Zip line apparatus

Embodiments of the present invention generally relate to a zip line or trolley system kit for propelling a person or an object using gravity along an extended cable line suspended between two trees or towers. The zip line or trolley system may include an easily installable support harness assembly, a braking system and a removable seat fixture to provide for the zip line system to be completely portable to be carried, installed and taken down in remote locations.

FIELD OF THE INVENTION

The invention relates to a trolley for guiding a person or an object using gravity along an extended cable line suspended between two spaced apart objects such as trees or towers, and more specifically relates to a zip line kit or system with an easily adjustable and removable seat and handle arrangement which in combination with a wheel and braking system for the device facilitates a safe and controllable descent along the cable line. The trolley is provided with at least two wheels spaced apart at a suitable distance to increase ride smoothness, provide sufficient space to accommodate the braking system and improve operation of the zip line system along the extended cable. The invention includes a ratchet tensioning system to more easily install, tighten and maintain the tension of the extended cable. The zip line system is also easily assembled and installed to and from the cable using a unique seat attachment fixture referred to herein as a seat ring or seat clamp that makes the zip line system completely portable for installation in remote locations.

BACKGROUND

A zip line system is a work or recreational device which allows a user to maneuver or traverse themselves, or another person, object or load by use of a trolley along a suspended line or cable generally from a higher point of elevation to a lower point of elevation using gravity, although the trolley, person, object or load may be moved in any direction along the suspended line or cable depending on the use of different forces, arrangement of the zip line system and necessity. The line or cable can be a rope, steel cable, wire or other similar elongate support, even a rigid elongate support such as a steel or wooden beam, which can be extended between two points. The line or cable and zip line system generally permits travel of the trolley along the vector defined by the cable or line. The trolley has at least a wheel and preferably a plurality of wheels rotatably supported by the trolley which in turn support the trolley upon the line or cable.

The trolley may be permanently and/or removably supported by the cable and will generally include at least a handle, sling, harness or netting affixed or suspended from the trolley to support the person, load or object. Commercial trolleys for instance for mountain climbing and eco-tourism like jungle canopy tours use a trolley to which a safety harness is secured. The safety harness is a support which is merely a set of fabric straps that are adjusted around the legs and buttocks of a person with a suspension strap that connects to the trolley or pulley system. The person is directly suspended from the trolley system and must hold onto the suspension strap as they traverse the zip line.

Known zip line systems do not have a seat to comfortably support the rider during the traverse, nor an adjustment mechanism which makes the seat easily adjustable for people of different sizes. Usually the rider dangles within the harness directly from the trolley system. Known zip line systems also generally do not have any type of handle for a rider to hold directly onto the trolley while they are also supported by the adjustable seat.

Additionally, known zip line systems do not have any type of braking system in the trolley itself and the user has little or no ability to slow themselves down, or even stop themselves during the traverse. In most current systems a rubber or cushioned bumper is positioned at the base of the cable to intercept and stop the trolley from sliding further down the cable. Most systems further affix the cable to a tree tower or other support by looping the cable through a steel ring and twisting a wire, clamping the cable, or otherwise fastening the cable to itself to suspend the cable. These current features provide little safety or control to the user and require lengthy installation or removal of the system thus there exists a need for an improved zip line system that is more easily installed and that includes portability features and easy installation and adjustment to the cable assembly. The zip line system may include a trolley, a seat support with a seat clamp that makes installation and removal of the trolley and the seat effortless, and an improved braking safety device to slow the descent of the trolley and person, load or object traversing along the cable of the zip line system.

OBJECTS AND SUMMARY OF THE INVENTION

The zip line system of the present invention may be offered as a completely assembled unit or a kit with various components including for example the trolley, a braking system, handle, webbing, a seat and a trolley return line. Other components of the system could include but are not limited to a safety harness, a cable assembly system as well as structural accessories, fasteners and tools such as a come-along and cable cutters which facilitate constructing and suspending the cable between two points. The come-along or ratchet provides for installation, adjustment and removal of the cable in a relative short amount of time making the zip line system portable for installation in remote locations.

The zip line kit has an improved trolley system that supports at least one, and preferably two or more wheels or pulleys sandwiched between two frame pieces. The frame pieces can be manufactured of aluminum or other metal, certain rigid plastics or other stiff durable materials such as carbon fiber could be used as well. The frames are affixed to one another sandwiching the wheels therebetween. The frames can be removably affixed for instance by bolts, screws or other such fastening devices. The frames can be permanently connected for instance by rivets or welding or even hingedly connected by a hinge or quick-release and fastening system which allows the frames to hinge along parallel or non-parallel planes with respect to one another. Such a hinge connection may facilitate taking the trolley on and off a cable without having to take the cable down or completely take the trolley apart.

In any event the trolley is securely affixed to and supported on the cable, line, rope or wire with the cable inserted through, i.e. generally in a planar relation between the two frame pieces and below the wheels, so the wheels rest on the top of the cable and support the trolley so that it can roll efficiently along and traverse the cable. It is to be appreciated that there could be an additional wheel or wheels below the cable to facilitate maintaining the trolley tracking along the cable.

A handle is secured through each of the frame pieces using cushioned grips, improving the comfort, and grip of the handle for the rider. Alternatively, a dual piece handle may be formed by engaging threadable sections which engage with one another, or which engage directly with frame pieces. The frame pieces also support fabric webbing, although a cable or rope may also be contemplated, that extends from the base of each of the frame pieces to support a seat for the zip line rider beneath the trolley. This adjustment allows the seat to be positioned at a desired distance below the handle for a rider to comfortably hold the handle essentially above their head while seated. The seat may be of aluminum, another metal or of a plastic composite with an ergonomic shape to allow for a rider to sit comfortably.

