Caster assembly having sinusoidal wheels

A caster assembly having a top cap configured to engage with a structure, a caster leg configured to pivotally engage with the top cap, such that the caster leg selectively pivots about a pivot axis, and a pair of sinusoidal wheels configured to be rotationally engaged with the caster leg, the sinusoidal wheels being configured to rotate about a wheel rotational axis and swivel with the caster leg as a required when the structure is moved. An angled member of the caster leg may be configured to engage with the sinusoidal wheels such that the wheel rotational axis is not intersected by the pivot axis. An offset angle formed between the angled member and a vertical member of the caster leg, when used in conjunction with the disclosed sinusoidal wheels, is configured to ease structure movement by minimizing resistances exerted on the sinusoidal wheels during rolling and caster leg pivoting.

BACKGROUND OF INVENTION

1. Field of the Invention

The invention relates generally to casters and specifically to caster assemblies having sinusoidal wheels.

2. Description of the Related Art

Casters and similar wheel based technologies are often placed on the bottoms of supported structures, such as tables, workbenches, etc. in order to allow a user to selectively move the supported structures around via rolling, while reducing the amount of strain and effort required to do so. Conventional casters may utilize common cylindrical wheels to facilitate the rolling of said supported structure, however, such technologies may have several notable limitations. For example, standard, cylindrical wheels may exhibit a notable resistance to being rolled, particularly if a significant amount of weight is being applied on them by the supported structure. Additionally, the flat profile of a standard cylindrical wheel may result in a significant amount of frictional resistance being exerted on said wheel while being swiveled, thus increasing wheel wear and the force required to swivel the caster to change the travel direction of the supported structure.

Therefore, there is a need to solve the problems described above by proving a device and method for a caster assembly configured to reduce the amount of resistance experienced while rolling and swiveling its wheels through the utilization of sinusoidally shaped wheels disposed at an offset angle.

The aspects or the problems and the associated solutions presented in this section could be or could have been pursued; they are not necessarily approaches that have been previously conceived or pursued. Therefore, unless otherwise indicated, it should not be assumed that any of the approaches presented in this section qualify as prior art merely by virtue of their presence in this section of the application.

BRIEF INVENTION SUMMARY

In an aspect, a caster assembly is provided, the caster assembly comprising: a pivot hub configured to be engaged with a supported structure, the pivot hub comprising: a pivot shaft configured to be engaged with the supported structure; and a plurality of ball bearings configured to be engaged with the pivot shaft; a caster leg configured to be engaged with the pivot hub, such that the caster leg is pivotally engaged with the supported structure and configured to pivot about a pivot axis, the caster leg having: a vertical member configured to be coaxially aligned with the pivot axis; a caster leg cavity nested within the vertical member, wherein each ball bearing of the plurality of ball bearings is configured to be nested within the caster leg cavity; and an angled member associated with the vertical member, the angled member being coaxially aligned with an offset axis, wherein the angled member engages with the vertical member such that an offset angle is formed between the pivot axis and the offset axis; a top cap associated with the caster leg, wherein the top cap is configured to cover the caster leg cavity; a pair of sinusoidal wheels configured to be rotationally engaged with the angled member of the caster leg, such that each sinusoidal wheel of the pair of sinusoidal wheels is configured to rotate independently about a wheel rotational axis, each sinusoidal wheel of the pair of sinusoidal wheels having: a wheel hub configured to be rotationally engaged with the angled member of the caster leg; and a rim configured to surround and be engaged with the wheel hub, the rim having: a pair of lateral edges; and a rim center engaged with and equidistantly disposed between the pair of lateral edges, wherein the rim center of each sinusoidal wheel of the pair of sinusoidal wheels follows a sinusoidal pattern around a circumference of the sinusoidal wheel, the sinusoidal pattern having a sinusoidal amplitude and sinusoidal frequency, wherein the rim center of each sinusoidal wheel of the pair of sinusoidal wheels is configured to be coaxially aligned with the wheel rotational axis. Thus, an advantage is that the amount of resistance experienced when rolling the sinusoidal wheels of the caster assembly is reduced, compared to the amount of resistance experienced when rolling a comparable caster assembly having standard, cylindrical wheels. Another advantage is that the resistance experienced while swiveling the caster assembly having sinusoidal wheels is less than when the resistance experienced while swiveling the caster having standard, cylindrical wheels, for wheels with rims having equivalent surface area. Another advantage is that each sinusoidal wheel of the pair of sinusoidal wheels may be configured to rotate independently of the other sinusoidal wheel, such that the caster assembly may be configured to perform tight pivots within a small area, thus aiding the maneuverability of the supported object. Another advantage is that the caster assembly may be configured to utilize a heavy load pivot hub to allow the caster leg to remain easily pivotable about the supported structure, even for heavier supported structures.

In another aspect a caster assembly is provided, the caster assembly comprising: a pivot hub configured to be engaged with a supported structure; a caster leg configured to be engaged with the pivot hub, such that the caster leg is pivotally engaged with the supported structure and configured to pivot about a pivot axis, the caster leg having: a vertical member configured to be coaxially aligned with the pivot axis; and an angled member associated with the vertical member, the angled member being coaxially aligned with an offset axis, wherein the angled member engages with the vertical member such that an offset angle is formed between the pivot axis and the offset axis; a pair of sinusoidal wheels configured to be rotationally engaged with the angled member of the caster leg, such that each sinusoidal wheel of the pair of sinusoidal wheels is configured to rotate about a wheel rotational axis, each sinusoidal wheel of the pair of sinusoidal wheels having: a rim configured to be pivotally engaged with the angled member of the caster leg, the rim having: a pair of lateral edges; and a rim center engaged with and equidistantly disposed between the pair of lateral edges, wherein the rim center of each sinusoidal wheel of the pair of sinusoidal wheels follows a sinusoidal pattern around a circumference of the sinusoidal wheel, the sinusoidal pattern having a sinusoidal amplitude and sinusoidal frequency, wherein the rim center of each sinusoidal wheel of the pair of sinusoidal wheels is configured to be coaxially aligned with the wheel rotational axis. Again, an advantage is that the amount of resistance experienced when rolling the sinusoidal wheels of the caster assembly is reduced, compared to the amount of resistance experienced when rolling a comparable caster assembly having standard, cylindrical wheels. Another advantage is that the resistance experienced while swiveling the caster assembly having sinusoidal wheels is less than when the resistance experienced while swiveling the caster having standard, cylindrical wheels, for wheels with rims having equivalent surface area. Another advantage is that each sinusoidal wheel of the pair of sinusoidal wheels may be configured to rotate independently of the other sinusoidal wheel, such that the caster assembly may be configured to perform tight pivots within a small area, thus aiding the maneuverability of the supported object. Another advantage is that the caster assembly may be configured to utilize a heavy load pivot hub to allow the caster leg to remain easily pivotable about the supported structure, even for heavier supported structures.

In another aspect, a caster assembly is provided, the caster assembly comprising: a caster leg configured to be pivotally engaged with a supported structure, wherein the caster leg is configured to pivot about a pivot axis, the caster leg having: a vertical member configured to be coaxially aligned with the pivot axis; and an angled member associated with the vertical member, the angled member being coaxially aligned with an offset axis, wherein the angled member engages with the vertical member such that an offset angle is formed between the pivot axis and the offset axis; at least one sinusoidal wheel configured to be rotationally engaged with the angled member of the caster leg, such that the at least one sinusoidal wheel is configured to rotate about a wheel rotational axis, wherein a rim of the at least on sinusoidal wheel follows a sinusoidal pattern around a circumference of the sinusoidal wheel, the sinusoidal pattern having a sinusoidal amplitude and sinusoidal frequency. Again, an advantage is that the amount of resistance experienced when rolling the sinusoidal wheels of the caster assembly is reduced, compared to the amount of resistance experienced when rolling a comparable caster assembly having standard, cylindrical wheels. Another advantage is that the resistance experienced while swiveling the caster assembly having sinusoidal wheels is less than when the resistance experienced while swiveling the caster having standard, cylindrical wheels, for wheels with rims having equivalent surface area. Another advantage is that each sinusoidal wheel of the pair of sinusoidal wheels may be configured to rotate independently of the other sinusoidal wheel, such that the caster assembly may be configured to perform tight pivots within a small area, thus aiding the maneuverability of the supported object. Another advantage is that the caster assembly may be configured to utilize a heavy load pivot hub to allow the caster leg to remain easily pivotable about the supported structure, even for heavier supported structures.

