Abstract:
A wheel for rolling bags and associated assembly methods are provided. The wheel includes a non-inflatable outer tire, a plurality of segments positioned inside the tire concentrically about an axis of the tire and supporting an inner surface of the tire, and first and second rims capping first and second openings in the tire, respectively, and supporting the plurality of segments.

Description:
[0001]     This application claims priority to U.S. Patent Application Ser. No. 60/802,117, filed May 22, 2006. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to wheels for use in rolling baggage. More specifically, the present invention relates to wheels for rolling baggage which travel easily over natural terrain and travel quietly over tiled surfaces.  
         [0004]     2. Discussion of Background Information  
         [0005]     Wheels for prior art baggage are typically made of solid plastic or rubber. Due to weight and manufacturing expenses, the wheels are often small and thin, on the order of in-line skate wheels. Indeed, in-line skate wheels are often used for rolling bags. Such wheels tend to be noisy when traveling over flat man-made surfaces, particularly over tiled surfaces where each wheel generates a “clack” sound as it hits joints between tiles. When traveling over loose natural terrain such as gravel, grass or soil, the wheels will dig into the terrain. The bottom of the bag comes to rest on the surface, and the user must drag the bag rather than roll it as intended. People are often forced to carry the bag to avoid dragging it and/or getting the bag dirty.  
         [0006]     Other available types of wheels are inappropriate for rolling bags. Thicker solid wheels add too much weight. Hollow plastic wheels used in toys will not support the weight of a loaded bag. Inflatable pneumatic wheels of such a size are difficult to repair and/or reinflate.  
       SUMMARY  
       [0007]     An embodiment of the present invention provides a non-inflatable wide tire for use in a rolling bag that is durable and reacts like an inflated tire that is not actually inflated. Its wider tire travels across natural surfaces such as dirt, gravel, grass, etc. without the wheels sinking down into the surface as in-line skate wheels do. The underside of the bag remains off the ground and will not drag across the natural surface. This creates a longer life cycle for the bag as well as an easier and smoother pull for the user. The materials and construction of the embodiment of the present invention use a soft-sided tire that allows for a smooth pull across man-made surfaces without the noisy “clack” sound that often accompanies bags with in-line skate wheels. The tire will always keep its shape (within weight tolerances) because it is made of solid components as opposed to an inflated tire that could lose its air. However the tire, wheel and axle combination is lighter than solid wheels of similar dimensions.  
         [0008]     According to an embodiment of the invention, a wheel, is provided. The wheel includes a non-inflatable outer tire, a plurality of segments positioned inside the tire concentrically about an axis of the tire and supporting an inner surface of the tire, and first and second rims capping first and second openings in the tire, respectively, and supporting the plurality of segments.  
         [0009]     The above embodiment may have various preferable optional features. The non-inflatable outer tire can be made of rubber. The plurality of segments and the first and second rims can be made of acrylonitrile butadiene styrene. The wheel preferably can support a maximum weight of about 500 lbs. The plurality of segments can form a contiguous circle. Each of the plurality of segments may have a curved outwardly facing portion, a flat inwardly facing portion, and/or a plurality of hollow chambers. The wheel may have an outer diameter between approximately 30 mm and approximately 215 mm, particularly 108 mm, and an axial thickness of between approximately 25 and 110 mm, particularly approximately 63 mm. The first rim may have a support configured to mate with an inwardly facing portion of each of the plurality of segments. The support may have a hexagon cross section. The first rim can be a male connector and the second rim a female connector, wherein the first rim at least partially inserts into the second rim. The plurality of segments need not be attached to the first and/or second rims. The wheels are preferably incorporated into a rolling bag.  
         [0010]     According to another embodiment of the invention, a method of assembling a wheel is provided. The method includes providing a non-inflatable outer tire, inserting a plurality of segments positioned inside the tire concentrically about an axis of the tire, inserting first and second rims capping first and second openings in the tire, respectively, and supporting the plurality of segments, and inserting an axle through the first and second rims.  
         [0011]     The above embodiment may have various preferable optional features. The method may include the step of attaching adjacent ones of the plurality of segments to each other. The tire and at least one of the first or second rim may hold the plurality of segments in place without attachment. The method may include providing a bag, and mounting the wheel on the bag.  
         [0012]     According to yet another embodiment of the invention, a rolling bag is provided. The bag includes a storage area, a housing, and a wheel in the housing. Each wheel includes a non-inflatable outer tire, a plurality of segments positioned inside the tire concentrically about an axis of the tire and supporting an inner surface of the tire, and first and second rims capping first and second openings in the tire, respectively, and supporting the plurality of segments.  