In further embodiments, the fabric webbing that supports the seat is inserted through a slot in the seat and extended to an appropriate length and then folded in half with the distal end inserted through the same or a second slot in the seat. The ends of the webbing are then sewn together or folded over and sewn to create a thickness of the webbing that is greater than the slot to prevent the webbing from being pulled out and through the slot. In this manner the webbing may be permanently attached to the seat. The half fold in the webbing is then inserted into and secured to a seat ring or seat clamp that has an opening to provide for the handle to be inserted through one side of the frame through the seat clamp and through the other side of the frame. This unique attachment for the seat allows for the handle to be removed from the frame and the seat clamp to be slid out from between the frame pieces to remove the seat from the trolley. This construction provides for the seat to be easily removed for safety, so that a user such as a small child does not attempt to ride the zip line without supervision. The easy attachment also provides for portability of the zip line, so that a cable could be extended in a remote location between any two suitable support structures such as trees or towers and the trolley could be mounted to the cable and the handle inserted through the frame and seat clamp to quickly and easily attach the seat, without the necessity of tools or disassembly of the trolley. Portability of the system and easy installation and removal is further supported by the quick release come-along or ratchet system that reliably and securely installs the zip line cable to the support structures.

The present invention further provides an innovative braking system with an actuator to allow a user to slow the speed of the trolley when descending or completely stop the trolley. The braking system is spring loaded or uses a high-strength heat and weather resistant elastic made from for example an ethylene propylene diene monomer (EPDM) rubber. In an embodiment the elastic is suspended from a pin or bolt inserted within a slot of the braking system support that holds the brake pad above the zip line cable. The elastic is affixed to each end of the support so that when actuating, the user pulls finger levers down to have the brake pad contact the cable. When the levers are released, the elastic pulls the brake pad and braking support away from the cable. The brake pad may be of a polyester based polyurethane. The hardness of the composite will reduce degradation as the pad is held against the cable by the user while descending. In some embodiments, the brake pad may have the unique feature of a perforation of openings in the frictional surface of the brake pad. As degradation of the pad from friction along the cable occurs over long periods of use, material between the perforated openings may fuse and fill the openings extending the life of the brake pad. The brake pad is removable from the braking support for replacement as needed. In other embodiments a tension or leaf spring instead of an elastic may be used to reset the brake pad to an unactuated position above the cable.

It is an object of the present invention to provide a trolley for a zip line system including a braking system including a brake pad and actuator to control the amount of braking desired by the rider as the rider slides along the cable.

It is an object of the present invention to provide a brake pad of high hardness to reduce degradation when heated due to friction along the cable to extend the life of the pad.

It is another object of the present invention to provide an improved zip line system and trolley for traversing a cable with the trolley having an increased distance between each wheel to permit the trolley to more efficiently traverse the cable and permit the braking system to be located between the spaced apart wheels.

It is another object of the present invention to provide a zip line system with an easily adjustable seat to more comfortably accommodate riders of different sizes.

It is another object of the invention to provide a seat clamp attached to the trolley using a removable handle to quickly and easily install and remove the seat for safety or portability of the zip line system.

It is still another object of the present invention to secure the pulley system of the zip line within a quick release trolley frame to allow the trolley to be easily secured and removed from a cable, rope or wire.

It is yet another object of the present invention to have a braking system which a rider activates to slow the descent of the zip line along the cable or wire.

It is still yet another object of the present invention to have a braking system which a rider actuates to slow the descent of the zip line along the cable or wire.

It is a further object of the present invention that an embodiment of the invention has a brake pad with a lining to increase frictional resistance while reducing wear on the wire or cable.

It is a further object of the present invention that an embodiment of the invention has a braking system that when activated curbs the rotation of the pulley to slow the descent of the zip line system.

It is a further object of the present invention that an embodiment of the invention has a braking system with a brake pad that when activated drags the brake pad along the cable to slow the descent of the zip line system.

It is a still further object of the invention that the wire or cable is supported using a quick-release ratchet to easily put up and take down the wire or cable when the zip line is not in use.

The present invention is directed to trolley for traversing a zip line system comprising a frame including at least two wheels rotatably affixed to the frame; a brake affixed to the frame for engaging an object supporting the trolley in the zip line system; a handle secured to the frame permitting a user to grasp the trolley; an adjustable seat secured to the frame; and wherein the brake is actuated by the user while grasping the handle of the trolley to control the descent of the user and the trolley along the zip line system.

The present invention is also directed to a method of carrying a person or object along an extended wire comprising the steps of attaching a pulley system to a frame, the pulley system adequate to roll along the wire; attaching a braking system to the frame to control the speed of the person or object along the wire; attaching a seat using fabric webbing to the frame, the fabric webbing being adjustable to change the distance of the seat from the frame; and attaching a handle to the frame.

The present invention is further directed to a kit for a zip line system comprising a frame; a pulley system; a braking system; one or more straps of fabric webbing; an adjustable seat; and a handle.

The present invention is further related zip line system comprising a frame supported on a suspended cable; at least one pulley supported by the frame; a handle attached to the frame; and a braking system that when activated curbs the rotation of the pulley to slow the descent of the zip line system. The braking system of the zip line system may comprise a brake pad and the brake pad may be replaceable. The frame of the zip line system may be removable from the cable by removing the handle. The zip line system may comprise a seat with a seat fixture removably attached to the frame using the handle.

The present invention is further related to a portable zip line system comprising a trolley having at least two wheels rotatably affixed between two frames; a cable assembly for extending a cable between two structural supports, the cable suitable to support the at least two wheels within the trolley; a seat fixture aligned between the two frames of the trolley; a handle inserted through the trolley to secure the seat fixture to the trolley; and an adjustable seat affixed to the seat fixture. The seat fixture of the portable zip line system may be removable from the trolley by removing the handle to have the zip line system be portable. The trolley of the portable zip line system may be removable from the cable by pulling the at least two wheels up and away from the support of the cable to have the zip line system be portable. The cable assembly of the portable zip line system may be removable from two structural supports using a ratchet to have the zip line system be portable. The portable zip line system may comprise a braking system affixed to the trolley. The braking system may comprise a distributive structural support frame. The braking system may comprise a replaceable brake pad. The braking system may comprise an actuator that causes the replaceable brake pad to come in contact with the extended cable. The replaceable brake pad of the braking system may comprise perforated openings. The brake pad may comprise a heat resistant material. The braking system may comprise an elastic member. The seat fixture of the portable zip line system may have a circular support for the webbing of the seat. The handle may have an attachment mechanism that releasably affixes the handle to the trolley. The seat of the portable zip line system may be flexible. The fabric webbing strap may be adjustable to shorten or lengthen the distance from the seat to the trolley.