The above aspects or examples and advantages, as well as other aspects or examples and advantages, will become apparent from the ensuing description and accompanying drawings.

DETAILED DESCRIPTION

What follows is a description of various aspects, embodiments and/or examples in which the invention may be practiced. Reference will be made to the attached drawings, and the information included in the drawings is part of this detailed description. The aspects, embodiments and/or examples described herein are presented for exemplification purposes, and not for limitation purposes. It should be understood that structural and/or logical modifications could be made by someone of ordinary skills in the art without departing from the scope of the invention. Therefore, the scope of the invention is defined by the accompanying claims and their equivalents.

It should be understood that, for clarity of the drawings and of the specification, some or all details about some structural components or steps that are known in the art are not shown or described if they are not necessary for the invention to be understood by one of ordinary skills in the art.

For the following description, it can be assumed that most correspondingly labeled elements across the figures (e.g.,102and202, etc.) possess the same characteristics and are subject to the same structure and function. If there is a difference between correspondingly labeled elements that is not pointed out, and this difference results in a non-corresponding structure or function of an element for a particular embodiment, example or aspect, then the conflicting description given for that particular embodiment, example or aspect shall govern.

FIG.1illustrates the front perspective view of a caster assembly (“caster”)100having sinusoidal wheels103, according to an aspect. The herein disclosed caster assembly100ofFIG.1may be configured to utilize a pair of sinusoidal wheels103in conjunction with specially arranged caster elements in order to facilitate easy rolling of a supported structure and selective swiveling of each caster assembly100as the structure travels in different directions. The caster assembly100may comprise a top cap101, a caster leg102, a pivot pin, such as pivot pin304ofFIG.3, configured to pivotally engage the top cap101with the caster leg102, a pair of sinusoidal wheels103, a wheel axle, such as wheel axle305ofFIG.3, configured to rotationally engage the pair of sinusoidal wheels103with the caster leg102and an axle washer, such as axle washer306of FIG.3, configured to engage with the wheel axle. The engagements between each element of the caster assembly100will be discussed in greater detail hereinbelow.

In an embodiment, the caster leg102may be configured to pivotally engage with the top cap101, such that the caster leg102may pivot freely about a pivot axis110while the top cap101may be irrotationally secured to a supported structure, such as a workbench or cart. Furthermore, in said embodiment, the sinusoidal wheels103may be configured rotate about a wheel rotational axis113, wherein the wheel rotational axis113may be perpendicular to the pivot axis110. While pivot axis110and the wheel rotational axis113may be perpendicular to each other, they may not occupy the same plane nor intersect each other, due to an offset angle of the caster leg102, such as offset angle212ofFIG.2C, which will be discussed hereinbelow. This particular configuration of the caster assembly100having a pair of sinusoidal wheels103disposed at an offset angle from the pivot axis110may experience reduced resistance when rolling of the sinusoidal wheels103, when compared to a caster assembly lacking the offset angle and using standard cylindrical, thus allowing for structures or objects placed on top of these caster assemblies100to be rolled without requiring as much force to move it as a caster assembly lacking the sinusoidal wheels and the offset wheel rotational axis113. In an embodiment, the herein disclosed caster assembly100may experience 57% less rolling resistance when compared to a conventional caster assembly utilizing wheels having a right circular cylinder shape and lacking an offset angle, wherein said conventional caster assembly otherwise has the equivalent specifications (same contact patch surface area for the wheels, same material, etc. As a result of the shape of the sinusoidal wheels, said sinusoidal wheels103may be able to, in certain situations, begin rolling after pivoting/rotating fewer degrees, when compared to conventional right circular cylindrical wheels, thus reducing the force required to pivot said sinusoidal wheels to a rollable orientation, as will be disclosed in greater detail hereinbelow.

In an embodiment, a table (not shown) having four legs may have one of the herein disclosed caster assemblies100attached to the bottom of each leg, for a total of four caster assemblies100. As the table is selectively pushed in a direction by a user, each caster assembly100may quickly pivot accordingly such that the sinusoidal wheels roll smoothly as the table is moved. If the user changes the movement direction of the table (e.g., changing a movement direction from left to right, for example), the caster leg102of each caster assembly100may selectively pivot about the pivot axis110accordingly, in order to orient the sinusoidal wheels103such that their wheel rotational axis113is perpendicular to the direction of travel, wherein said orientation allows the sinusoidal wheels103to roll with the least amount of resistance. Furthermore, an offset angle, such as offset angle212ofFIG.2C, may be formed between the portion of the caster leg102attached to the sinusoidal wheels103and the portion of the caster leg102pivotally engaged with the top cap101on the pivot axis110. Said offset angle, as well as the utilization of sinusoidal shaped wheels103, may ensure optimized caster performance (e.g. minimized resistance to rolling the sinusoidal wheels103, minimized resistance to pivoting the caster leg102and the attached sinusoidal wheels103) while moving a supported structure.

FIGS.2A-2Fillustrate the front elevation, rear elevation, left side elevation, right side elevation, top plan and bottom plan views, respectively, of a caster assembly200having sinusoidal wheels203-1,203-2, according to an aspect. As disclosed hereinabove, the top cap201of a caster assembly200may be configured to engage directly with a portion of a supported structure (not shown), while also being pivotally engaged with the caster leg202, such that the attached sinusoidal wheels203-1,203-2are pivotally engaged with the supported structure. From the front elevation view ofFIG.2A, the pivot axis210and wheel rotational axis213may be shown as being perpendicular to each other (e.g., forming a 90 degree angle between each other, from the viewed perspective), but not intersecting (not occupying a shared plane). As can be seen inFIG.2C, while a vertical member202aof the caster leg202may be coaxially aligned with the pivot axis210, an angled member202bof the caster leg202may be bent at an offset angle212to the pivot axis210, such that the angled member202bof the caster leg202is coaxially aligned with an offset axis211. As such, an offset angle212may be formed between pivot axis210and the offset axis211. This offset angle212may help to maintain the pivoting function of the caster leg202and rotating function of the sinusoidal wheels203-1,203-2, even when supporting greater weights.

The top cap201may include several features that allow it to facilitate a secure engagement between the supported structure and the caster leg202, wherein the caster leg202is pivotally engaged with the supported structure. The top cap201may comprise a cap body201ahaving a first raised edge201band a second raised edge201c, wherein the first raised edge201band a second raised edge201cform a continuous raised rim201earound a front end201hof the cap body201a. In an embodiment, the top cap201may be symmetrical, while in an alternative embodiment, the top cap201may be asymmetrical. The disclosed caster assembly embodiment200ofFIG.2A-2Fmay be configured to engage with a suitcase, such as suitcase1319ofFIG.13, wherein the top cap201is configured to securely engage with the bottom corner of a suitcase to enable enhanced maneuverability of said suitcase. The top cap201may have any suitable shape, as long as said top cap201facilitates secure, pivotal engagement between the supported structure and the caster leg202. In an embodiment, a plurality of fastening pockets201dmay be nested within the cap body201a, wherein each fastening pocket201dmay be configured to aid engagement of the caster assembly200with the supported structure, such as the suitcase1319ofFIG.13. It should be understood that the shape and structure of the top cap201may be configured to facilitate secure engagement between the top cap201and a supported structure.

The disclosed caster assembly200embodiment ofFIGS.2A-2Fmay utilize two sinusoidally shaped wheels203-1,203-2to facilitate rolling of the caster; a first sinusoidal wheel203-1and a second sinusoidal wheel203-2. It should be understood that other quantities of wheels may also be utilized within the disclosed caster assembly while remaining within the scope of the application. As will be discussed in greater detail hereinbelow, the “sinusoidal” aspect of the sinusoidally shaped wheels203-1,203-2may relate to the shape of their rims, such as rim403b, ofFIG.4B.

As can be seen inFIG.2F, the particular shape of the sinusoidal wheels203-1,203-2may be configured to allow for easy directional changes of the caster leg202, and thus directional changes of the supported object, under certain conditions. In an embodiment, a caster leg202is facing in a current travel direction230. In said embodiment, the user wishes to move the supported object in an intended travel direction231. As a result of the sinusoidal wheels203-1,203-2having a sinusoidally shaped rim203b, the rim203bof each sinusoidal wheel203-1,203-2may “wave” or “reciprocate” back and forth around the circumference/outer perimeter of the corresponding sinusoidal wheel203-1,203-2, thus resulting in the rim203bof each sinusoidal wheel “bending”232toward or away from the intended travel direction231.

