Abstract:
Play yards and methods of operating the same are disclosed. A disclosed example includes a collapsible upper frame, a collapsible lower frame, and posts to support the upper frame above the lower frame. The posts include respective tracks. The example also includes a foldable, frameless enclosure operatively coupled to the upper frame, the lower frame and the posts. The enclosure has a plurality of sides and a bottom to define an enclosure volume. The enclosure also has a plurality of corner beads dimensioned for receipt in a respective one of the tracks to secure the enclosure to the posts.

Description:
RELATED APPLICATIONS 
     This patent arises from a continuation of U.S. patent application Ser. No. 12/494,932 (now U.S. Pat. No. 8,490,227), which was filed on Jun. 30, 2009, which is a continuation of U.S. patent application Ser. No. 11/063,811 (now U.S. Pat. No. 7,568,242), which was filed on Feb. 23, 2005. Priority to both U.S. patent application Ser. Nos. 12/494,932 and 11/063,811 is claimed. Both U.S. patent application Ser. Nos. 12/494,932 and 11/063,811 are hereby incorporated by reference in their entireties. 
    
    
     FIELD OF THE DISCLOSURE 
     This disclosure relates generally to childcare products, and, more particularly, to play yards and methods of operating the same. 
     BACKGROUND 
     In recent years, portable play yards have become very popular. Portable play yards typically include a frame, a flexible enclosure supported by the frame, and a removable floor board or mat. The frame is largely or completely contained within the flexible enclosure so that there are few if any loose parts when the frame is collapsed or when the frame is erected. When collapsed, the portable play yard typically has a compact form factor to enable easy transport and storage of the play yard. Sometimes, the floorboard is wrapped around the collapsed frame to prevent the frame from inadvertently leaving the collapsed state. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an example play yard constructed in accordance with the teachings of the invention. 
         FIG. 2  is a perspective view of the example play yard of  FIG. 1  shown without the enclosure. 
         FIG. 3  illustrates the example play yard of  FIG. 1  with the removable floor board raised to expose the lower frame. 
         FIG. 4  illustrates the example play yard of  FIG. 1  in a semi-folded state with arrows indicating the direction in which the joints of the frame of the play yard move to collapse the play yard. 
         FIG. 5  is a side view of the example play yard of  FIG. 1  in a semi-folded state. 
         FIG. 6  is a perspective view of the example play yard of  FIG. 1  in a fully folded state. 
         FIG. 7  is side view of the example play yard of  FIG. 1  in the fully folded state. 
         FIG. 8  is a cross-sectional view of an end cap of the example play yard taken along line  8 - 8  of  FIG. 1  and illustrating the pivotable connection of an upper frame rail to the end cap. 
         FIG. 9  is a cross-sectional view taken along line  9 - 9  of  FIG. 8 . 
         FIG. 10  is an enlarged side view of a post of the example play yard of  FIG. 1 . 
         FIG. 11  is a cross-sectional view of the post taken along line  11 - 11  of  FIG. 10 . 
         FIG. 12  is an exploded perspective view of another example post of the example play yard of  FIG. 1 . 
         FIG. 13   a  is a perspective view of another example post that may alternatively be used with the example play yard of  FIG. 1  showing the post prior to receiving the enclosure. 
         FIG. 13   b  is a perspective view similar to  FIG. 13   a , but showing the enclosure coupled to the post. 
         FIG. 14  is a cross-sectional view of the post taken along line  14 - 14  of  FIG. 13   b.    
     
    
    
     DETAILED DESCRIPTION 
     An example play yard  10  is shown in  FIG. 1 . The play yard  10  is portable in that it is intended to be collapsible from an erected position such as the example position shown in  FIG. 1  to a collapsed position such as the example position illustrated in  FIGS. 6-7 . When the play yard  10  is in the erected position, it provides an enclosure for a small child or infant. The play yard  10  has a smaller form factor when it is in the collapsed position then when it is in the erected position. Therefore, the play yard  10  may be easily stored or transported when collapsed. 
     As shown in  FIG. 1 , when in the erected position, the illustrated play yard  10  has a rounded rectangular shape. In particular, the illustrated play yard  10  has four sides  12 , each of which is bowed outward away from the center of the play yard  10 . In addition, the play yard  10  of  FIG. 1  includes four corner posts  14  joining the sides  12  that define the rounded rectangular shape. Like the sides  12 , the corner posts  14  are bowed outward away from the center of the play yard  10 . However, whereas the sides  12  bow about a generally vertical axis, the corner posts  14  curve about a generally horizontal axis. As a result of the bowed sides  12  and corner posts  14 , the play yard  10  defines a rounded rectangular volume. 