The present invention is related to a method of assembly of a portable zip line system comprising the steps of rotatably affixing at least two wheels between two frames to form a trolley; extending a cable between two structural supports using ratchets, the cable suitable to support the at least two wheels within the trolley; aligning a seat fixture between the two frames of the trolley; inserting a handle through the trolley to secure the seat fixture to the trolley; and affixing an adjustable seat to the seat fixture. The method of assembly of a portable zip line system comprising the step of removing the seat fixture from the trolley by removing the handle. The method of assembly of a portable zip line system comprising the step of removing the trolley assembly from the cable by pulling the at least two wheels up and away from the support of the cable. The method of assembly of a portable zip line system comprising the step of removing the cable from two structural supports using the ratchets. The method of assembly of a portable zip line system comprising the step of affixing a braking system to the trolley.

The present invention is related to a portable zip line system comprising a cable assembly having a cable and ratchet system; a trolley supported by the cable; a handle attached to the trolley; and a seat affixed to a seat fixture removable from the trolley by removing the handle. The trolley of the portable zip line system may be removable from the cable by removing the handle and pulling the trolley up and away from the cable. The trolley may have at least one pulley rotatable on the cable. The cable assembly of the portable zip line system may be removable from two structural supports using the ratchet system. The portable zip line system may comprise a braking system with a brake pad that when activated drags the brake pad along the cable to slow the descent of the zip line system. The braking system of the portable zip line system may comprise a distributive structural support frame that transfers forces evenly and smoothly in slowing the zip line system. The brake pad of the portable zip line system may be replaceable and may comprise a heat resistant material. An actuator of the braking system of the portable zip line system may be supported by an elastic member. The handle of the portable zip line system may have a releasable attachment mechanism that secures the handle to the trolley. The seat of the portable zip line system may be flexible and adjustable.

The present invention is further related to a method of assembly of a portable zip line system, comprising the steps of installing a cable to two structural supports using a ratchet system; aligning at least one pulley of a trolley on the cable, the at least one pulley attached between two frames of the trolley; affixing a seat to a seat fixture; aligning the seat fixture between the two frames of the trolley; and inserting a handle through the trolley and the seat fixture to secure the seat to the trolley. The method of assembly of a portable zip line system may comprise the step of removing the seat and seat fixture from the trolley by removing the handle. The method of assembly of a portable zip line system may comprise the step of removing the trolley from the cable by pulling the at least one pulley of the trolley up and away from the cable. The method of assembly of a portable zip line system may comprise the step of removing the cable assembly from two structural supports using the ratchet system. The method of assembly of a portable zip line system may comprise the step of affixing a braking system to the trolley.

These and other features, advantages and improvements according to this invention will be better understood by reference to the following detailed description and accompanying drawings.

DETAILED DESCRIPTION

Embodiments of the present invention relate to a trolley for guiding a person or an object using gravity along an extended cable line suspended between two spaced apart objects such as trees or towers, and more specifically relates to a zip line kit or system with an easily adjustable seat and handle arrangement which in combination with a wheel and braking system for the device facilitates a safe and controllable descent along the cable line. The trolley is provided with at least two wheels spaced apart at a suitable distance to increase ride smoothness, provide sufficient space to accommodate the braking system and improve operation of the zip line system along the extended cable.

FIG. 1shows in general a zip line system10of the present invention including a trolley11with a braking system12supported on an extended cable14. The trolley11comprises two frame pieces16that house one or more wheels18for engaging the cable14. The cable is understood to be in one embodiment an extended steel cable, but could alternatively be a rope, line, rail or wire, but for purposes of description is hereinafter referred to as cable14. The cable is fastened at either end between two spaced apart points B-C to generally define a longitudinal travel axis A for the trolley. The trolley11may also include a braking system12, handle20, a seat22and an adjustment mechanism26facilitating changing the spacing between the seat22and the trolley11.

A basic zip line kit30is shown inFIG. 2and the components of the kit30are shown inFIGS. 2A-2Ecomprising the trolley11, handle20, braking system12, seat22, and adjustment mechanism26, respectfully. The kit30could alternatively include more or less components, for example, the kit might not contain the braking system12if such a braking system where not necessary or desired in a certain zip line application. The kit could, by way of example, also include additional components like the cable14and parts for securing and extending the cable14between the points B-C.

The generally triangular shaped frame pieces16of the trolley11as shown inFIG. 2Adefine a series of pivot points38, attachment points39as well as other openings and slots to facilitate the attachment of the wheels18, secure the opposing frame pieces16together and position the braking system12, handle20, seat22and adjustment mechanism26. Pivot points38are positioned at what are defined here as the upper opposing corners of the trolley11to rotatably attach the wheels18between the triangular shaped frame pieces16. Two wheels18are used in the preferred embodiment although additional pivot points and wheels may be configured and overall dimensions of the frame pieces16may be altered to accommodate alternative configurations.

The center portion of the trolley has an opening40for the handle20to be inserted through or bolted onto the frame16, the handle20may be a metal, wood or other similar rigid material bar or rod, which is inserted through the opening40so as to extend perpendicularly relative to the planar surface42of the frame16as shown inFIG. 1. The handle20may be round, or other profile such as square or rectangular with the opening40similarly designed, and be of a various diameter or width to comfortably accommodate the hands of a rider24gripping the handle20by wrapping their fingers around the handle20.