If the sinusoidal wheels203-1,203-2are both “bending”232toward an intended travel direction231, while the user is attempting to move the supported object in said intended travel direction231, then the amount of scrubbing (e.g. frictional resistance) that the sinusoidal wheels203-1,203-2will experience before being able to roll in the intended travel direction231may be reduced, in comparison to the same scenario using conventional, right circular cylindrical wheels. In contrast, in embodiments wherein the sinusoidal wheels203-1,203-2are not already “bending”232in the intended travel direction231, scrubbing of the sinusoidal wheels203-1,203-2may still occur, but the amount of force required to scrub/pivot the sinusoidal wheels203-1,203-2until they may roll in an intended travel direction231may be no greater than what would be required to do the same for standard cylindrical wheels.

FIG.3illustrates the exploded, front perspective view of a caster assembly300having sinusoidal wheels303-1,303-2, according to an aspect. As disclosed hereinabove, the caster assembly300may comprise a top cap301, a caster leg302, a pivot pin304configured to pivotally engage the top cap301with the caster leg302, a first sinusoidal wheel303-1, a second sinusoidal wheel303-2, a wheel axle305configured to rotationally engage the first sinusoidal wheel303-1and the second sinusoidal wheel303-2with the caster leg302, and an axle washer306configured to engage with the wheel axle305to maintain the rotational engagement between first and second sinusoidal wheels303-1,303-2and the caster leg302. Each component of the caster assembly300and their various sub-components will be described in greater detail hereinbelow. While not visible inFIG.3, it should be understood that each sinusoidal wheel303-1,303-2and the caster leg302may each have a corresponding port, such as wheel axle port403cofFIG.4C, for the wheel axle305to be nested within them (e.g. slotted through) to facilitate the rotational engagement/interconnection between said elements, and thus the rotation of the sinusoidal wheels303-1,303-2relative to the caster leg302and resultant rolling of the caster assembly300. It should be understood that the term “pivotal” may be used in describing the pivoting of caster leg302about the pivot axis, such as pivot axis110ofFIG.1, whereas the term “rotational” may be used in describing the rotating of the sinusoidal wheels303-1,303-2about the wheel rotational axis, such as wheel rotational axis113ofFIG.1.

It should be noted that the sinusoidal wheels303-1,303-2may be configured to rotate independently of each other. In an example, a first sinusoidal wheel303-1may be rotated clockwise, while the second sinusoidal303-2wheel may be rotated counterclockwise. In said example, the independent rotation of each sinusoidal wheel303-1,303-2in an opposite direction may be configured to pivot the attached caster assembly300in a tight radius, thus allowing the caster assembly to change directions rapidly within a small area.

While the caster leg302may be configured to be pivoted about its engagement with a supported structure, it should be understood that various different arrangements may be utilized in order to facilitate this pivoting of the caster leg302about a supported object. As seen inFIG.3, the caster leg302may be pivotally engaged with the top cap301by the pivot pin304, wherein the top cap301may be irrotationally engaged with a supported structure. In contrast, alternative embodiments of the caster assembly, such as caster assembly1000ofFIG.10, may omit the top cap entirely, wherein the caster assembly may be pivotally engaged with the supported structure by a corresponding pivot pin. It should be understood that any suitable element(s) may be disposed between the caster leg302and the supported structure to facilitate pivoting of the caster leg302and thus the attached sinusoidal wheels303-1,303-2. As such, the element or collection of elements configured to engage with the supported structure with the caster leg302to facilitate pivoting of the caster leg302about the pivot axis, such as pivot axis210ofFIG.2A, may be referred to as a pivot hub325. In the caster assembly300embodiment ofFIG.3, the pivot hub325comprises a top cap and a pivot pin304.

FIGS.4A-4Cillustrate the front perspective, front elevation and side elevation views, respectively of a sinusoidal wheel403, according to an aspect. The sinusoidal wheel403described herein should be understood to correspond to the first sinusoidal wheel303-1or second sinusoidal wheel303-2ofFIG.3, wherein both sinusoidal wheels have the same structure. The sinusoidal wheel403may comprise a rim403band a wheel hub403aengaged with and surrounded by the rim403b, as seen inFIG.4A-4C. It should be understood that a corresponding wheel axle port403cmay be nested within the center of the wheel hub403ato facilitate rotational engagement of the sinusoidal wheel403with the aforementioned wheel axle, such as wheel axle305ofFIG.3.

As seen inFIG.4B, the rim403bmay have a consistent width403garound the perimeter403jof the wheel hub403a. The rim403bmay be configured to contact the ground directly as the sinusoidal wheel403rotates, wherein the rim403bhas a rim center403ddisposed between and engaged with a pair of lateral edges (“edges”)403e,403f. The rim center403dmay remain equally offset between the first lateral edge403eand the second lateral edge403f, such that the axial distance between the rim center403dand the first lateral edge403eand the axial distance between the rim center403dand the second lateral edge403fare equivalent around the perimeter of the rim (e.g., for any corresponding angle of the sinusoidal wheel403). Furthermore, the outer diameter of the wheel rim403b(as measured from the rotational axis413) may decrease as it approaches each lateral edge403e,403fof the rim403bfrom the rim center403d, thus resulting in the rims403b(and thus the sinusoidal wheels403) having a rounded profile, and thus a smaller contact surface403kthat touches the ground, as seen inFIG.4B, making the sinusoidal wheel403easier to pivot. In contrast, a sinusoidal wheel having a flat profile, and thus a larger contact surface403k, would have a wheel rim with a uniform outer diameter.

It should be understood that the “profile” of the sinusoidal wheel403is referring to the general shape of the wheel rim surface that contacts (or is otherwise adjacent to) the ground, as viewed from in front of or behind the wheel403, as seen inFIG.4B, wherein the profile of the wheel influences the width (and thus the area) of the contact surface (“contact patch”)403kthat directly contacts the ground while rolling. In an embodiment, a sinusoidal rim403b/sinusoidal wheel403with a more rounded profile may have a contact surface403kwith a smaller area, as will be discussed hereinbelow.

It should be understood that the profile of a sinusoidal wheel403may be adjusted, depending on the desired properties of the sinusoidal wheel403. In an embodiment, the profile of the sinusoidal wheel403may be more rounded, such that the wheel rim403bhas a smaller area contact surface403kthat directly touches the ground. In said rounded profile embodiment, the lesser area of the contact surface403kmay result in a greater PSI (pounds per square inch) being exerted upon the ground, but easier swiveling due to the reduced frictional resistance. In an alternative embodiment, a profile of a sinusoidal wheel403may be flatter, such that the wheel rim403bhas a larger contact surface403kthat directly touches the ground. In said flat profile embodiment, the greater area of the contact surface403kmay result in a lesser PSI being exerted upon the ground, but more difficult swiveling, due to the increased frictional resistance between the wheel rim403band the floor. As such, in an embodiment, a caster assembly configured to minimize rolling resistance may utilize sinusoidal wheels with a more rounded profile.

It should be understood that the “axial distances” described herein refer to the distance between corresponding elements as measured in the direction of/along the wheel rotational axis413, as seen by the width403gof the rim403b. In an embodiment, the lateral edges403e,403fof the rim403bmay be mutually laterally offset to maintain the consistent width403gof the rim403b. In other words, a separation distance between the pair of lateral edges403e,403fof each rim may be configured to be consistent around a circumference of the corresponding rim403b.

In an embodiment, each sinusoidal wheel403may be identified as “sinusoidal” as a result of their rim center403dreciprocating back and forth on the wheel rotational axis413around the wheel rim403b, as shown inFIG.4B. In other words, the wheel rim403bmay execute/follow, or otherwise form, a continuous, sinusoidal curve/pattern around the perimeter403jof the wheel hub403a, wherein said continuous, sinusoidal curve has a sinusoidal frequency (thus executing a set amount of sinusoidal periods around the wheel hub403a) and a sinusoidal amplitude. In essence, the rim center403dmay follow a sine curve having an amplitude (e.g., axial distance or displacement along wheel rotational axis413), said amplitude having a maximum intensity/displacement and a minimum intensity/displacement that it smoothly transitions between as it continuously wraps around the circumference/outer perimeter403jof the wheel hub403a. The quantity of sinusoidal periods executed by the rim center403d, and thus the wheel rim403bmay be any suitable whole number, such as 2 periods, such that the sinusoidal pattern is continuous and uninterrupted as it travels around the perimeter403jof the rim403b. As a result of each lateral edge403e,403fbeing equally offset from the rim center403d, each lateral edge403e,403fmay also follow a corresponding sinusoidal curve. It should be understood that sinusoidal curves of the lateral edges403e,403fmay be “in phase” with the sinusoidal curve of the rim center403d, such that the peaks (maximums) and troughs (minimums) of each sinusoidal curve are disposed on the same radial position on the sinusoidal wheel403. Furthermore, the sinusoidal curves of the lateral edges403e,403fand rim center403dof the rim403may be coaxially aligned on the wheel rotational axis, as seen inFIG.4B.

