3B illustrates the wheel 200 after an outer section 220 has been mechanically coupled to the inner section 210 In certain embodiments, the outer section 220 may also be chemically bonded to the inner section 210 hi the front elevational view, the pluralities of apertures 216 218 are not visible because the second material of the second section 220 covers or occupies the space of the pluralities of apertures 216, 218 In certain such embodiments, the wheel 200 has a clean appearance (e g , not being evident how the outer section 220 is coupled to the inner section 210), which may reduce the propensity for tampering as well as being aesthetically pleasing In some embodiments, the material of the outer section 220 at least partially covers the ground-facing surface 212c of the rim 212 of the inner section 210 hi some embodiments, the outer section 220 completely covers the ground-fating surface 212c of the πm 212 of the inner section 210 In some embodiments,
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GEOPL 024A the outer section 220 completely covers the πbs 217 and flange 219 of the rim 212 of the inner section 210
[0062] In some embodiments the outer section 220 comprises a plurality of recesses 224, thereby creating a tire-hke appearance (e g , the appearance of a pneumatic tire, the appearance of a solid tire) In embodiments in which the πm 2] 2 compnses ribs 217, the second assembly 220 may be molded around the ribs 217 to produce the recesses 224 In embodiments in which the πm 212 does not comprise πbs 217, the second assembly 220 may be molded to produce the recesses 224 (e g , having a core of the second material rather than having a πb core) In some embodiments, the recesses 224 help the wheel 200 to grip the ground surface, for example by adapting to varying ground conditions, by channeling water, etc
]0063] Figure 4A illustrates a back elevational view of the inner piece 210 of the wheel 200 As described above, the πm 212 compnses a plurality of apertures 216, a flange 219 and a plurality of apertures 218 In some embodiments m which the hub 214 is configured to accept a sleeve or hub assembly as descπbed above the inner piece 210 compnses a tool passageway configured to allow a user that wishes to separate the wheel 200 from an axle 150 to insert a toof to manipulate a retaining member (e g an axle-retaining sleeve) In certain such embodiments the inner piece 210 compnses a membrane or "puncture skin" 230 at least partially covenng the tool passageway l he membrane 230 is preferably thm enough to be punctured by the tool pπor to engagement with the retaining member (e g , about 0 01 inch thick) The membrane 230 may provide evidence of tampeπng with the wheel 200 The membrane 230 may also disguise access to the retaining member, such that only a person having knowledge of the retaining member is able to detach the wheel 200 from the axle 150 without damaging the wheel 200 The membrane 230 may be flush with a spoke 232 of the hub 214 The edges of the tool passageway may be raised with respect to a spoke 232 to identify the tool passageway if covered by a membrane 230
10064] Figuie 4B is a back ele\ ational view of the outer piece 220 that may be mechanically coupled to the inner piece 210 (e g , by injection molding) to form the wheel 200 In certain embodiments, the outer piece 220 may also be chemically bonded to the inner piece 210 The outer piece 220 comprises a plurality of buttons (or knobs, protrusions, rivets, heads, etc ) 222 that extend through the plurality of apertures 218 of the second side 212b of the πm 212 of the inner piece 210 Figure 4C illustrates the wheel 200 compπsmg the outer piece 220 and the mnei piece 210 in embodiments m which the outer piece 220 is injection
Knobbe Martens Olson &. Bear, LLP -14- GCO Plastics
GEOPL 024A molded, the molten second material flows or weaves through the apertures 218 until contacting a mold, after which the molten second material flows transverse to the apertures 218 on the inner portion of the rim 212. The buttons 222 thus extend through the second side 212b of the inner piece 210 to mechanically couple the second piece 220 to the first piece 210. Although not visible in this back elevational view, the outer piece 220 is also mechanically coupled to the rim 212 on the opposite first side 212a of the rim 212.
|0065] Figure 5 A illustrates a portion of the inner section 210 of the wheel 200 that illustrates the optional features of the rim 212. The plurality of apertures 216 extend through the flange 219 between the ribs 217. The second assembly 220 may thereby be mechanically coupled through the rim 212 at the first side 212a of the rim 212 between at least some of the ribs 217. Figure 5B illustrates the wheel 200 with the outer section 220 mechanically coupled to the inner section 210. As described above, a plurality of buttons 222 extend through the plurality of apertures 218, to thereby mechanically couple the outer section 220 to the inner section 210 on the second side 212b of the rim 212. Figure 5B further illustrates that the outer section 220 may substantially cover (e.g., overlap) the flange 219 and the ribs 237. In embodiments in which the flange 239 comprises a lip 213, the outer section 220 may at least partially overlap the lip 213. The outer section 220 may also be disposed through each of the plurality of apertures 216 to mechanically couple the outer section 220 to the inner section 210 on the first side 212a of the rim 212.