The handle20, as shown inFIG. 2B, may have a removable cushioned grip44that is slid onto or affixed onto the handle20, providing comfort to the rider24and helping to secure the handle in the opening40where the ends of the grips44abut against the portion of the frame16surrounding the handle opening40. In this way, the opening40in the frame16for the handle20may be of a diameter smaller than an outer circumference of the grip44providing for the grip44to maintain the handle20in the opening40with the trolley11. The grip44may be of a stiff foam or rubber that tightly adheres to the handle20, but is generally manually removable if necessary to remove the handle20from the trolley11.

One embodiment of a seat22and the adjustment mechanism26as flexible fabric webbing is shown inFIGS. 2D and 2E. The seat22may be of any ergonomical design and material to comfortably and safely support a rider24. In the embodiment ofFIG. 2D, the seat is designed to be sat upon by the rider with the seat22arranged under the user's hamstrings and/or gluteus maximus. The general diamond shape of the seat22here facilitates the rider sitting upon the seat and essentially straddling the webbing of the adjustment mechanism26. The seat22may be other shapes, and may be rigidly formed from a piece of metal, such as aluminum, or the seat may be flexible, i.e. a flexible fabric or plastic such that the flexible seat conforms to the riders body size and shape. This is an important safety consideration since a flexible seat would be able to bend around the body proportions of any size rider from child to adult, and securing them closely without changing the size of the seat for different riders. In either a rigid seat or a flexible seat, the seat may have cutouts46, slots47or other openings50, which define alternative securing points to allow flexibility in attachment of the seat22to the adjustment mechanism26.

The adjustment mechanism26is in one embodiment fabric webbing50of a reasonable length, generally between for instance 2.44 m-4.57 m (8-15 feet) long, to provide sufficient adjustment between the seat and trolley for the size of the rider. The critical distance for which the adjustment mechanism26is adjusted is based on the extension of the rider's arms over their head to grasp the handle20while sitting on the seat22so that their head is entirely below the trolley. In other words it is the distance between the handle20and the seat22which permits the rider to sit comfortably on the seat22and reach over their head and grasp the handle20so that they are securely suspended below the trolley11and upon the seat22. For a child the webbing would be adjusted to shorten the distance between the seat and trolley, and for an adult of course the webbing50would be lengthened to provide a greater distance therebetween.

Although other ways of adjusting the relative seat and trolley distance are possible, webbing is a good choice for the adjustment mechanism because of its flexibility and tensile strength. The flexibility enables the user to easily adjust the length of webbing to accommodate a rider. Webbing is inexpensive, strong and available in a myriad of widths. An appropriate size for the adjustment mechanism26is a width of between about 1.91 cm-3.81 cm (¾″ to 1/½″) and preferably 1″ with a tensile strength of ˜15 kN-˜35 kN (˜3000 lb.-˜7000 lb.) and more specifically a tensile strength of ˜20 kN (˜4000 lb.). The webbing is preferably resistant to mildew, aging and abrasion. Alternative adjustments and attachments of the frame to the seat are discussed in detail below.

The braking system12as shown in one embodiment inFIG. 2Cis also supported within the frame16of the trolley11and generally includes a brake pad52aligned anywhere adjacent the cable14for contacting the cable, although the most practicable alignment is above or below the cable14for contacting the cable14when the braking system12is operated by the rider. The brake pad52may have a contact length which depends on the amount of friction desired to be generated during braking operations. The contact length of the brake can be extended to the full length between the wheels18or to any desired length to sufficiently contact the cable14and create a frictional resistance to slow the trolley system10down upon actuation of the braking system. The brake pad52may be retained and float above the cable14using a tension spring or below the cable14resting on support or spacer34prior to activation. By floating adjacent the cable the brake pad52may be in light contact with the cable14and ride along the cable without creating much braking friction until energized by the rider. The brake pad52may also be provided with a contact surface which is angled or curved to provide additional frictional contact with the cable14.

Turning toFIG. 3A, in one embodiment, the two wheels18may be positioned at the upper corners of the trolley11providing spacing between the pivot points38in a range of at least 10.2 cm to 20.3 cm (4″ and 8″) and more specifically at a distance c of 11.4 cm to 14 cm (4½″ to 5½″). The wheels18are secured in the trolley11and thus along the cable14at an increased distance relative to known zip line systems so that rider, load or weight is distributed along a greater length and surface area of the cable14reducing tension and bending of the cable, giving the rider a smoother ride. The wheels18are generally fabricated of stainless steel, brass or other durable material with sealed, internal or external bearings27to optimize rolling and rotation of the wheels and trolley along the cable14. Such wheels18are often referred to as a sheave which is a wheel or roller with a groove32along its edge for engaging a belt, rope or cable14. When hung between two supports equipped with a belt, rope or cable14, one or more sheaves make up a pulley, or as in this case are embodied as the trolley11. The words sheave and pulley may be sometimes used interchangeably.

Spacers34may be positioned between the frame and the connecting bolts36of the frame16and additionally at an offset to the pulleys18to act as a guide for the cable14along the pulley18. Optionally runners or brackets (not shown) may also be positioned offset from the pulleys to act as cable guides.

In the embodiment as shown inFIGS. 3A-3B, a U-shaped brake frame54is affixed in the frame16by a center connecting pin36and the brake frame54supports the brake pad52above the cable14. The brake frame54has an elongate slot57in which the center connecting pin36permits the brake frame54to move linearly up and down. In this embodiment, a leaf spring58is depicted, although any spring or retention support may be contemplated, to maintain the brake frame54in a disengaged position shown inFIG. 3A. The leaf spring58has one end abutting the handle20and another end biasly engaging the brake frame54to maintain the brake frame54in a normally raised position, holding the brake pad52above, or in very slight or tenuous contact with the cable14. The brake pad has a cable engaging surface59and may be formed from a metal bar of steel, aluminum or other metals as shown inFIG. 3A. The cable engaging surface59may be flat or it may be angularly formed or rounded to increase the overall contact area of the brake pad52with the cable14as shown inFIG. 3B-3C. The brake pad cable engaging surface59may have a lining of a heat resistant material with a desired durability and coefficient of dynamic friction in a range of 0.35 to 0.42 meaning a force of 1000 kg (or pounds) will result in a brake force close to 400 kg (or pounds).