The sinusoidal wheels403may provide several benefits when implemented within the herein disclosed caster assembly. The sinusoidal wheels403may experience less resistance to being rolled when compared to standard cylindrical wheels (e.g., wheels that do not have a rim center that executes/follows a sinusoidal pattern), which may be very helpful for maintaining the ability to roll the sinusoidal wheels403to move a supported structure, particularly for heavier supported structures that may require significantly more force to move. Additionally, the disclosed sinusoidal wheels403may be configured to pivot/change their travel direction more easily, as a result of the sinusoidally wheels403potentially “bending” in an intended travel direction, as described hereinabove. The shape of the sinusoidal wheel403, and thus the resultant shape of the sinusoidal wheel rim403b, may result in each sinusoidal wheel403experiencing less “scrubbing” or frictional resistance as each sinusoidal wheel403is pivoted, when compared to the shape of a traditional right circular cylindrical wheel having flat, planar rim edges. The utilization of sinusoidal wheels403within each herein disclosed caster assembly may also allow a user to change the direction a supported structure is moving by pivoting each caster with less force than would be required if standard cylindrical wheels were utilized for the caster assembly.

FIG.5illustrates the front perspective view of a pivot pin504, according to an aspect. As disclosed hereinabove, the pivot pin504may be configured to facilitate pivotal engagement between the top cap and the caster leg, such as top cap101and caster leg102ofFIG.1. The pivot pin504may comprise a pin body504a, a support ring504bdisposed above and associated with the pin body504a, a pin top504cdisposed above and associated with the support ring504band a rivet head504ddisposed below and associated with the pin body504a. In an embodiment, the rivet head504dand pin body504amay be configured to nest within caster leg, whereas the pin top504cmay be configured to nest within the top cap, such that the top cap rests upon support ring504b.

As can be seen inFIG.5, the rivet head504dand the support ring504bmay have a greater thickness (e.g. diameter) than the pin body504ato facilitate secure engagement with the caster leg and supporting of the top cap, respectively. The thickness of the pin body504amay narrow slightly as it approaches the rivet head504d, in order to make it easier to nest the rivet head504dwithin the corresponding port of the caster leg. The pin top504cmay have the same outer diameter as the pin body504a, thus allowing said pin top504cto be nested within the corresponding port of the top cap, as will be described in greater detail hereinbelow. In an embodiment, a pin slot504emay be nested within the pin top504cto improve engagement between the top cap and the pivot pin504.

FIG.6illustrates the front perspective view of a wheel axle605, according to an aspect. As disclosed hereinabove, the wheel axle605may be configured to engage with the caster leg and rotationally engage with the sinusoidal wheels, such as caster leg302and sinusoidal wheels303-1,303-2ofFIG.3. In order to facilitate this described rotation of the sinusoidal wheels, the wheel axle605may be configured to be nested within the wheel axle port of each sinusoidal wheel, such as wheel axle port403cofFIG.4C, as well as nested within the leg axle port of the caster leg, such as leg axle port802dof caster leg802ofFIG.8B. It should be understood that wheel axle605may be configured such that upon being nested within each wheel axle port and nested within the leg axle port that each wheel axle port and the leg axle port may be coaxially aligned on the wheel rotational axis.

The wheel axle605may comprise an axle body605a, a textured surface605bdisposed on the axle body605a, an end cap605cdisposed on a first end of the axle body605aand a leading end605ddisposed on a second end of the axle body605a. In an embodiment, the wheel axle605may have a hollow center portion605enested within the axle body605ato reduce its weight and use less material. The leading end605dmay be configured to slide through each of the corresponding wheel axle ports and the leg axle port to facilitate engagement of the wheel axle605with each sinusoidal wheel and the caster leg. The end cap605cmay have a diameter greater than that of the wheel axle ports and the leg axle port such that the end cap605citself is not configured to nest within any wheel or leg axle ports. Instead, the end cap605cmay be configured to prevent one of the sinusoidal wheels from sliding off of the wheel axle605upon being rotationally engaged with the caster leg, by virtue of the corresponding sinusoidal wheel being disposed between the caster leg and the end cap605c. The other wheel may be secured to the wheel axle605through the utilization of an axle washer, such as axle washer706ofFIG.7, or another suitable axle capping structure, as will be described hereinbelow. As such, the leading end605dmay be disposed on the opposite side of the wheel axle605as the end cap605c, thus preventing either wheel from disengaging with the wheel axle605.

In an embodiment, the textured surface605bof the wheel axle605may be disposed on a central portion of the axle body605a, such that upon construction of the caster assembly via insertion of the wheel axle605through the corresponding axle ports, that the textured surface605bis engaged directly with the leg axle port of the caster leg, such as leg axle port802dof caster leg802ofFIG.8B. By securing the textured surface605bof the wheel axle605to the caster leg, the wheel axle605itself may not rotate about its engagement with the caster leg, but the attached sinusoidal wheels may still be configured to rotate about their rotational engagement with the wheel axle605, as intended. As such, the textured surface605bof the axle605may itself function as a stopper, thus preventing the axle605from sliding out of the leg axle port, thus ensuring the sinusoidal wheels remain rotationally affixed to the axle605. The axle body605amay have a smooth, low friction finish, as well as a slightly lesser diameter than the wheel axle ports of each sinusoidal wheel, thus allowing each sinusoidal wheel to rotate freely about its engagement with the wheel axle605with minimal resistance, thus facilitating the smooth rolling of the sinusoidal wheels of the associated caster assembly.

In an embodiment, in order to maintain a more affordable price for the caster assembly, said wheel axle605may engage directly with the caster leg without the utilization of a corresponding wheel axle bearing (not shown). However, in alternative embodiments in which caster performance is to be optimized, it may be desirable to implement a wheel axle bearing within the structure of the caster assembly to enable smoother, lower friction rolling of the wheels. In an embodiment, a wheel axle bearing may be nested within the leg axle port of the caster leg, such as leg axle port802dofFIGS.8A-8B, wherein the wheel axle605would thusly be suitably engaged with said wheel axle bearing. Maintenance of the independent rolling of each sinusoidal wheel may be desirable to facilitate easy pivoting of the caster assembly, and thus each sinusoidal wheel may be configured to maintain rotational independence from the wheel axle605, as well as the other sinusoidal wheel.

FIG.7illustrates the front perspective view of an axle washer706, according to an aspect. In an embodiment, the axle washer706may have a shape roughly equivalent to that of a cylindrical ring. The axle washer706may be configured to engage with the traveling end of the wheel axle, such as leading end605dofFIG.6, such that one of the two sinusoidal wheels is confined between the axle washer706and the caster leg, upon engagement of each wheel with the wheel axle. It should be understood that the axle washer706may be nested between an axle cap (not shown) and the corresponding sinusoidal wheel, wherein said axle cap may be configured to engage with the traveling end of the wheel axle upon installation of the corresponding wheel, to help prevent corresponding sinusoidal wheel from falling off of the wheel axle and further prevent the wheel axle from sliding off of the caster assembly. In this way, the axle cap may function similarly to the end cap, such as the end cap605cofFIG.6, but for the opposite sinusoidal wheel of the pair.

In an embodiment, upon engagement of the wheel axle with the caster leg, the first sinusoidal wheel and the second sinusoidal wheel, such as wheel axle305, caster leg302, first sinusoidal wheel303-1and second sinusoidal wheel303-2ofFIG.3, the axle washer706may be configured to engage with a traveling end of the wheel axle, such as leading end605dofFIG.6. In such an embodiment, the first sinusoidal wheel may thusly be confined between the axle washer706and the caster leg, while being configured to rotate freely about the wheel rotational axis, whereas the second sinusoidal wheel may thusly be confined between the end cap of the wheel axle, such as end cap605cofFIG.6, and the caster leg while also being configured to rotate freely about the wheel rotational axis. The axle washer706may be configured to engage with the wheel axle through conventional engagement mechanisms, such as nesting around the wheel axle.