[0066] Figure 6A illustrates another portion of the inner section 230 of the wheel 200 that illustrates the optional features of the rim 212. The plurality of apertures 216 extend through the flange 219 between the ribs 217. The apertures 218 may be disposed below (e.g., radially inward of) at least some of the ribs 217. The second assembly 220 may thereby be mechanically coupled through the rim 212 at the second side 212b of the nm 212 radially inward from the ribs 217.
[0067] Figure 6B illustrates a portion of another example embodiment of the inner section 610 of the wheel 200 that illustrates additional optional features of the rim 612. The rim 612 includes a plurality of partially annular πbs 650 transverse (e.g., substantially orthogonal, generally perpendicular) to the flange 619 and transverse (e.g.. substantially orthogonal, generally perpendicular) to the πbs 652. In some embodiments, a narrow end of the annular ribs 650 abuts the flange 619 and a generally hoπzontal surface of the annuJar πbs 650 abuts a generally vertical surface of the ribs 652 (or vice versa), as the features appear m a localized area, although the annular ribs 650 may include some curvature. The second
Knobbc, Martens. Olson & Bear. LLP - 15- GEO Plastics
GEOPL.024A material of the outer section 210 may be confined between the annular πbs 650 and the ground-facing surface 212c to aid m retaining the outer section 220 to the inner section 612, thereby forming a nb undercut feature The rib undercut features of such embodiments aie T- shaped Other shapes that can cause undercut or at least partial confinement of the outer section 210 are also possible, for example and without limitation, L-shaped, J-shaped or hook-shaped, and arrowhead- shaped Combinations of undeicut feature shapes are also possible The annular πbs 650 may also occupy space, thereby reducing the amount of the second mateπal used The annular πbs 650 may be disposed above some of the πbs 652 and not above others of the πbs 617, for example as illustrated in Figure 6B Alternatively, more of the ribs 617, 652 may include an undercut feature (e g , all of the πbs 617, 652. two-thirds of the πbs 617, 652, etc ) or fewer of the πbs may include an undercut feature (e g , none of the πbs 617, 652 one-third of the πbs 617, 652, etc ), The width of the annular πbs 650 may be selected based on flow properties of the second matenal (e g configured to avoid formation of cavities between the first and second materials due to surface tension at corners)
[0068] Figure 6C illustrates the wheel 200 with the outer section 220 mechanically coupled to the inner section 210 In certain embodiments, the outer section 220 may also be chemically bonded to the inner section 210 Figure 6C further illustrates that the outer section 220 may substantially cover (e g , overlap) the flange 219 and the ribs 217 T he outer section 220 may also be disposed through each of the plurality of apertures 216 to mechanically couple the outer section 220 to the inner section 210 on the first side 212a of the ran 212
(0069] Figures 7A-7C illustrate cross-sectional views of the wheel 200 The cross-section of Figure 7A, taken along the line 7A-7A of Figure 5B, is thiough an aperture
216 The cross-section of Figure 7B, taken along the line 7B-7B of Figure 5B, is through a rib 217 and an aperture 218 The cross-section of Figure 7C taken along the line 7C-7C of Figure 5B, is through a portion of the ran 212 not comprising an aperture 216, 218 or a πb
217 Each cross section of the illustrated embodiment of the wheel 200 includes a πm 212 including the flange 219 and the lip 213 Each cross-section of the nm 212 of the first assembly 210 has a first side 212a, a second side 212b opposite the first side 212a, a ground- facing surface 2) 2c. and a hub-facing surface 212d The second assembly 220 is mechanically coupled through the πm 212 at the first side 212a of the πm 212 and the second side 212b of the πm 232 The second assembly 220 at least partially covers the ground-facmg surface 212c of the πm 212 The second assembly 220 extends below (e g , radially inward
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GEOPL 024A of) the hub-facmg surface 212d of the ran 212 The hub-facing surface 2]2d of the rim 212 is generally devoid (e g , substantially devoid, completely devoid as illustrated in Figures 7A- 7C) of the second assembly 220 The second assembly 220 weaves through the apertures 216 on the first side 212a of the πm 212 as illustrated in Figure 7A, and the second assembly 220 is further secured to the first side 212a by overlapping the lip 213, as illustrated in figures 7B and 7C The second assembly 220 also weaves through the apertures 218 on the second side 212b of the πm 212, as illustrated in Figure 7C