As shown in an exploded view of the frame16and brake system inFIG. 3B, the actuator56is coupled to the brake frame54and inserted through both legs of the U-shaped brake frame as shown. A central portion60of the actuator56provides a bearing or attachment point for a second end of the leaf spring58so that the leaf spring can directly influence the brake frame54. Alternatively, the second end of the leaf spring58can be directly affixed to the brake frame54.

The actuator56is essentially a trigger for the user to actuate the brake. The ends of the actuator56pass through a brake pin slot62in each frame piece16, where the slot62is located above the handle opening40to allow for a rider24to easily grasp the brake actuator56with one or more fingers while still holding the handle20. In the present embodiment, with their hands grasping the handles20, the rider24can easily extend their pointer finger on either side of the trolley to engage the actuator56while continuing to maintain their grip on the handle20. In this way the rider can compress the actuator56to pull down the brake frame54and brake pad52against the bias of the leaf spring58and so fully engage the brake pad52with the cable14. As the brake pad52contacts the cable14, frictional resistance between the brake pad52and cable14is increased creating drag on the cable slowing the trolley11along the cable14.

The actuator56inserted through the brake pin slot62in the frames16of the trolley11as shown inFIG. 3Cfacilitates easy actuation of the brake. The positioning of the actuator immediately above the handle20is ergonomically appropriate even for small or inexperienced riders. The ability for a rider24to grasp the actuator56while holding the handle20and pull down whenever the rider feels their speed is too great is critical as it allows the rider to hold or release the brake12in any desired manner to control their rate of travel, generally descent, along the cable14.

In an alternative embodiment as shown inFIG. 4the brake frame54is supported in the disengaged position by one or more coil springs64influencing the brake frame54. A spring support66may be snapped or clamped on to the handle20or otherwise affixed to the frame16or brake frame54. Similar to the previous embodiment, the actuator56is inserted through the frame16and the brake frame54and actuated by pulling down the brake frame54and brake pad52using the actuator56to bring the brake pad52into contact with the cable14.

Different types of springs and biasing devices may be used to bias the brake frame and brake pad52. In an alternative device, the brake pad52may be positioned below or to the side of the cable14with the coil springs64holding the brake frame54and brake pad52below and/or away from the cable14. The rider would then operate the actuator56to engage the braking system12and slow or stop the descent of the trolley along the zip line system10.

In a further embodiment, the braking system12may be a simple lever pin66that is affixed to the actuator56and pivots on an axis Z around a lever midpoint, such as the connecting bolt36as shown inFIG. 5A. The use of a smaller spacer68would allow the lever to be secured within the frame16, but also provide for an axis of rotation of the lever pin66about the bolt36. The lever pin66may have a brake pad70that extends along an entire length of the lever66from the actuator56to the pulley18or as shown inFIGS. 5A-5Ca smaller surface area that contacts the wire14immediately at the pulley to curb rotation of the pulley18and slow the descent of the zip line system10. As shown inFIG. 5B, the actuator56is inserted through an opening69in the lever pin, allowing the pin to swing down and pivot around the Z axis and force the opposing end of the lever pin66having the brake pad70to contact the cable14.

As noted above the lever pin66may be positioned below the cable14as shown, or alternatively be positioned above the cable14by shortening the length of the lever66and repositioning the axis point Z perpendicular to a point in the center of the frame16near the area of the brake pin slot62. The actuator56and brake pin slot62would then be positioned at the opposite end of the lever brake pad70and be pulled or pushed up to actuate the braking system12.

The lever pin brake pad may have a heat resistant lining made of a material with a high coefficient of dynamic friction as described above. In this embodiment with a simple lever, a spring may not be necessary if the brake pad70is permitted to merely float or glide along the cable14in the disengaged position and operation of the actuator56provides a greater frictional force from the brake pad70to the cable14.

The present invention is not intended to be limited to only the braking systems described above. Other braking system structures could also be used to slow the trolley11, for example a braking system where the brake is generally in an actuated state, i.e. firmly gripping the cable and the actuation of the actuator56causes the braking system to essentially release the cable14. In this way, a rider would actively control their descent by releasing the brake a desired amount, and if their hands came off the trolley11and/or released the brake12, the trolley11would immediately slow due to the influence of the brake12on the cable14.

The present invention also provides for alternative methods of attaching the frame assembly16to the seat22which supports the rider24. As shown inFIGS. 6A and 6Bthe frame16has a series of adjustment openings for linking and tightening the support webbing26to attach the seat or harness to the frame16. The support webbing26is first attached to the seat22by looping one or more straps of webbing26through one or more slots47or openings50in the seat or around a seat attachment beam48. A plastic roller74may be affixed to or snapped on to the opening or beam to smooth the surface edge and prevent cutting of the seat22into the strap26. The first end of the webbing26may be secured to the seat22or alternatively the strap26is looped through and around therefore providing two ends of the webbing26for attachment to the frame16.

In a first embodiment, the webbing26is inserted through two attachment beams48and each webbing end76is drawn up to each of the two frame pieces16, with one end being looped through a first upper slot78of a first frame piece16and the other end being looped through a first upper slot78of the other frame piece16. Each of the webbing ends76for each frame piece16are then inserted through a lower slot80having teeth to grip the webbing26and secure the webbing at a specific length and position. As shown inFIG. 6A, by inserting a longer length of webbing through each slot (78,80) the distance d from the seat22to the frame16is shortened for a smaller rider24as compared to the distance D inFIG. 6B. For a taller rider24with longer arm length, a shorter length of webbing is inserted through the slots (78,80) leaving a greater distance between the seat and the frame and leaving a shorter length of webbing extending from the toothed slot80. The webbing26may be adjusted to any length that is comfortable for the rider.