     The illustrated portable play yard  10  includes a frame  22  (see  FIGS. 2 and 3 ) and an enclosure  23  supported on the frame  22 . The frame  22  includes a collapsible lower frame  24  (see  FIG. 3 ) and a collapsible upper frame  26  (see  FIG. 2 ). The upper frame  26  is suspended above the lower frame  24  by the corner posts  14 . Each of the corner posts  14  is connected between a foot  28  and an end cap or bracket  30 . Each foot  28  is coupled to the lower frame  24 . Each end cap  30  is coupled to the upper frame  26 . 
     As shown in  FIG. 1 , in the illustrated play yard  10  two of the feet are implemented as conventional wheels and two of the feet  28  are implemented as stationary supports to facilitate movement of the erected play yard  10  when desired and to prevent unwanted rolling of the play yard  10  when movement is not desired. However, persons of ordinary skill in the art will appreciate that a different number of feet  28  (e.g., 0, 1, etc.) may be implemented by wheels and/or stationary supports, if desired. 
     The lower frame  24  of the illustrated play yard  10  includes four outer sides which, when the lower frame is in the erected position, together define a generally rectangular perimeter. Each of the outer sides comprises a pair of rails  32  joined by a central joint  34 . One end of each of the rails  32  is pivotably coupled to one of the feet  28 . The opposite end of each of the rails  32  is pivotably coupled to one of the central joints  34 . The pivotable couplings enable the sides of the lower frame  24  to be moved between the erected position and the collapsed position. As shown in  FIGS. 4 and 5 , the joints  34  move upward and translate inward when the play yard  10  is moved from the erected position to the collapsed position. 
     For the purpose of selectively locking the lower frame  24  in the erected position and for providing support for the center of the play yard  10 , the lower frame  10  is further provided with a central assembly  40 . The central assembly  40  is pivotably coupled to the central joints  34  of two opposite sides of the lower frame  24 . More specifically, the central assembly  40  includes two rails  42  and a central hinge  44 . In the illustrated example, one end of each rail  42  is pivotably coupled to a respective one of the central joints  34  of the long sides of the play yard  10 . The opposite ends of the rails  42  are coupled to the central hinge  44  of the central assembly  40 . 
     The central hinge  44  includes a conventional lock mechanism to selectively permit or prevent movement of the central assembly  40  and, thus, the lower frame assembly  24  from the erected position to the collapsed position. The lock mechanism comprises a handle  46 . When the handle  46  is pivoted into a generally horizontal position (see  FIG. 3 ), a sleeve associated with the handle  46  substantially prevents the rails  42  of the central assembly  40  from pivoting upward. As a result, the central assembly  40  and, thus, the lower frame  24  cannot be collapsed. When the handle  46  is pivoted into a generally vertical position (See  FIG. 4 ), the sleeve associated with the handle  46  does not prevent the rails  44  of the central assembly  40  from pivoting upward. As a result, the central assembly  40  and, thus, the lower frame  24  may be collapsed by lifting the handle  46 . 
     To provide support for the center of the play yard floor when the play yard  10  is in the erected position, the central assembly  40  includes a pair of centrally located feet  48 . To provide further lateral support for the lower frame  24 , a pair of opposed outrigger feet  50  are coupled to opposed ones of the central hinges  34  (see  FIGS. 3 and 4 ). Like the feet  28 , the outrigger feet  50  and the centrally located feet  48  are positioned to engage a ground surface supporting the play yard  10  when the play yard  10  is in the erected position. 
     The upper frame  26  of the illustrated play yard  10  includes four outer sides which, when the upper frame  26  is in the erected position, together define a rounded rectangular (i.e., four sided) perimeter. The rounded rectangular shape may be an oval, a half-oval, or any combination of rounded and straight sides. However, at least one of the sides is preferably rounded. It is even more preferable that at least two opposite sides are rounded to provide symmetry. 
     In the illustrated example, each of the outer sides comprises a pair of outwardly bowed rails  52  joined by a central joint  54 . One end of each of the rails  52  is pivotably coupled to one of the end caps  30 . The opposite end of each of the rails  52  is pivotably coupled to one of the central joints  54 . The pivotable couplings enable the sides of the upper frame  26  to be moved between the erected position and the collapsed position. 
     Each of the central joints  54  is provided with a releasable lock to enable selective collapsing of the upper frame  26 . The construction of the releasable lock forms no part of the present invention and will not be discussed in detail here. Persons of ordinary skill in the art are aware of the numerous types of joint locks that are used in portable play yards. Any of those known locks may be employed in the illustrated play yard  10 . For example, the releasable locks described in U.S. Pat. No. 6,250,837, which is hereby incorporated herein by reference, may be used in this role. 