FIGS.8A-8Billustrate the front perspective and bottom perspective views, respectively, of the caster leg802, according to an aspect. The caster leg802may be configured to be pivotally engaged with the top cap and/or the supported structure through the utilization of a pivot pin, to facilitate pivoting of the attached sinusoidal wheels about their engagement to the supported structure, as disclosed hereinabove. The caster leg802may comprise a vertical member802a, an angled member802battached to the vertical member802a, a leg pin port802cnested within the vertical member802a, and a leg axle port802dnested within the angled member802b. As disclosed hereinabove, the leg pin port802cmay be configured to engage with the rivet head portion of a pivot pin, such as rivet head504dofFIG.5, whereas the leg axle port802dmay be configured to have a wheel axle, such as wheel axle305ofFIG.3, nested within it, wherein the wheel axle is coaxially aligned with the wheel rotational axis813.

The vertical member802aand the angled member802bmay be configured to adjoin at an engagement surface802e, wherein the angled member802bbranches off from the vertical member802aat an offset angle812defined between the pivot axis810of the caster leg802and the offset axis811of the angled member802b. In an embodiment, the offset axis811may be defined by a straight line traveling between the engagement surface802eand the leg axle port802d, as seen inFIG.8A. In an embodiment, a pair of wheel pockets802fmay be nested within the caster leg802to allow the sinusoidal wheels to be positioned beneath the vertical member802a, without extending laterally away from the810pivot axis along the wheel rotational axis813. In said embodiment, the pair of wheel pockets802fmay be utilized to define the engagement surface802ebetween the vertical member802aand the angled member802b, wherein the engagement surface802eis disposed between the wheel pockets802fand the vertical member802a. It should be understood that the wheel pockets802fthemselves may be nested within the angled member802b, and thus may reduce the “thickness” of the angled member802b(e.g., how far the angled member802bextends along the wheel rotational axis813.

It should be noted that while the offset angle812between the vertical member802aand the angled member802b(or more specifically, between the pivot axis810and the offset axis811) may be adjusted based on the application of the associated caster assembly, such that the caster assembly may provide better performance (e.g., less frictional resistance to rolling and pivoting) when the offset angle812is maintained between a certain range of suitable offset angles812. In an embodiment, the offset angle812may be an obtuse angle between 90 degrees and 180 degrees. In a preferred embodiment, the offset angle812may be between about 145 degrees and about 150 degrees. In a preferred embodiment, the offset angle812may be greater than 135 degrees but less than 180 degrees in order to ensure proper function of the caster assembly.

In an embodiment, having an offset angle812of less than 135 degrees may cause the attached sinusoidal wheels to tilt too far away from the pivot axis810. This may negatively influence the smoothness of the ride for the caster assembly (e.g. the ease with which the sinusoidal wheels roll), as a result of how the force of the supported structure is exerted upon the sinusoidal wheels. It should be understood that the offset angle812may be selected based upon optimizing caster performance, including ease of rolling and ease of pivoting, with the disclosed sinusoidal wheels.

FIGS.9A-9Billustrate the top perspective and bottom perspective views, respectively, of a top cap901, according to an aspect. As disclosed hereinabove, the top cap901of the caster assembly may be configured to engage with a supported structure while being pivotally engaged with the caster leg through the utilization of a pivot pin, as shown inFIG.3. The top cap901may comprise a cap body901ahaving a first raised edge901band a second raised edge901c. A raised rim901emay be formed by the first and second raised edges901b,901con the front end901hof the top cap901. A plurality of fastening pocket901dmay be nested within the cap body901ato facilitate engagement between the supported structure and the top cap901, as disclosed hereinabove. In an embodiment, the top cap901may be suitably shaped to securely engage with the supported structure, while maintaining a uniform appearance, as shown by suitcase1319ofFIG.13engaging with the corresponding top cap.

In order to facilitate engagement with the pivot pin, such as pivot pin504ofFIG.5, a cap pin port901fmay be nested within or otherwise associated with the cap body901a. As disclosed hereinabove, the top cap901be configured to engage with the pivot pin such that the pin top of the pivot pin, such as pin top504cofFIG.5, may be configured to nest within the cap pin port901f, whereas the cap body901amay be configured to rest on top of the supporting ring of the pivot pin, such as supporting ring504bofFIG.5. It should be understood that the friction between the supporting ring and the cap body901amay be minimized through the selection of suitable element materials, to ensure smooth and easy pivoting of the caster leg about its engagement with the top cap901, as applicable.

With regards to the materials utilized for the herein disclosed caster assembly, it should be understood that strong, lightweight, durable materials, such as plastics and metals, may be utilized for the various components of the caster assembly, unless otherwise noted. In an embodiment, each element of the caster assembly may be made out of a high-strength metal, such as steel or aluminum, in order to provide the necessary structural integrity to the caster assemblies to allow them to support a heavy supported structure, such as a tool case, while allowing said supported structures to be rolled and the caster assemblies pivoted with ease. In an embodiment, the wheel rims, such as wheel rim403bofFIGS.4A-4B, may be made of a higher friction material, such as rubber, to allow the wheels to grip the floor more easily, to ensure the supported object does not slide unintentionally. In an alternative embodiment, the wheel rims403bmay be made of a lower friction material, such as a hard plastic to allow the wheels to pivot with less friction.

It should be understood that the wheel axle and pivot pin, such as wheel axle305and pivot pin304ofFIG.3, may be made out of a strong, lightweight material that is configured to allow for the pivotal/rotational engagement between adjoined elements, as outlined above, with minimal friction between them, such as a metal material having a smooth external texture. In an embodiment, element materials may be selected to minimize the friction between the wheel axle and sinusoidal wheels, to ensure that the sinusoidal wheels may easily roll in a direction to move a supported object across a floor. In an embodiment, element materials may be selected to minimize the friction between the pivot pin and the top cap and caster leg, such that the caster leg may pivot freely about its pivotal engagement with the top cap/supported structure, to facilitate smooth, easy pivoting of each caster assembly when a supported structure is pushed in changing directions.

FIG.10illustrates the side perspective view of an alternative embodiment of the disclosed caster assembly1000secured to the leg1016of a structure, according to an aspect. As disclosed hereinabove, in order to facilitate the easy movement of a supported structure, one of the disclosed caster assemblies1000may be secured to a bottom portion1016aof each of the supported structure's legs1016. By providing a caster assembly1000between each leg1016and the ground1017, the supported structure may be selectively moved with significantly less force than trying to drag or push the structure across the ground without caster assemblies1000beneath the legs1016.

It should be understood that, in certain embodiments, the caster assembly1000may omit the top cap structure, such as top cap101ofFIG.1, while still pivotally engaging the caster leg1002with the supported structure using a corresponding pivot pin or pivot hub embodiment. In an embodiment, the caster leg1002may be configured to engage with the circular tubing/leg1016of the supported structure through the usage of a grip ring stem embodiment of the pivot pin, such as grip ring stem1420ofFIG.14, or a threaded stem embodiment of the pivot pin, such as threaded stem embodiment1518ofFIG.15. Regardless of the type of pivot pin or pivot hub utilized, as long as the caster leg1002is suitably configured to pivot about a direct or indirect engagement with the supported structure, any suitable pivot pin/pivot hub embodiment may be utilized.

The disclosed alternative embodiment of the caster assembly1000may also differ somewhat from the caster assembly embodiments disclosed hereinabove inFIG.1-9Bas a result of additional features. Two additional features, including the wheel cover1014and a wheel lock1015may be implemented into the alternative caster assembly1000ofFIG.10. It should be understood that elements of the prior disclosed caster assembly embodiments ofFIG.1-9Band the hereinbelow disclosed alternative caster assembly embodiments ofFIG.10-12may be utilized together, such that the resultant caster assembly may achieve the desired combination of functional capabilities. For example, the hereinbelow described wheel cover1014may be implemented within the structure of caster assembly100ofFIG.1, if the corresponding functionality of said wheel cover1014(e.g., protecting the wheels) is desirable for an application or use-case.