In a further embodiment as shown inFIGS. 7A and 7B, one or more straps of webbing26may be attached or looped around attachment beams48or openings50on either end of the extended end of the seat22to form a swing to accommodate even smaller riders that may more easily hold onto the straps rather than the over head handle20. A preferred embodiment of the seat with a number of alternative attachment points using cutouts46, beams48or openings50is shown inFIG. 7B, but numerous seat configurations are contemplated to safely support and adjust distances of the frame to the seat for comfort of the rider. In a further embodiment the number of openings50may be increased in number and size to provide for a leg and buttocks harness to be attached to the seat22to provide additional support and security to the rider. It is to be appreciated that the seat may also be a flexible seat23, such as a playground swing seat, supported on both ends and which is pliable enough to form around and hug the rider's body when the rider24sits in the middle of the seat as shown inFIG. 8. The rider24may hold on to the straps or alternatively reach around the straps to hold onto the handle20, allowing the pliable seat23and straps to curve around and safely secure the rider24.

Actuation of the braking system12as shown inFIG. 9, allows the rider24to slow down the zip line system10, prior to reaching the end of the cable14. Alternatively to the above described braking systems or in conjunction therewith, the trolley11can be stopped at the desired end of descent by a bumper or stopper84of a durable polymeric material such as high-density polyethylene (HDPE) or other comparable materials positioned close to the end of the cable14. The bumper84may be supported on the cable14and attached to an anchor point or points by shock cords88, or other type of force absorbing material which permits the bumper84and hence the trolley11to absorb all or some of the forces developed by the trolley11along the zip line and bring the trolley11to a safe stop. The braking system12provides additional safety and control to the rider to slow their descent and safely reach the ground or tower. The trolley braking system12and bumper84also provide control to the rider to ease the zip line system10to a stop in preference to bumping into the ground or an object and causing injury.

A support harness101that simplifies the installation of the zip line system10of the present invention is shown inFIG. 10A. The support harness101using a ratchet mechanism102allows a user to easily set up the cable14of the zip line system10in accordance with embodiments of the present invention. The setup of the harness101may require no additional tools, and be relatively inexpensive when compared with other cable attachment means. The ratchet102may allow a user to adjust the tension in the cable14and to easily connect and/or disconnect the cable14to or from a support103. The cable14may comprise galvanized aircraft cable or other wire and/or rope having a looped or latch connector105at one or more ends for securing the ends of the cable14to an attachment fixture, such as D-ring107or other metallic support. The support103such as a tree, tower or pole must have sufficient strength to support the weight of a user when the user or object that is supported and/or traveling along a zip line system10in accordance with the present invention.

In an embodiment, the support harness assembly101may attach to the support103by first installing a protective cover109such as a felted pad around for example a tree to protect the tree from damage from the installation of the zip line10. The cable14is secured using a support strap111that is installed over the protective cover109. The support strap111may be looped through a buckle or tensioning ring113. A portion of the strap115extends through the tensioning ring113and is attached and extends through the bracket117of the ratchet102. An end portion119of the cable111is drawn through and affixed to the attachment fixture107that is attached to the zip line cable14. A handle121provides for pulling and tensioning the support strap111to provide adequate tension for the zip line cable14, as shown inFIG. 10B. The handle127is a rod that extends between the handle frames129as shown inFIGS. 11A and 11B. By moving the handle121back and forth, the teeth125of the gear123catches on a latch portion128of the frame handle129and pulls the support strap111in only one direction so that each movement further tightens the strap around the tree support103and thereby tensioning the zip line cable14. A portion of the strap131is woven through spindles133and135that extend between the ratchet frames129. The end of the strap119is wrapped around the D-ring107or other cable connector and sewn or otherwise securely attached to a lower portion of the strap137. A release lever139provides for loosening the tension to detach or adjust the tension of the zip line cable14. A safety strap (not shown) may also be attached to D-ring107and be similarly secured to the support103using a ratchet harness as described herein to support the cable14and the weight of the user in the event the support strap111fails.

A ratchet support harness assembly101may be installed on one end with the other end of the zip line cable14looped around a support103and through an eye connector (not shown) or other cable connector or mechanical fastener to properly secure the cable to a second support103. In some embodiments, the opposite end of the cable14may be threaded through an eye connector, or the like, and may be clamped using a thimble and cable clips, or the like. Alternatively, both ends of the zip line cable14may have a ratchet support harness assembly101to adjust the cable to proper tensioning to support the user of the zip line10with a safety strap also attached at each end. The cable14may be attached to one support103at a higher elevation than the attachment of the cable14at the other support103. When the ratchet support harness assembly101has been attached to one or both supports103, the tension in the cable14may be adjusted to reduce or increase the slack in the zip line cable14. The support strap111and safety strap may comprise a width adapted to support the weight of a user when supported on the cable14. For example, the support strap111and safety strap may be made from webbing of nylon, polyester, or structurally similar material and may have a width from about ½″ to about 6″ and in a preferred embodiment a 2″ width. In some embodiments, the support strap111and safety strap may comprise different widths with the support strap111of a greater width than the safety strap. The ease of installation and flexibility of the support harness101provides for an embodiment of the zip line system100to be portable, where one or more support harness assemblies101can attach the cable quickly and easily to a tree, tower or other support without the need for heavy tools, fasteners, or disassembly of the trolley. The removable seat as described below further provides for the handle to be easily removed from the trolley and stored for easy carrying.

In further embodiments, the braking system140of the zip line system100may retain the brake pad148to float above the cable14via an elastic member142that may be attached to each end of the brake pad148and be suspended from the center connecting pin145as shown inFIG. 12. The braking system140may comprise the elastic member142, a distributive structural support frame144, a braking lever146for actuating the braking system140, and the brake pad148. The elastic member142is suspended from the connecting pin145that is affixed to the trolley assembly210and inserted within a slot150. As the braking lever146is pulled to contact the brake pad148with the cable14, the connecting pin145moves along the slot150. The braking lever146is attached to the braking system140using a bolt147or other attachment means. The braking lever146has a bracket143that supports a handle149. The handle149has a rounded surface151for a user to place one or more fingers on and pull down to actuate the braking system140.