|007θ] In some embodiments, the radial width t 0 of the second assembly 220 at the second side 212b of the πm 232 is greater than a radial width t, of the second assembly 220 at the first side 212a of the πm 212 This provides the visual appearance of a thick tread 220, but utilizes a relatively small amount of the second material Reduction of the amount of the second assembly 220 may reduce the costs of manufacturing the wheel while still remaining functional and commercially viable For example, while consumers generally prefer a thick-appeaπng tire to a thm-appeaπng tire, some applications such as refuse carts generally do not require thick tires (e g , because the travel distance is low, because the contents are not valued, etc ) In some embodiments, a ratio of weight of the second assembly 220 to weight of the first assembly 210 is Jess than about 0 5 to 1 (i e , 0 5 1 , 0 5/1) For example, m an embodiment in which the first assembly 210 weighs about 1 pound (approximately 454 grams), the second assembly 220 weights less than about 0 5 pounds (approximately 227 grams) In some embodiments, a ratio of weight of the second assembly 220 to weight of the first assembly 210 is less than about 0 4 1 less than about 0 3 1 , less than about 0 2 1, less than about 0 1 1 , less than about 0 05 1 , less than about 0 01 1 , or less than about 0 001 1 In certain embodiments, a ratio of weight of the second assembly 220 to weight of the first assembly 210 is between about 0 3 ) and about 0 4 1 For example, m an embodiment m which the first assembly 210 weighs about 1 pound (approximately 454 grains), the second assembly 220 weights between about 0 3 pounds (approximately 136 grams) and about 0 4 pounds (approximately 1 81 grams) (e g , about 0 36 pounds (approximately 163 grams)) Such an embodiment may be practical when the first assembly 210 compnses HDPE and the outer section 220 compnses TPE For another example, in an embodiment in which the first assembly 210 weighs about 1 pound (approximately 454 grams), the second assembly 220 weights between about 0 1 pounds (approximately 45 grams) and about 0 2 pounds (approximately 91 grams) (e g , about 0 18 pounds (approximately 82 grams)) Such an embodiment may be practical when the first assembly
Knobbe Martens, Olson & Bear, LLP -1 7- GEO Plastics
GEOPL 024A 210 comprises HDPE and the outer section 220 comprises TPU In certain embodiments, a ratio of weight of the second assembly 220 to weight of the first assembly 210 is between about 0 1 1 and about 0 5 1, between about 0 1 1 and about 0 4 1, or between about 0 001 1 and about 0 1 1 Other ratios are also possible
[0071] In some embodiments, the weight of the second assembly 220 is less than about 30% of the weight of the total weight of the wheel 200 In certain embodiments, the weight of the second assembly 220 is less than about 50%, Jess than about 40%, less than about 20%, less than about 10%, less than about 1 %, or less than about 0 1 % of the weight of the total weight of the wheel 200 In some embodiments, the weight of the second assembly 220 is between about 20% and about 30% of the total weight of the wheel 200 (e g . about 26%) In certain embodiments, the weight of the second material is between about 0 1% and about 50%, between about 1 % and about 30%, between about 5% and about 40%. between about 10% and about 30%, or between about between about 23% and about 29% of the total weight of the wheel 200 Other percentages are also possible
|0072J The thickness of the second assembly 220 to the radius of the wheel 200 in combination with the relative weight of the second assembly 220 to the radius of the wheel 200 may also be used to identify a quantity oi second assembly 220, regardless of the material or density of the first assembly 210 In some embodiments, a ratio of radial width t 0 of the second assembly 220 on the second side 212b of the ran 212 to a radius of the wheel 200 is between about 0 1 1 and about 0 3 1 Foi example, m an embodiment m which the radius of the wheel 200 is about 5 inches (approximately 0 127 meters), the radial width to of the second assembly 220 on the second side 2] 2b ol the πm 212 is between about 0 5 inches (approximately 0 013 meters) and about ] 5 inches (approximately 0 038 meters) (e g about 1 inch {approximately 0025 meters)) hi some embodiments, a ratio of iadial width I 0 of the second assembly 220 on the second side 212b of the πm 212 to a radius of the wheel 200 is between about 0 05 1 and about 0 75 1 , between about 0 1 1 and about 0 5 1 , or between about 0 15 1 and about 0 25 1 In certain such embodiments, the weight ol the second assembly 220 divided by radius of the wheel 100 may be between about 0 8 ib/ft (approximately 1,200 g/m) and about 1 lb/ft (approximately 1 ,500 g/m) In certain alternative such embodiments, the weight of the second assembly 220 divided by radius of the wheel 1 10 may be between about 0 1 lb/ft (approximately 350 g/m) and about 2 lb/ft (approximately 3,000 g/m), between about 0 5 lb/ft (approximately 740 g/m) and about 1 5 lb/ft
Knobbe Martens Olson &. Bear LLP -18- GEO Plashes
GEOPL 024 A (approximately 2,200 g/m), or between about 0 75 lb/fi (approximately l ,]00 g/m) and about 1 25 lb/ft (approximately 1,900 g/m) Other ratios and fractions are also possible