In an embodiment, the caster leg1002of the caster assembly1000may further comprise a wheel cover1014associated with the vertical member1002aof the caster leg1002, wherein the wheel cover1014is configured to surround and protect a top portion1003hof each sinusoidal wheel1003. It should be understood that the top portion1003hof each sinusoidal wheel1003may change as each sinusoidal wheel1003rolls, based on the current orientation of the sinusoidal wheel1003. The bottom portion1003iof each sinusoidal wheel1003may still be configured to contact the ground1017, despite the presence of the wheel cover1014.

In addition, the alternative caster assembly ofFIG.10may further comprise a wheel lock1015associated with the caster leg1002, or more specifically the wheel cover1014, wherein the wheel lock1015is configured to selectively engage with the sinusoidal wheels1003of the caster assembly1000to prevent them from rolling. This wheel lock1015may facilitate the selective prevention of sinusoidal wheel1003rotation by directly contacting the sinusoidal wheels1003when actuated. A portion of the wheel lock1015configured to selectively contact the sinusoidal wheels1003may have a high coefficient of friction, such that said portion's selective contact with said sinusoidal wheels1003significantly increases the amount of force required to roll the sinusoidal wheels. As such, a user may choose to disengage the wheel lock1015on each caster assembly1000before moving a corresponding supported structure, and reengage the wheel lock1015of each caster assembly1000after moving the supported structure into the desired position, thus locking said supported structure in place.

FIG.11illustrates the side perspective view of an alternative embodiment of the caster assembly1100without the top cap, according to an aspect. It should be understood that multiple variations of each element of the caster assembly1100may be implemented as needed for a particular application of the caster assembly1100. In an embodiment, the alternative caster assembly1100may utilize a threaded embodiment of the pivot pin1104having a pin top1104c, wherein said pivot pin is configured to engage the caster leg1102directly with the supported structure. It should be understood that threads, or other known interconnection structures, may be utilized to interconnect the caster assembly elements to the supported structure as necessary, as long as the presence of said interconnection structures does not negatively impact caster functionality or performance. It should be understood that the pivotal engagement between the threaded pivot pin1104and the vertical member1102aof the caster leg1102may be maintained to facilitate the necessary pivoting/swiveling action of the caster assembly1100. It should also be understood that the alternative embodiments of the caster assembly1100may utilize sinusoidal wheels1103as well.

As disclosed hereinabove, the element of a caster assembly1100configured to facilitate the pivotal engagement of the caster leg1102with a supported structure may be a pivot pin1104. As such, for the caster assembly1100embodiment ofFIG.11, the pivot hub1125may be just a pivot pin1104, as the pivot pin1104is the structure responsible for pivotally engaging the caster leg1102with the supported structure.

FIG.12illustrates the side perspective view of an alternative embodiment of the caster assembly1200having an octagonal top cap1201, according to an aspect. In an embodiment, the shape and characteristics of the top cap1201may be modified as necessary in order to achieve the necessary functional capabilities and appearance. As seen inFIG.12, the top cap1201is configured to pivotally engage with the caster leg1202may have an octagonal shape (e.g. an octagonal cross section). This octagonally shaped top cap1201may be further engaged with a threaded stem1218embodiment of the pivot pin, wherein said threaded stem1218is configured to be engaged directly with the supported structure, such as leg1016ofFIG.10, such that the octagonal top cap1201is configured to be pivotally engaged with the supported structure, along with the attached caster leg1202, and thus the attached sinusoidal wheels1203, which are also configured to pivot about the pivotal engagement between the octagonal top cap1201and the supported structure.

The sizing of each element, such as the length, width, height, diameter, etc. of each element, may be modified as necessary depending on the desired wheel size, offset angle, weight of the supported structure, etc. In an embodiment, the length of the vertical member1202aofFIG.12may be longer than the length of vertical member1102aofFIG.11. The height of the vertical member1202aof a caster leg1200may be adjusted depending on a variety of factors, including the desired height of the supported structure. It may be preferable to have each caster assembly1200configured to attach to a specific supported structure having the same specifications to ensure that supported structure remains level and rolls evenly as it is pushed. In certain embodiments, it may be desirable to attach caster assemblies having different specifications or elements to different legs of a supported structure. For example, a structure having four legs may only need two out of the four caster assemblies to include wheel locks1215, as the selective immobilization of the wheels1203two of the caster assemblies1200out of the four total caster assemblies may be sufficient to render a supported structure stationary as needed.

As disclosed hereinabove, the octagonal top cap1201may be configured to be fitted to tube-like elements such as the legs of furniture, tables, etc. In an embodiment, this fitting of the octagonal top cap1201to the tube-like element of the supported structure may increase the structural stability to the caster1200. Furthermore, having the cross-sectional shapes of directly adjoining elements be similar allows the caster assembly1200to pivot as described without having an overly noticeable overhang between the differing geometries of the top cap1201, the caster leg1202and the tube like element of the supported structure. For example, if an object having a square cross-section were rotated on top another object having a square cross-section, then there would be a noticeable overhang when the corner of one object was rotated to align with the middle of an edge for the other object. In contrast, for an object with an octagonal cross section, such as the octagonal top cap1201, rotating on top of (or beneath) an object with a circular cross section, such as the vertical member1202aof the caster leg1202or the leg of a supported structure, the overhang between these elements will not be nearly as noticeable, thus providing a more unified, clean appearance. For the disclosed caster assembly1200ofFIG.12, the pivot hub1225may comprise a threaded stem1218and an octagonal top cap1201, wherein the octagonal top cap1201is configured to engage with the caster leg1202and the threaded stem1218and the threaded stem1218is configured to be pivotally engaged with the supported structure.

FIG.13illustrates the front perspective view of a caster assembly1300engaged with a suitcase1319, according to an aspect. It should be understood that in order to facilitate secure engagement of the caster assembly1300with a supported structure or object, the top cap1301of the caster assembly1300may need to have a shape that is complementary to or otherwise compatible with the surface of the supported structure or object it is configured to engage with. In an embodiment, a caster assembly1300having a top cap1301equivalent to those seen inFIG.1-9Bmay be configured to engage with a suitcase1319, while conforming to the shape of the corner1319aof said suitcase1319. Other casters assemblies may also have top caps configured to have a shape that is complementary to the supported structure or object that they are being engaged with, or for certain embodiments, the top cap may be omitted, and the pivot pin or equivalent pivot hub may be configured to engage directly with the supported structure, while allowing the caster leg1302to be pivotally engaged with the supported structure.

FIG.14illustrates a front elevation view of grip ring stem1420embodiment of the pivot pin, according to an aspect.FIG.15illustrates a front elevation view of a threaded stem embodiment1518of the pivot pin, according to an aspect. As mentioned hereinabove, various embodiments of the pivot pin may be utilized in order to facilitate the pivotal engagement of a caster assembly component with a supported structure. In embodiments lacking a top cap, an appropriate embodiment of the pivot pin, such as the grip stem1420ofFIG.14or the threaded stem embodiment1518ofFIG.15, may be utilized to pivotally engage the caster leg of the caster assembly to the supported structure. In said embodiments, the pivot pin embodiment may be engaged with the caster leg and the supported structure, wherein the pivot pin is pivotally engaged with caster leg and/or the supported structure to facilitate the pivoting of the caster leg about the supported structure.

In embodiments having a top cap, such as caster assembly300ofFIG.3and caster assembly1200ofFIG.12, the engagements made with the pivot pin embodiment may differ somewhat. As can be seen inFIG.3, the pivot pin304may be configured to engage directly with the top cap301and the caster leg302, wherein the top cap301was configured to be irrotationally engaged with the supported structure, such as suitcase1319ofFIG.13and the pivot pin304is configured to be pivotally engaged with top cap301and/or the caster leg302to facilitate rotation of the caster leg302about the top cap301. In contrast, as seen inFIG.12, the threaded stem1218embodiment of the pivot pin may be engaged with the top cap and be configured to pivotally engage with the supported structures, such that the top cap1201rotates with the caster leg1202as the caster assembly1200is pivoted.

FIG.16illustrates the top plan view of a flat plate1621embodiment of the top cap, according to an aspect. The flat plate1621embodiment of the top cap may be desirable for supported structures having a flat bottom surface. The flat plate1621may comprise a plate body portion1621aand a plurality of plate ports1621bnested within the plate body portion1621a. The flat plate1621may be configured to engage with a corresponding supported structure through the utilization of plurality of screws or other applicable fasteners, wherein said fasteners are configured to be nested within the plate ports1621band corresponding structures on the supported object, thus securing the flat plate1621to the supported structure. It should be understood that the flat plate1621may also be pivotally engaged with the caster leg through the utilization of a corresponding pivot pin, wherein the pivot pin is configured to engage with the flat plate1621and to pivotally engage with the caster leg, as seen inFIG.18.