In an embodiment of the braking system140, the braking support frame144as shown inFIG. 13Amay be triangular or trapezoidal in shape with opposing angular frame members152and154that extend from a base156to an upper member. The upper member in one embodiment may be first and second lateral frame extensions158and160that extend to interior wall members162and164that form the brake pin slot150for the connecting pin145. Alternatively, the slot150may be formed through the support frame144. A series of struts172may extend between the frame members to distribute forces in tension and compression through the structural support frame144and thereby transfer forces evenly along brake pad148. In this manner, a minimal force by the user is distributed along the cable engaging surface174to smoothly slow the zip line system100down. The distributed forces further reduce wearing of the brake pad148because nearly the entire cable engaging surface174of the pad is in continuous engagement with the cable14when the brake is actuated. The mid-portions176between the struts172and frame members may be openings that extend through the support frame144or alternatively be areas of lesser material to provide the structural support144and reduce costs and weight.

A mounting hole178may be formed through the support frame144with a second mounting hole179formed through the brake pad holder184. The brake pad mounting hole179may be formed through a handgrip181in the holder184. The brake pad148may be removably affixed to the brake pad holder184and the holder184may be removably affixed to the braking system support frame144. In an embodiment, the ends182of the brake pad holder184may extend the brake pad148. The ends182may then snap into clips186formed on either end of the support frame144as shown inFIGS. 14A and 14B. The ends182that extend beyond the end188of the brake pad148may have tabs190that provide for attachment of the elastic member142. A ledge or shelf192is formed at the base of the clip186with a channel194for the tab190to extend beyond the frame members152and154of the braking system support frame144. By separating the clip186from an inner surface196of the support frame144, the end182of the brake pad holder184can be snapped into and be secured to the support frame144and once snapped in may be snapped out to remove and replace the brake pad148.

The braking support frame144may further include a guide198as shown inFIG. 14Athat provides a surface200to align the elastic member142over and around the braking support frame144. The guide198may extend from each side of the support frame144and be formed as a triangle, trapezoid or in another shape to create support surfaces200for the elastic member142along the side of the braking support144. In some embodiments, the entire braking structural support frame144may be formed as a single piece with the guide198from a lightweight, strong, rigid material such as aluminum or preferably from a plastic such as nylon 6-6 polyamide using a molding or extrusion process. Alternatively, the guide198may be a separate piece that is snapped onto or otherwise affixed to the support frame144. At the base156of the support frame144and guide198a slot199is formed, as shown inFIG. 15A. The slot199provides for the handgrip181of the brake pad holder184to be inserted into the support frame144to align the mounting holes178and179for mounting the braking system140to the trolley assembly210.

As shown inFIG. 15B, the frictional component202of the brake pad148and the brake pad holder184may be formed as a single piece from a polyurethane or other heat resistant thermosetting plastic. Alternatively, the frictional component202may be a separate piece that is affixed to the brake pad holder184so that it can be removed and replaced as the brake pad component202wears down from contact with the zip line cable14. In a further embodiment, the frictional component202may be formed from a thermosoftening plastic that may become pliable above a certain temperature and then return to a solid state upon cooling. A further embodiment of the frictional component202is shown inFIG. 15D. The lower surface204of the frictional component202has a series of openings or perforations206aligned through the surface. The perforations206provide for the thermosoftening material of the frictional component to soften or melt as the pad is heated while being dragged along the zip line cable14and then reform and reset as the pad is cooled, reducing overall wear and extending the life of the brake pad148.

The braking system140is shown inFIG. 16with the braking lever146but without installation of the braking system140to the trolley assembly210. In installing the braking system140, the connecting bolt147extends through the bracket143of the lever146, through a slot208in a further embodiment of a first frame piece211, shown inFIG. 17, through the mounting hole178in the structural braking support frame144, through the mounting hole179in the brake pad148and through a slot208in a second frame piece212shown inFIG. 18and through a second bracket143to attach the levers146to either side of the further embodiment of the zip line system100. The connecting bolt147is secured using a nut214or other attachment fixture. The connecting pin145extends through an opening216in the frame210, through the braking system slot150and through the second frame piece212to remain stationary and suspend the elastic member142. The elastic member142rides along the surface200of the braking support144to reduce wear and prevent stress points in the elastic member142as a user pulls down on the levers146to have the braking system140contact the cable14to reduce the speed and slow the zip line system100down.

In an embodiment, the frame piece as shown inFIG. 17are of a smaller size and weight with smooth contours along each edge218and a more triangular shape with rounded corners220and decorative cutouts222that may be of any shape to uniquely stylize the zip line system100. A triangular extension224in the upper center of the frame piece210provides a minimal amount of surface area for the opening216for the connecting pin145that supports the elastic142. In a lower center portion of the frame piece210, an opening226is provided for a handle230as shown inFIG. 18that similar to previous embodiments is inserted through the opening226and secured on each exterior side232of the frame pieces211and212using cushioned grips234that are tightly slid around each end of the handle230. The handle230may have a releasable attachment mechanism such as a detent231in the form of a ball or pin affixed to a leaf spring that extends through an opening in the handle230. As the handle230is slid through openings in the trolley frame pieces211and212and the removable seat holder fixture250, the detent231can be compressed to slide the handle230through the trolley assembly210. The detent231when extended may latch the handle230to the removable seat fixture250as described herein.