[0073J In some embodiments, a mold or mold slide used to form the outer piece 220 includes a first surface (e g , a generally flat surface) configured to substantially seal the inside of the inner piece 210 by engaging the πm 212 at a portion 242 that is raised with respect to the rest of the mside of the inner piece 210 In some embodiments, a mold used to form the outer piece 220 includes a second surface (e g , a generally flat surface) confϊguied to substantially seal the inside of the inner piece 210 by engaging the πm 212 at a portion 240 that is raised with respect to the rest of the outside of the inner piece 210 In some embodiments, the mass of material proximate to the portion 240 and/or the portion 242 may be reduced where such material intersects surrounding parts of the inner piece 220 (e g , by making the portion 240 and/or the portion 242 thicker, by making the surrounding parts of the first piece 210 thinner, and/or by raising the portion 240 and/or the portion 242 relam e to the surrounding parts of the inner piece 210 to space the intersection) Certain such features may reduce {e g , minimize, eliminate) the possibility of sink marks (areas where the first material will be reduced due to fluid dynamics of molten first material) where the portion 240 and/or the portion 242 intersect the surrounding parts of the inner piece 210, which can cause the outer piece 220 to occupy the sink marks thereby utilizing excess second material and causing the wheel 200 to have an unpleasing aesthetic appearance where a user may see the outer piece 220 where the inner piece 210 would be expected Reducing sink marks for example as descnbed above, may advantageously provide a clean demarcation between materials, which can enhance the appearance of the wheel 200. and/or may reduce the amount of material used for the outer piece 220
10074} Figures 8A-8C illustrate cross-sectional views of another embodiment ol a wheel 800 The cross-section of Figure 8A is through an aperture 816 The cross-section of Figure 8B is through a πb 817 and an aperture 818 The cross-section of Figure 8C is through a portion of the rim 812 not comprising an aperture 816, 818 or a rib Each cross section of the illustrated embodiment of the wheel 800 includes a nm 812 including the flange 819 and a lip 813 Each cross-section of the πm 812 of the first assembly 810 has a first side 812a a second side 812b opposite the first side 8] 2a, a ground-facing surface 812c, and a hub-facing surface 812d The second assembly 820 is mechanically coupled through the πm 812 at the first side 812a of the πm 812 and the second side 812b of the rim 812 The second assembly 820 at least partially covers the ground-facing surface 812c of the πm 812 The second
Knobbe Martens Olson &. Bear LLP - 19- GEO PlastiLS
GEOPL 024A assembly 820 extends below (e g , radially mward of) the hub-facing surface 812d of the πra 812 The hub-facing surface 812d of the rim 812 is generally devoid (e g , substantially devoid, completely devoid as illustrated in Figures 8A-8C) of ihe second assembly 820 The second assembly 820 weaves through the apertures 816 on the first side 812a of the nm 812 as illustrated m Figure 8A, and the second assembly 820 is further secured to the first side 812a by overlapping the hp 813, as illustrated m Figures 8B and 8C The second assembly 820 also weaves through the apertures 818 on the second side 812b of the πm 812, as illustrated in Figure 8C Other mechanical and/or chemical couplings are also possible (e g , an undercut as illustrated in Figure 6B)
|0075] hi some embodiments, a mold used to form the outer piece 820 includes a first surface (e g a generally flat surface) configured to substantially seal the inside of the inner piece 810 by engaging the nm 812 at a portion 842 that is raised with respect to the rest of the inside of the inner piece 810 hi some embodiments, a mold used to form the outei piece 820 includes a second surface (e g , a generally flat surface) configured to substantially seal the inside of the inner piece 810 by engaging the nm 812 at a portion 840 that is raised with respect to the rest of the outside of the inner piece 810 In some embodiments, the πm 840 comprises a shape (e g , tπangular, trapezoidal) configured to be compressed (e g , deformed) by a surface of a mold Ln certain such embodiments the mass of material proximate to the portion 840 may be reduced (e g , by raising the portion 840 relative to the surrounding parts of the inner piece 810 to space the intersection) In some embodiments, the πm 842 comprises a shape (e g , triangular, trapezoidal) configured to be compressed (e g , deformed) by a surface of a mold In certain such embodiments the mass of material proximate to the portion 842 may be reduced (e g , by raising the portion 842 relative to the surrounding parts of the inner piece 810 to space the intersection) In some embodiments, the outer piece 820 does not extend to the edge of the rim 840 and/or the nm 842 Certain such features may reduce (e g . minimize, eliminate) the possibility of smk marks (areas where the first matenal will be reduced due to fluid dynamics of molten first material) where the portion 840 and/or the portion 842 intersect the surrounding parts of the inner piece 810, which can cause the outer piece 820 to occupy the smk marks, thereby utilizing excess second matenal and causing the wheel 800 to have an unpleasing aesthetic appearance where a user may see the outer piece 820 where the inner piece 810 would be expected Reducing sink marks, for example as descnbed above, may advantageously provide a clean demarcation between