FIG.17A-17Billustrate the rear perspective and top perspective views, respectively, of a caster assembly1700having a threaded stem1718, according to an aspect. As disclosed hereinabove, in the absence of a top cap, a caster assembly1700may be configured to pivotally engage with a supported structure through the use of a pivot pin, such as a threaded stem1718, acting as the entirety of the pivot hub. This pivot pin may be configured to pivotally engage the caster leg1702with a corresponding part of the supported structure that has a circular cross section, such that a unified appearance is established between the caster assembly1700and the supported structure.

FIG.18illustrates the rear perspective view of a caster assembly having a flat plate1821, according to an aspect. A caster assembly1800having a flat plate1821embodiment of the top cap may be configured to engage with a portion of the supported structure that has a similar cross-sectional shape. In an embodiment, for a leg of a supported structure having a square cross-sectional shape, the flat plate1821configured to engage with the leg of the supported structure may also have a square cross-sectional shape, as seen inFIG.18.

It should be understood that the particular cross-sectional shape of the caster assembly element configured to engage and coaxially align with the supported structure may be adapted to be the same (or sufficiently similar to) to the portion of the supported structure that it is configured to engage with. As seen inFIG.10, a top cap assembly may be omitted from the corresponding caster assembly, such that the circular cross section of the vertical member1002aof the caster assembly1000may coaxially align with a circular cross section leg1016of the support structure. For support structures having legs with a square cross section (not shown), the disclosed caster assembly1800ofFIG.18may be desirable, wherein its square flat plate1821may be suitably sized and proportioned to coaxially align with the leg of the supported structure. Alternatively, a caster assembly having an octagonal cross section top cap, such as octagonal top cap1201ofFIG.12, may be configured to engage with support structure legs have octagonal, square or circular cross sectional-shapes, as said octagonally shaped top cap may be sufficiently close in shape to both square and circle cross section structures to still provide the desired appearance and performance.

FIG.19Aillustrates an exploded side perspective view of a caster assembly having enhanced load bearing capabilities, according to an aspect.FIG.19Billustrates an exploded top perspective view of a caster assembly having enhanced load bearing capabilities, according to an aspect.FIG.19Cillustrates a top perspective view of a retainer ring1944, according to an aspect. In order to enable the disclosed caster assembly1900to support a supported structure or object having a greater weight, a pivot hub1925configured to maintain the rotational capabilities of the caster assembly under said greater weight may be incorporated into the structure of the prior disclosed caster assemblies, such as caster assembly1200ofFIG.12. It should be understood that a caster assembly1900having this alternative pivot hub1925may be described as a “heavy load caster assembly”1900, wherein the pivot hub1925itself may be described as a “heavy load pivot hub”1925. In addition to utilizing alternative structures, caster assemblies may also be constructed of different materials to influence load capacity. In an embodiment, versions of the caster assembly1900having caster assembly components (e.g., wheel hubs, caster legs, etc.) made of plastic may be configured/rated to safely support 150 lbs per caster assembly, whereas versions of the caster assembly1900having caster assembly components made of aluminum may be configured/rated to safely support 250 lbs per caster assembly.

As can be seen inFIG.19A-19C, the pivot hub1925may comprise a retainer ring1944configured to be nested within a caster leg cavity1902g, wherein the caster leg cavity is nested or otherwise disposed within a top part1902hof the vertical member1902aof the caster leg1902, the retainer ring1944having a retainer ring body1944aand a bearing channel1944bnested within retainer ring body1944a, a plurality of ball bearings1943configured to be seated in the bearing channel1944bof the retainer ring1944, a pivot ring1942configured to be seated on top of, or otherwise engaged with, the plurality ball bearings1943and a pivot shaft (“pivot topper”)1941configured to engage with a supported structure and rest upon pivot ring1942. The pivot hub1925ofFIG.19may be configured such that the caster leg1902may rotate freely about its indirect engagement with the pivot shaft1941, by virtue of the pivot shaft1941being seated on top of, or otherwise engaged or associated with, a plurality of ball bearings1943, wherein each ball bearing of the plurality of ball bearings1943is configured to roll freely within the bearing channel1944b.

As can be seen in the embodiment ofFIG.19A, the pivot shaft1941may further comprise a plurality of elements combined into a monolithic structure. In an embodiment, the pivot shaft1941may further comprise a threaded rod1941a, a pivot shaft nut1941bengaged with and disposed below the threaded rod1941a, and a pivot shaft base1941cengaged with and disposed below the pivot shaft nut1941b. In an embodiment, the threaded rod1941amay be configured to be engaged with the supported structure, whereas the pivot shaft nut1941bmay be configured to be seated on or otherwise engaged with the pivot ring1942, such that the supported structure is configured to be pivotally engaged with the caster leg1902. In said embodiment, such as the caster assembly1900embodiment ofFIG.19D, the pivot ring1942and retainer ring1944may both be configured to surround the pivot shaft base1941c, such that the pivot shaft base1941cis nested within or otherwise surrounded by an empty central opening1942aof the pivot ring1942and an empty central opening1944cof the retainer ring1944. The capability for the plurality of ball bearing1943to move within the bearing channel1944ballows the pivot ring1942, and thus the pivot shaft1941resting upon the pivot ring1942, to be pivotally engaged with the caster leg1902, such that the caster leg1902may pivot about the supported structure.

In an embodiment, the pivot shaft nut1941bmay have an octagonal shape/cross-section, similarly to the top cap1201ofFIG.12. In said embodiment, the pivot shaft nut1941bmay be sufficiently sized to cover the caster leg cavity1902gdisposed beneath it, such that debris and other materials may be kept out of the caster leg cavity1902gto ensure proper pivotal engagement between the caster leg1902and the supported structure. This octagonal shape/cross-sectional shape of the pivot shaft nut1941bmay be configured to provide a uniform appearance for the caster leg as it pivots about the corresponding element of the supported structure, as disclosed hereinabove.

The particular configuration of the heavy load caster assembly1900ofFIG.19A-19Bis such that the weight of the supported structure is exerted evenly across the plurality of ball bearings, thus ensuring that the heavy load caster assembly may evenly support greater weights1900without being damaged. In the disclosed caster assembly1900, the weight of the supported load may be distributed over a greater surface area than if the pivot hub1925was engaged with the caster leg1902via a single rod or thread. In an embodiment, the caster leg1902may be irrotationally engaged with the retainer ring1944and the pivot shaft1941may be irrotationally engaged with the supported structure. As a result of the ball bearings1943being able to travel freely within the bearing channel1944b, the pivot ring1942seated on top of the plurality of ball bearings1943may be configured to pivot about the pivot axis, such as pivot axis2010ofFIG.20, thus facilitating a pivotal engagement between the pivot shaft1941and retainer ring1944. This in turn results in the pivotal engagement between the caster leg1902and the supported structure.

FIG.20Aillustrates the side elevation cross-sectional view of an alternative caster assembly2000having enhanced load bearing capabilities, according to an aspect.FIG.20Billustrates the top plan view of an alternative caster assembly2000having enhanced load bearing capabilities, according to an aspect. As can be seen inFIG.20A-20B, the structure of this alternative caster assembly2000may differ somewhat from the previously described heavy load caster assembly1900ofFIG.19A-19B. This being said, the alternative caster assembly2000ofFIG.20A-20Bmay utilize a similar heavy load pivot hub2025, and thus may be classified as another type of heavy load caster assembly2000.

The exact mechanism through which the plurality of ball bearings2043enable pivotal engagement between the caster leg2002and a supported structure may differ somewhat from the engagement mechanism described hereinabove inFIGS.19A-19B. As can be seen inFIG.20A, the pivot hub2025may further comprise of an inner gasket2048engaged with and surrounding the pivot shaft base2041cof the pivot shaft2041and an outer gasket2047may be engaged with the caster leg2002and nested within the caster leg cavity2002g. In an embodiment, the inner gasket2048may be disposed between the retainer ring2044and the pivot ring2042. In contrast to the caster assembly1900embodiment ofFIGS.19A-19B, the plurality of ball bearings2043may be sandwiched/compressed or otherwise disposed between the inner gasket2048and the outer gasket2047to enable pivotal engagement between the pivot shaft2041(and thus the supported structure) and the caster leg2002. In said embodiment ofFIG.20A, the retainer ring2044may not be utilized to directly seat the plurality of ball bearings2043, but may instead be utilized to suitably seat the inner gasket2048engaged with the pivot shaft2041such that the inner gasket2048may be both coaxially aligned with, and the same elevation as, the outer gasket2047nested within the caster leg cavity2002g.