The handle230may be a rigid, hollow bar of aluminum or another lightweight metal to further reduce the overall weight of the zip line system100. The grips234may have ergonomic contours236that provide finger rests for the user of the zip line system100. Stoppers238are frictionally fit into the hollow ends of the handle230form a tight seal to further secure the grips234to the handle230. Additional openings228in the upper left and right portions of the frame pieces211and212are provided for bolts227to secure the pulleys or wheels240to the frame pieces211and212. A nut229or other attachment fixture is connected to the bolt227to connect the wheels240and two frame pieces211and212together to form the trolley assembly210. In an embodiment, the wheels240have lubricant free internal bearings that maximize the speed of descent and require limited or no maintenance.

The smaller size of the frame pieces211and212of the trolley assembly210, ease of installation and flexibility of the support harness101, and the unique removable seat fixture250shown in the exploded view ofFIG. 18as front and back snap fit pieces252and254provide for the zip line system100to be completely portable. Storage of the system100in a back pack or bag allows a hiker or camper to trek into the wilderness, find appropriate trees to install the zip line system100and be quickly and easily traversing the terrain from above. The seat fixture250with the seat260shown in an embodiment inFIG. 19as an oval or elliptical shaped seat261and as a round disk seat263inFIG. 20. By removing the handle230, the seat fixture250slides out of the base of the trolley assembly210providing an additional level of safety where the seat can be removed and the trolley assembly210can be pulled up and off of the cable14in order to transport the zip line system100or so that a small child does not attempt to use the system100when unattended.

The seat260is secured to the removable seat fixture250using webbing258that loops around a donut shaped surface266of the removable seat fixture250and is clamped between the front and back snap fit pieces252and254. The webbing258then extends in between the frame pieces210and212and through openings in the seat260. The seat260as described may be of aluminum, another metal or of a plastic composite with an ergonomic shape to allow for a rider to sit comfortably. In a further embodiment seat260may be a strong flexible material such as a rubber based plastic that may be folded and stowed for portability of the zip like system100. The webbing258is secured by being inserted through a hole in the seat263and be tied into a knot265at the bottom of the seat263as shown inFIG. 20or using in one embodiment a snap buckle264that may have teeth along an edge that holds the webbing258in place so that once secured it is difficult to remove the webbing258from the buckle264as shown inFIGS. 19 and 21. The length of the webbing258may be adjusted by pulling more or less webbing through the buckle264or in tying the knot265below the seat260.

The removable seat fixture250is comprised of the back snap fit piece254, as shown inFIG. 22and the front snap fit piece252, as shown inFIG. 23. The back snap fit piece254has a base270that supports a circular extension or donut272. The donut272has a smooth circular outer surface274along the entire circumference with upper and lower cutouts280that separate semi-circular walls276and278. The cutouts280complement the semi-circular extensions282of the front snap fit piece252that extend further from the base284than opposing semi-circular wall portions286and288. The cutouts280and extensions282interlock to align the front and back snap fit pieces252and254to provide a partially continuous circular outer surface for the seat webbing258. The circular outer surface may have a gap that provides for the releasable detent231of the handle230to be interlocked within the gap to lock the handle to the trolley assembly210preventing the handle230from slipping or being pulled out without a requirement that additional force be used to compress the detent231while pulling the handle230out of the trolley assembly210. A shallow shoulder290that surrounds the lower half of the donut272may be formed along the inner surface292of the bases270and284of the front and back snap fit pieces252and254. The bases270and284of the pieces may also be similar in shape with a rounded outer edge294with straight sides296that extend to rounded corners298and a flat edge300. Along the inner surface292and extending from the flat edge300a raised portion302having an upper edge304that provides reasonably tight compression and alignment of the seat webbing258through the lower flat edge of the front and back pieces252and254.

The front and back pieces252and254are aligned using posts306that may extend from either base with the posts being inserted in openings308in the opposing piece. The snap fit is provided using clips310that also may extend from either piece252or254to secure the two pieces together. As shown inFIGS. 24 and 25, posts306extend from the back piece254into openings308in the front piece252to align the pieces and clips310extend from the back piece254and are fitted into snap surfaces312. In an embodiment, the clips310are secured to each snap surface312using a radial overhang316that is directed inwards towards the opposing clip314. The radial overhang316that extends from the upper portion of the deflecting beam318that is of sufficient elasticity and rigidity to deflect around a nub320in the slot312to frictionally hold the overhang316against the external surface322of the nub320preventing separation of the two pieces252and254. Each of the front and back pieces252and254may be formed as a single piece from strong resilient plastic such as such as nylon 6-6 polyamide using a molding or extrusion process.

Prior to assembly of the removable seat fixture250using pieces252and254, the seat webbing258is looped around the donut272of one of the pieces252and254and overlapped along the raised portion302as shown inFIGS. 26 and 27. The posts306are inserted through the openings308and the clips310are expanded around the base of the nubs320with the overhang316snapped over the top surface322of the nub320within the slots312. The layered seat webbing258extends out between the raised portions302of the front and back pieces252and254to hang out from the removable seat fixture250as shown inFIG. 28. The opening330through the upper portion of the removable seat fixture250is provided for the handle230that is shown with the grips234with stoppers238inserted in the ends324of the grips234and handle230inFIG. 29. InFIG. 29, the positioning of the braking system140, wheels240, and handle with the removable seat fixture250is shown from a perspective view. The axis X defines the path of the cable14that the wheels240are supported on and that the braking pad148of the braking system140is drawn down and against to slow the speed or stop the zip line system100. A front perspective view of these components with the elastic142is shown inFIG. 30and the components affixed to a frame piece210inFIG. 31. The second frame piece212is assembled to these components and the further embodiment of the zip line system100is shown inFIG. 32. This embodiment of the system100includes the distributive braking system140with the brake pad148that evenly slows the system100and reduces wear and tear limiting requirements to replace the brake pad148. Further embodiments of the zip line system100also include the support harness assembly101, removable seat fixture250, and foldable seat260that provides for the zip line system to be completely portable so that it may be carried, installed and taken down in remote locations.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. For example, although numerous embodiments having various features have been described herein, combinations of such various features in other combinations not discussed herein are contemplated within the scope of embodiments of the present invention.