     It is desirable for the form factor of the play yard  10  to be as small as possible when the play yard  10  is folded into the collapsed position of  FIG. 6 . A small form factor translates into less packaging costs for the manufacturer and smaller storage requirements for the end user. Because the rails  52  of the upper frame  26  are outwardly bowed to create the rounded rectangular perimeter, the central joints  54  extend further away from the center of the play yard  10  when the upper frame  26  is in the erected position than would the central joints of a conventional rectangular frame. Therefore, if the central joints  54  are permitted to move directly downward when the upper frame  24  is moved from the erected position to the collapsed position, the joints  54  would increase the form factor of the collapsed play yard  10 . 
     Therefore, to reduce the form factor of the collapsed play yard  10 , the rails  52  of the upper frame  26  are coupled to the end caps  30  such that the centers of each side of the upper frame  26  (e.g., the central joints  54 ) move inward and downward as the upper frame  26  moves from the erected position to the collapsed position, as indicated by the arrows in  FIGS. 4 and 5 . (The inward component of this motion is in addition to the inward translation caused by moving the posts  14  toward one another as shown in  FIG. 6 ). As a result, when the upper and lower frames  24 ,  26  are in the collapsed positions shown in  FIG. 6 , the joints  54  are positioned inward of the posts  14 . Positioning the joints  54  inward of the posts  14  when the play yard  10  is in the fully collapsed position creates a smaller, more compact structure, which eases storage and transportation. 
     To produce the desired inward and downward movement of the centers of the rails  52  as the upper frame  26  is collapsed, the rails  52  of the upper frame  26  are pivotably coupled to the end caps  30  by mechanical fasteners  60  that are positioned at an angle α from the horizontal. In the example of  FIGS. 8 and 9 , each mechanical fastener  60  penetrates an end cap  30  and a corresponding one of the rails  52  of the upper frame  26 . Each mechanical fastener  60 , thus, defines an axis of rotation for a corresponding one of the rails  52 . Selecting the angular orientation of the mechanical fasteners  60 , thus selects the pivoting motion of the corresponding rails  52 . 
     Preferably, all of the mechanical fasteners  60  are positioned at the same angle α, but persons of ordinary skill in the art will readily appreciate that different angular orientations could optionally be used for different sides of the upper frame  26  if different pivoting motions are desired for those different sides. For example, if it is desirable to have sides that extend different distances from the center of the play yard when the play yard is erected, but which still close in to substantially the same distance from the center of the play yard when the play yard is collapsed such that the collapsed play yard has a generally rectangular form factor, the fasteners of the differently positioned sides would be positioned at different angular orientations to achieve the different movements of the differently extending sides. Similarly, in the illustrated example, the angle α is approximately 11 degrees from the horizontal plane, but other angles may be selected to obtain a desired movement of the centers of the rails  52 . The mechanical fasteners may be implemented by bolts, screws, rivets, etc. 
     To further enlarge the volume of the play yard  10  and to enhance its rounded appearance, the posts  14  that support the upper frame  26  above the lower frame  24  are curved. In the illustrated example, the posts  14  include a body having a generally straight upper section  64 , a generally straight lower section  66 , and a curved central section  68  (see  FIG. 10 ). The upper section  64  of each post  14  is coupled to a respective one of the end caps  30  by one or more mechanical fasteners (e.g., rivets). The lower section  66  of each post  14  is coupled to a respective one of the feet  28  by one or more mechanical fasteners (e.g., rivets). Preferably, the curved section  68  of each post is oriented to bow away from the center of the play yard  10  about a generally horizontal axis. The posts  14 , like the rails  32 ,  52  of the lower and upper frames  24 ,  26 , may be constructed of metal (e.g., steel, aluminum, etc.) or of extruded plastic tubes. 
     As mentioned above, the illustrated play yard  10  includes an enclosure  23  that is supported by the frame  22 . Preferably, the enclosure includes five flexible sides, namely, a bottom and four sides. The top is open. The enclosure  23  may be made of fabric, plastic, mesh and/or any other material which is sufficiently strong and durable to define the enclosure volume throughout the desired useful life of the play yard  10  and which is flexible enough to be folded. In the illustrated example, the enclosure  23  is a fabric structure including mesh side panels. The illustrated enclosure  23  includes upper sleeves which receive the rails  52  of the upper frame  26  and lower sleeves which receive the rails  32  of the lower frame  24 . In other words, the sides of the enclosure  23  are stretched between the upper and lower frames  24 ,  26 . 