Additional structures may also be utilized within the heavy load caster assembly2000ofFIG.20A-20Bto ensure the desired look and performance for said caster assembly2000. Atop cap2001may be engaged with the caster leg2002by a plurality of screws2046to provide a covering for the caster leg cavity2002g. This top cap2001embodiment may have a cap body2001aand a cap port2001inested within the cap body2001a, wherein the cap port2001iis configured to allow the pivot shaft2041to travel between the caster leg cavity2002gand the external environment2060, to facilitate pivotal engagement between the caster leg2002and the supported structure through said pivot shaft2041. In an embodiment, the pivot shaft2041(including its threaded rod2041a, pivot shaft nut2041band pivot shaft base2041c), top cap2001(including its cap port2001i), pivot ring2042, retainer ring2044, inner gasket2048, outer gasket2047and caster leg cavity2002gmay be coaxially aligned on the pivot axis2010. The plurality of ball bearings2043may be arranged into a circular pattern, as seen by ball bearings1943ofFIG.19B, in accordance with the circular ring shapes of the corresponding elements that engaged with them. In an embodiment, the top cap2001may be identified as a component of the pivot hub2025.

In the embodiment ofFIG.19A-19B, the circular arrangement of the plurality of ball bearings1943is the result of the circular bearing channel1944b. In the caster assembly2000ofFIG.20A-20B, the circular arrangement of the plurality of ball bearings1943is the result of the circular shape of the inner gasket2048(as a result of the inner gasket2048wrapping around the circular cross section of the pivot shaft base2041c) and the circular shape of the outer gasket (as a result of the circular cross section of the caster leg cavity2002g). Because of the circular shapes of the inner gasket2048and the outer gasket2047, as well as their coaxial alignment and same elevation, the circular pattern formed by the plurality of ball bearings2043disposed between the inner and outer gaskets2048,2047may be circular as well. As is understood, the circular shapes utilized for each corresponding structure of the pivot hub2025may allow for smooth pivoting of the caster leg2002about its engagement with a supported structure, even when the weight of the supported structure is significant. In an embodiment, the pivot shaft2041may not come into direct contact with the caster leg cavity (as seen by a small gap2061seen between the bottom of the pivot shaft base2041cand the base2002iof the caster leg cavity2002g.)

It should be noted that the sizing specifications included herein are purely provided to illustrate a potential embodiment, rather than to limit the potential sizing specifications that may be utilized in alternative embodiments of the invention. In an embodiment, the outer diameter of the rim2003bof each wheel2003may be about 58.8 mm. In said embodiment, the distance between the center of the wheel axle port2003cand the top of the pivot shaft nut2041bmay be about 53 mm, wherein the top of the pivot shaft nut2041bis about 3.0 mm tall, has a hexagonal shape, and an about 14.0 mm separation between the center of each hexagonal face and the corresponding opposing hexagonal face, as seen inFIG.20B. The threaded rod2041amay have height that extends the top of the pivot shaft nut2041bby about 19.05 mm, wherein the threaded rod2041amay have a ½″-13 UNC thread size. In an embodiment, a lock pin2070may be configured to engage with the wheel lock2015and the caster leg2002to secure the wheel lock2015to the caster leg2002.

FIG.21illustrates a side perspective cross-sectional view of an alternative caster assembly2100having enhanced load bearing capabilities, according to an aspect. As seen inFIG.21, this alternative caster assembly2100embodiment may have several differences from the hereinabove described alternative caster assembly2000ofFIG.20A-20B. In the alternative caster assembly2100embodiment ofFIG.21, the pivot ring2149aand base ring2149bmay be incorporated into the structure of the pivot shaft2141, such that the threaded rod2141a, pivot ring2149aand base ring2149bform a monolithic structure. Similarly to the caster assembly embodiment2000ofFIG.20A-20B, the inner gasket2148may be configured to surround the pivot shaft base2141cand be nested between the pivot ring2149aand base ring2149b. In an embodiment, unlike the caster assembly embodiment2000ofFIG.20A-20B, the top cap2101may be directly engaged to the threaded rod2141a, such that the top cap2101does not pivot with the caster leg2102, but instead remains irrotationally affixed to the supported structure as the caster leg2102rotates around said top cap2101and the supported structure.

As can be seen inFIG.21, the top cap2101may comprise a cap body2101aand a threaded cap port2101inested within the cap body2101a. The threaded rod2141aof the pivot toper2141may be configured to engage with the threaded cap port2101isuch that the threaded rod2141ais partially nested within the threaded cap port2101iand extends above the top cap2101, whereas the pivot shaft base2141cis disposed below the top cap2101. Aside from the disclosed difference regarding the engagement between the top cap2101and the pivot shaft2141, the disclosed alternative caster assembly2100ofFIG.21may be largely the same as the alternative caster assembly2000ofFIGS.20A-20B. The disclosed plurality of ball bearings2143may be configured to be compressed between the inner gasket2148and the outer gasket2147to facilitate the rotation of the caster leg2102about the pivot shaft2141. In an embodiment, the inner gasket2148may be secured to the pivot shaft2141and the outer gasket may be secured to the caster leg2002in order to facilitate this pivotal engagement. The plurality of ball bearings2143disposed between the inner gasket2148and the outer gasket2147may for a circular arrangement, wherein said circular arrangement is configured to be coaxially aligned with the inner gasket2148, the outer gasket2147and the pivot shaft2141.

In an embodiment, an outer gasket retaining ring2150may be configured to be nested within the caster leg cavity2102g, as shown inFIG.21. In said embodiment, the outer gasket retaining ring2150may be configured to further enable the smooth rotation of the caster leg2102about a supported structure by securely holding the outer gasket2147in place. By holding the outer gasket in place2147, the plurality of ball bearing2143may also be held in place, as a result of being compressed between the secured outer gasket2147and the inner gasket2148.

As disclosed hereinabove, the pivot hub2125may be configured to enable the pivotal engagement between the caster leg2102and a supported structure. While the exact rotational behavior of each element of the pivot hub2125may vary, each embodiment may allow the caster leg2102to swivel accordingly as the supported structure is moved. As is understood, the disclosed heavy load embodiments of the caster assembly2100may utilize the sinusoidal wheels2103described herein, such that the said caster assembly2100may be provided the corresponding advantages disclosed hereinabove.

Further, as used in this application, “plurality” means two or more. A “set” of items may include one or more of such items. Whether in the written description or the claims, the terms “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of,” respectively, are closed or semi-closed transitional phrases with respect to claims.

Throughout this description, the aspects, embodiments or examples shown should be considered as exemplars, rather than limitations on the apparatus or procedures disclosed or claimed. Although some of the examples may involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives.

Acts, elements and features discussed only in connection with one aspect, embodiment or example are not intended to be excluded from a similar role(s) in other aspects, embodiments or examples.

Aspects, embodiments or examples of the invention may be described as processes, which are usually depicted using a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may depict the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. With regard to flowcharts, it should be understood that additional and fewer steps may be taken, and the steps as shown may be combined or further refined to achieve the described methods.

If means-plus-function limitations are recited in the claims, the means are not intended to be limited to the means disclosed in this application for performing the recited function, but are intended to cover in scope any equivalent means, known now or later developed, for performing the recited function.

Claim limitations should be construed as means-plus-function limitations only if the claim recites the term “means” in association with a recited function.

If any presented, the claims directed to a method and/or process should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.

Although aspects, embodiments and/or examples have been illustrated and described herein, someone of ordinary skills in the art will easily detect alternate of the same and/or equivalent variations, which may be capable of achieving the same results, and which may be substituted for the aspects, embodiments and/or examples illustrated and described herein, without departing from the scope of the invention. Therefore, the scope of this application is intended to cover such alternate aspects, embodiments and/or examples. Hence, the scope of the invention is defined by the accompanying claims and their equivalents. Further, each and every claim is incorporated as further disclosure into the specification.