         [0013]     The above embodiment may have various preferable optional features. The housing may overlap a central axis of the wheel on both sides of the wheel. An axle may passing through the central axis of the wheel and adjacent portions of the housing on both sides of the wheel.  
         [0014]     Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of certain embodiments of the present invention, in which like numerals represent like elements throughout the several views of the drawings, and wherein:  
         [0016]     FIGS.  1 ( a )-( c ) illustrates an assembly process of a wheel according to an embodiment of the invention;  
         [0017]     FIGS.  2 ( a )-( d ) show various views of a non-inflatable tire according to an embodiment of the invention;  
         [0018]     FIGS.  3 ( a )-( d ) show various views of an individual segment that supports the outer tire according to an embodiment of the invention;  
         [0019]     FIGS.  4 ( a )-( f ) show various views of a first rim according to an embodiment of the invention;  
         [0020]     FIGS.  5 ( a )-( f ) show views of various possible alternative configurations of the rims according to embodiments of the invention.  
         [0021]     FIGS.  6 ( a )-( d ) show various views of a housing recess that holds the wheel according to an embodiment of the invention;  
         [0022]      FIG. 7  shows a housing recess and a wheel mounted on a sports bag according to an embodiment of the invention; and  
         [0023]     FIGS.  8 ( a ) and  8 ( b ) show alternate configurations of segments that support a tire according to an embodiment of the present invention.  
     
    
       [0024]     Several of the above drawings identify various possible dimensions of the corresponding embodiment of the invention, with such dimensions in millimeters.  
       DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS  
       [0025]     The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.  
         [0026]     Referring now to  FIG. 1 , a wheel  100  of the present invention is shown. A non-inflatable hollow tire  102  serves as the outer portion of wheel  100 . Six endoskeletal segments  104  are individually inserted into the wheel and held in place by epoxy. A first rim  106  with an internally facing support is inserted into the central hole of tire  102 ; as discussed below, the outer radial portion of the support is configured to support the inner radial portion of each of the six segments  104 . A second rim  108  with an internal support is inserted into the central hole on the opposite side of tire  102  to mate with first rim  106 . The two rims support the segments  104 , and the segments support the tire  102 . Collectively, the entire wheel weighs only a few ounces, but can support upwards of about 500 lbs.  
         [0027]     The assembled wheel  100  is inserted into a molded housing recess  110 , which may or may not already be attached to a bag (not shown in  FIG. 2 ). Both sides of housing recess  110  have a through hole concentric with a corresponding through hole in first and second rims  106  and  108 . An axle  112  is inserted into the through holes and secured with a nut  114 . The assembly process repeats for at least one other housing unit  110  to make multiple wheels for a rolling bag.  
         [0028]     FIGS.  2 ( a )-( d ) show an example of tire  102 . Tire  102  preferably has an outer diameter of approximately 30-215 mm, particularly approximately 108 mm, and a width of approximately 25-110 mm, particularly approximately 63 mm. The outer surface preferably has treads that improve the grip between tire  102  and a natural surface, and a logo (“Fat Boys” in the figures) may be molded onto the side. These dimensions and treads allow the wheel  100  to travel over natural surfaces without sinking, which prior art in-line skate wheel are apt to do. However, the invention is not so limited, as larger and smaller wheels, and/or different (or no) tread designs may be used. Tire  102  is preferably made of rubber, although plastic or other materials may be used. Tire  102  provides a durable surface intended for use against both natural and man-made surfaces.  
         [0029]     FIGS.  3 ( a )-( d ) show an example of an individual segment  104 . The outer portion of each segment  104  is curved to match the radius of curvature of the inner surface of tire  102 . Each segment extends over an approximately 60° angle, such that six segments  104  will collectively form a contiguous circle within tire  102 . The bottom of each segment  104  is preferably flat to mate with a corresponding flat surface on rims  106  and  108  (discussed below). Several radial and axially extending walls  302  extend from the bottom to the top, defining a plurality of hollow chambers. Eight such chambers are shown in FIGS.  3 ( a ) and  3 ( b ), although any number may be present. Walls  302  will provide support and transfer force from tire  102  to rims  106  and  108 , and vice versa. Segments  104  thus take the place of air as a normal inflatable tire would have and prevent tire  102  from collapsing. Because segments  104  are not solid in this embodiment, they provide support with minimal addition of weight.  