     Unlike traditional play yards, the posts  14  are not covered or encased in the enclosure  23 . Instead, the enclosure  23  of the illustrated play yard is coupled to the inner surface of the posts  14 . As a result, the outward facing surfaces, (particularly of the curved sections  68 ), of the posts  14  are completely exposed. 
     In order to facilitate coupling of the enclosure  23  to the posts  14 , each of the corners of the enclosure  23  is sewn, glued, fused or otherwise fastened into a sleeve which receives a flexible cylindrical member to define a corner bead  70  as shown in  FIGS. 11 and 12 . The flexible cylindrical member may be implemented by a wire, a rope, a foam or plastic tube, etc. Further, each post  14  defines a channel  72  for receiving a respective one of the corner beads  70 . 
     In a presently preferred implementation, each channel  72  is defined by a track  74  which is coupled to the exterior of a respective one of the posts  14 . Because the tracks  74  are coupled to the inner surfaces of the curved posts  14 , the tracks  74  are curved in a manner that complements the post shape. In the example of  FIGS. 11 and 12 , the track  74  includes a backing  76  which is secured to a respective one of the posts  14  via mechanical fasteners  78  (e.g., rivets, screw, etc.). The channel  72  is defined adjacent the backing  76  by opposed arms  80 . Each of the opposed arms  80  has a first end coupled to the backing  76  and a second free end. The free ends of the arms  80  are curved toward one another to define a slit having a width through which the corner bead  70  may not pass. In the illustrated example, four sets of opposed arms  80  are employed, but other numbers of arms  80  (e.g., 1, 2, 3, 5, etc.) might likewise be appropriately employed. The backing  76  and the arms  80  of the illustrated example are integrally formed, since the track  74  is made of molded plastic. 
     In the example of  FIGS. 11 and 12 , the tracks  74  are preferably fastened to their corresponding posts  14 , and the corner beads  70  are then threaded down into the channels  74  defined by their respective tracks  74 . To facilitate assembly, it may be easier to thread the corner beads  70  of the enclosure  23  into their respective channels  74  before assembling the end caps  30  and the upper frame  26  to the posts  14 . 
     An alternative post  14  is shown in  FIGS. 13   a ,  13   b  and  14 . In the example of  FIGS. 13   a ,  13   b  and  14 , a post  114  is extruded to define a channel  172 . The channel  172  is located within the post  114  and is in communication with a slot  175 . The channel  172  follows the shape of the post  114 . Thus, in the illustrated example, the channel  172  is curved like the post  114 . The enclosure  23  is joined to the post  114  by threading the corner bead  70  down into the channel  172  as shown in  FIG. 13   a . As shown in  FIGS. 13   b  and  14 , the enclosure  23  passes through the slot  175  when the bead is threaded into the channel  172 . However, the slot  175  and the corner bead  70  are sized such that the corner bead  70  may not pass through the slot  175 . Although the post  114  requires a more complicated manufacturing process than the post  14 , the post  114  has the advantage of not requiring the track  74 . 
     In order to provide a rigid, comfortable support for a child or infant located within the play yard  10 , the play yard  10  is further provided with a floor board  90 . When the illustrated play yard  10  is erected, the floor board  90  is located within the enclosure  23  on top of the lower frame  24  in a generally horizontal plane (assuming, of course, that the surface on which the play yard  10  is erected is generally horizontal). The illustrated floor board has a rounded rectangular outer perimeter substantially corresponding to the rounded rectangular shape of the upper frame  26 . Since the lower frame  24  has a generally rectangular outer shape, portions of the floor board  90  extend outwardly of (i.e., overhang) the lower frame  24 . 
     Other than its shape, the floor board  90  of the illustrated example is conventional. For example, the illustrated floor board  90  includes one or more foam pads secured to one or more boards. The pad(s) and board(s) are encased in a plastic sleeve as is conventional in portable play yards sold today such as the Travelin&#39; Tot® play yards sold by Kolcraft Enterprises. Seams are defined between adjacent boards of the floor board  90  to facilitate folding of the floor board  90  in discrete sections. In the illustrated example, the floor board  90  includes four boards and is foldable in fourths. The floor board  90  may, thus, be wrapping around the collapsed play yard  10  for transport and/or storage. 
     The floor board  90  may be removably secured to the floor of the enclosure  23  by any suitable fasteners. In the illustrated example, the floor board  90  is secured to the floor of the enclosure  23  by Velcro® strips. Alternatively, the floor board  90  may be held in place by gravity without the benefit of fasteners. 
     Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the claims either literally or under the doctrine of equivalents.