Knobbe Martens Olson &. Bear LLP -20- GEO Plastics
GFOPL 024A materials, which can enhance the appearance of the wheel 800, and/or may reduce the amount of material used for the outer piece 820
J0076] Figure 9A illustrates a cross-section of an example embodiment of a portion of a method of manufacturing a wheel 900 (e g , the wheel 200, the wheel 800) The method comprises forming a first material into a first part 910 of the wheel 900, for example injection molding the first part 910 The method further comprises molding a second mateπal mto a second part 920 of the wheel 900 using two mold pieces 970, 973 , the result of which is illustrated in Figure 9A The first part 910 is disposed between the mold pieces 970, 971 by squeezing the molds 970, 971 together, as indicated by the arrows 990 The mold 970 comprises a surface 9SO (e g , a substantially flat surface) that bears against a πm 940 of the outside of the first part 910 to form a seal In some embodiments, the moid 970 at least partially compresses the πm 940 to create a tighter seal In certain such embodiments, the πm 940 comprises a shape (e g , triangular trapezoidal) configured to be compiessed (e g , deformed) by the surface 980 When the molten second material is injected between the molds 970, 971, the seal between the πm 940 and the surface 980 stops the flow of the second material, thereby forming a clean demarcation between the first part 910 and the second part 920, which may enhance the appearance of the wheel 900 In some embodiments, the seal between the πm 940 and the surface 980 reduces the amount ol the second mateπal used because the amount of second materia! lost due to seepage over the first part 910 is reduced (e g eliminated) In some embodiments, the mold 971 comprises a surface 981 (e g , a substantially flat surface) that bears against a rim 942 of the inside of the first part 910 to form a seal When the molten second mateπal is injected between the molds 970, 971 , the seal between the πm 942 and the surface 981 stops the flow of the second mateπal thereby forming a clean demarcation between the first part 910 and the second part 920 In some embodiments, the seal between the πm 942 and the surface 981 reduces the amount of the second mateπal used because the amount of second mateπal lost due to seepage over the first part 910 is reduced (e g , eliminated) Although a clean demarcation between the first part 9] 0 and the second part 920 may also be formed on the inside of the wheel 900, that portion of the wheel 900 is typically not in view such that enhancement of the aesthetic appearance is acceptable but is not necessaπly desired After molding the second part 920, the wheel 900 is removed from the molds 970, 971 by spreading the molds 970. 971 as indicated by the arrows 990
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G EOPL 024 A }0077J Figure 9B illustrates a cross-section of another example embodiment of a method of manufacturing a wheel 901 (e g . the wheel 200, the wheel 800) The method comprises forming a first matenal into a first part 911 of the wheel 901 In some embodiments, forming the first part 911 comprises using at least one of the mold pieces 972, 973 in conjunction with other mold pieces at least partially by squeezing the molds 972, 973 together, as indicated by the arrows 991 In certain alternative embodiments, forming the first part 911 uses entirely different molds, a different type of molding process, or a non-molding process The method further comprises molding a second material mto a second part 921 of the wheel 901 using four mold pieces 972, 973, 974, 975, the result of which is illustrated in Figure 9B The first part 91 1 is disposed between the mold pieces 972, 973, 974, 975 In certain embodiments, the mold 972 comprises a surface 982 {e g , a substantially flat surface) that bears against a nm 941 of the outside of the first part 911 to form a seal In some embodiments, the mold 972 at least partially compresses the πm 941 to create a tighter seal In certain such embodiments, the πm 941 comprises a shape (e g , triangular, trapezoidal) configured to be compressed {e g , deformed) by the surface 982. When the molten second material is injected between the molds 972, 973. 974, 975, the seal between the πm 94] and the surface 982 stops the flow of the second materia], thereby forming a clean demarcation between the first part 91 1 and the second part 921 , which may enhance the appearance of the wheel 901 In some embodiments, the seal between the πm 941 and the surface 982 reduces the amount of the second material used because the amount of second matenal lost due to seepage over the first part 911 is reduced (e g . eliminated) In some embodiments, a portion of the molds 974. 975 is configured to bear against the mold 972 to define the outside of the second part 921 hi some embodiments, a portion of the molds 974, 975 is configured to bear against the rim 941 to define the outside of the second part 921 hi certain such embodiments, the molds 972, 973 may be unused
[0078] In certain embodiments, the mold 973 comprises a surface 983 (e g , a substantially flat surface) that bears against a πm 943 of the outside of the first part 911 to form a seal In some embodiments, the mold 973 at least partially compresses the πm 943 to create a tighter seal In certain such embodiments, the πm 943 comprises a shape (e g , tπangufar, trapezoidal) configured to be compressed (e g , deformed) by the surface 983 When the molten second matenal is injected between the molds 972, 973, 974, 975, the seal between the πm 943 and the surface 983 stops the flow of the second matenal, thereby forming a clean demarcation between the first part 91 1 and the second part 921 In some
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GEOPL 024A embodiments, the seal between the rim 943 and the surface 983 reduces the amount of the second material used because the amount of second material lost due to seepage over the first part 91 1 is reduced (e.g., eliminated). In some embodiments, a portion of the molds 974, 975 is configured to bear against the mold 973 to define the inside of the second part 921. In some embodiments, a portion of the molds 974, 975 is configured to bear against the rim 943 to define the inside of the second part 921. In certain such embodiments, the molds 972, 973 may be unused. Although a clean demarcation between the first part 911 and the second part 921 may also be formed on the inside of the wheel 901, that portion of the wheel 901 is typically not in view such that enhancement of the aesthetic appearance is acceptable but is not necessarily desired. After molding the second part 921 , the wheel 901 is removed from the molds 972, 973, 974, 975 by spreading the molds 972, 973, 974, 975, as indicated by the arrows 991 , 992.
[0079] Figure 9C is an elevational view of the molding process of Figure 9B with the molds 972, 973 removed or unused. The molds 974, 975 each surround about half of the wheel 901. The molds 974, 975 are squeezed and spread as indicated by the arrows 992. Figure 9D is an elevational view of another molding process with side molds removed or unused. The molds 976, 977, 978, 979 each surround about a quarter of the wheel 901. The molds 976, 977, 978, 979 are squeezed and spread as indicated by the arrows 993. The number of molds may be increased as the complexity of the second part 923 of the wheel 901 increases. For example, depending on the complexity of the second part 921 , the method may comprise using from about 2 to about 20 molds and/or mold slides, from about 2 to about 8 molds and/or mold slides, and from about 2 to about 4 molds and/or mold slides. Other numbers of molds are also possible.
|0080] Although this invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. For example and without limitation: different ratios, percentages, and fractions; different mechanical coupling methods; different quantities of apertures and/or buttons; different numbers, orientations, and designs of rib undercut features; different coverage of various surfaces; different types of materials; different wheel designs; different intended wheel uses; different axle attachment features; different inner portion shapes with corresponding different outer portion shapes, including using features to reduce the amount of material of the outer
Knobbe, Martens, Olson & Bear. LLP -23- GEO Plastics
GEOPL.024A portion and/or to increase the apparent thickness of the outer portion, different part formation procedures including various molding techniques, different part coupling techniques including chemical and non-chemica! bonding, hot and cold assembly, and immediate and time-lapse assembly, assembly after mounting to an axle or product, parts supplied by different entities, etc
[0081] In addition, while several variations of the invention have been shown and descπbed in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill m the art based upon this disclosure It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope ol the invention It should be understood that vaπous features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the disclosed invention Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments descπbed above
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GEOPL 024A