         [0030]     Various modifications could be made to the nature of segments  104  within the skill of the art. Any number of segments could be used, e.g., eight segments of 45° to form an octagon instead of six pieces to form a hexagon. All six pieces need not be used, such that the pieces would not form a contiguous circle. Individual segments could be solid instead of having hollow cavities. The pieces need not be identical. Segments shown individually could be molded or attached together in whole or in part, such as shown in FIGS.  8 ( a ) and  8 ( b ).  
         [0031]     FIGS.  4 ( a )-( f ) show various perspectives and cross sections of first rim  106 . As shown, the rim includes an outer circular section  402  and a support section  404  connected by mating structures around the periphery thereof, although an integral unit could also be used. The inwardly facing portion of support section  404  defines a shape that mates with and supports the individual endoskeletal segments  104 . Support section  404  is of sufficent length to extend approximately halfway into non-inflatable tire  102 . Several protrusions  406  extend inwardly (i.e., into tire  102 ), and will engage with corresponding recesses in second rim  108 . Second rim  108  is preferably identincal to first rim  106 , except that the protrusions  406  are replaced with corresponding mating recesses that engge with protrusions  406 . The protrusions may be identical and symetrical so to allow for simple engagement. In the alternative, at least one of protrusions  406  may have a different angle, shape or relative from the others to require a specifc orientation of first rim  106  and second rim  108  for assembly purposes.  
         [0032]     In this embodiment, first rim  106  may be considered a male connector and second rim  108  a female connector. However, the invention is not so limited. Both rims may have any types or distribution of projections and recesses. Proejctions/ recesses could be omitted altogehter in favor of other known methods of attachment.  
         [0033]     In the preferred emobidment of six segments  104  with flat inward surfaces, support section  404  of first and second rims have a cross section of a hexegon. The invention is not so limited, however, and any appropriate number of sides and shapes may be used based on the number, size and shape of the corresponding segments  104 . FIGS.  5 ( a )-( f ) show various non-limiting examples of possible shapes used with rims  106  and  108 .  
         [0034]     Each segment  104 , first rim  106  and second rim  108  are preferably made from molded acrylonitrile butadiene styrene (“ABS”—chemical formula (C 8 H 8 ·C 4 H 6 ·C 3 H 3 N) x ), although other materials could be used. ABS is a common thermoplastic used to make light, rigid, molded products such as protective head gear and toys, including LEGO bricks. It is a copolymer made by polymerizing styrene and acrylonitrile in the presence of polybutadiene. The proportions can vary from 15% to 35% acrylonitrile, 5% to 30% butadiene and 40% to 60% styrene.  
         [0035]     Referring now to  FIG. 6 ( a )-( d ), an embodiment of housing recess  110  is shown. Housing recess  110  has an appropriate size and shape to accommodate wheel  100 , although considerable latitude is available for artistic modeling. It is preferably made from plastic, but other materials may be used. Housing recess  110  has a through hole on both sides configured concentrically with a corresponding through hole in first and second rims  106  and  108 . Axle  112  is inserted into the through holes and secured with nut  114  to rotatably mount wheel  100  to housing recess  110 . Axle  112  can be any pin, bolt, screw, rod, etc., that can support the applied weight. A nut  114  is preferred to hold axle  114  in place, but any appropriate securing structure can be used.  
         [0036]      FIG. 7  shows the housing recess  110  and wheel  100  mounted on a sports bag. Other types of bags could also be used, such as golf bags, briefcases, luggage etc. Wheels  100  need not be used with a bag at all, but could be incorporated into any similar environments, e.g., carts or toys. Housing recess  110  is preferably made of ABS, although other materials could be used.  
         [0037]     In the above embodiment, the radial sides of segments  104  creates a semi-locking environment in which segments  104  can move loosely within tire  102  but do not tend to fall out. The addition of first and second rims  106  and  108  create a tension fit with tire  102  that prevents segments  104  from shifting. Projections  406  in first rim  106  are slightly larger than the corresponding recess in second rim  108 , forming a pressure lock engagement that hold the rims together, at least until the assembled wheel  100  is placed in housing  110 . The flanking portions of housing  110  that support wheel  110  prevent rims  106  and  108  from separating. The components can thus be assembled without any permanent (e.g. glue) or semi-permanent (e.g, screw) attachment. Of course, the invention is not so limited, and any form of attachment may be additionally and/or alternatively be used.  
         [0038]     Preferably each housing  110  includes one wheel  100 . However, the invention is not so limited. Each housing  110  may support multiple wheels and/or additional structures.  
         [0039]     During testing, the inventors observed that bags with wheels  100  made considerably less noise travelling over man-made surfaces compared with rolling bags that use solid wheels.  
         [0040]     It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to certain embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims