Patent Publication Number: US-8973181-B2

Title: Wheel assembly for a foldable child enclosure

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to U.S. Provisional Patent Application No. 61/636,111, filed Apr. 20, 2012, entitled “Wheel Assembly for a Foldable Child Enclosure”. The entire disclosure of this application is incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a foldable child enclosure, such as a play yard, playpen, or crib apparatus, and, more particularly, to a child enclosure apparatus having a wheel assembly adapted for supporting the child enclosure apparatus and facilitating movement on a plurality of surfaces. 
     2. Description of Related Art 
     Foldable play yards, playpens, and crib devices are well-known, as perhaps best exemplified by U.S. Pat. No. 4,811,437 for a “Foldable Playyard” to Dillner et al. The foldable device disclosed therein is light in weight and, when collapsed, a fairly convenient compact package. One major problem with such devices, however, is that they are difficult to handle because they are cumbersome to open and unwieldy to fold with clumsy operating mechanisms. Additionally, they are difficult to move across a variety of surfaces, such as smooth floors and thick carpet. Another device is shown in an application, U.S. Patent Application Publication No. 2007/0017025, for a “Folding Play Yard” by Myer. There is no disclosure in this reference concerning a wheel assembly for facilitating movement of the play yard on a variety of surfaces. The release means play no part in such a movement. 
     A more easily operated device that opens and folds smoothly is desirable, especially for those users doing so while attention is being directed to young children. An efficient, low weight, and robust structure is also desirable. In addition, a further need exists for such a play yard that includes a wheel assembly adapted for supporting the play yard and facilitating movement on a plurality of surfaces. 
     SUMMARY OF THE INVENTION 
     Accordingly, an object of the present invention is to provide a foldable structure, such as an enclosure for a child, that can be easily operated to open and fold in a fast and smooth manner, and that can be pushed over a plurality of different surfaces with little effort on the part of the user. More specifically, the foldable structure of the present invention advantageously provides a one-step process to open or fold the enclosure, where pushing down on or lowering of a centrally-located hub assembly opens the structure, and pulling up on or raising the hub assembly folds the structure. 
     According to one embodiment of the invention, the foldable structure may include: an upper assembly forming an upper portion of the structure; a base assembly forming a lower portion of the structure; a centrally-located hub assembly operatively connected to the base assembly; and a post extending from each corner of the upper assembly to a corner of the base assembly, thereby forming the structure. The upper assembly may include a plurality of arm assemblies. A wheel assembly may be provided at each corner of the base assembly extending from the base assembly to engage a surface. Movement of the hub assembly towards a surface upon which the foldable structure is positioned desirably causes the foldable structure to move from a folded position to an opened position, and movement of the hub assembly away from the surface desirably causes the foldable structure to move from the open position to the folded position. The hub assembly may be operatively connected to the at least one latching mechanism by an operating structure. Movement of the hub assembly towards a surface upon which the foldable structure is positioned may cause the operating structure to force the at least one latching mechanism into a locked position, and movement of the hub assembly away from the surface causes the operating structure to force the at least one latching mechanism into a released position. The operating structure may be configured as a cable or any other suitable operating device. The posts may be hollow, and the operating structure may extend from the hub assembly to the at least one latching mechanism through at least one of the posts. The base assembly may include upper and lower base legs in an X-shaped configuration. 
     Each wheel assembly may include: a wheel body having a central axis about which the wheel assembly rotates; at least one support surface adapted for supporting and guiding the wheel on a surface; and at least one groove provided on opposing sides of the support surface. The at least one groove may be recessed with respect to the at least one support surface. Each support surface desirably has a pair of faces extending on opposing sides of the support surface. A plurality of support surfaces are separated by a plurality of grooves. The wheel may be configured such that one or both faces are angled or perpendicular relative to a plane of the support surface. 
     According to another embodiment of the invention, the foldable structure may include: an upper assembly having a plurality of upper arms; a base assembly having a plurality of base legs; a side structure having a plurality of side posts connecting the upper assembly to the base assembly; a centrally-located hub assembly that causes the apparatus to move between a closed position and an open position; and a wheel assembly provided at each corner of the base assembly. The structure is prevented from moving from an open position to a closed position by at least one latching mechanism provided on at least one corner of the upper assembly. The structure is movably supported on a surface by the plurality of wheel assemblies. 
     According to still another embodiment of the invention, each wheel assembly may include: a wheel body having a central axis about which the wheel assembly rotates; at least one support surface adapted for supporting and guiding the wheel on a surface; and at least one groove provided on opposing sides of the support surface. The at least one groove may be recessed with respect to the at least one support surface. Each support surface desirably has a pair of faces extending on opposing sides of the support surface. The grooves may be adapted for engaging an operating structure, such as at least one cable. 
     According to yet another embodiment of the invention, a foldable structure may include: an enclosure defining a space within; a hub assembly centrally located at a bottom of the structure; and at least one wheel assembly provided at each corner of the foldable structure. Each wheel assembly may include a wheel body having a central axis about which the wheel assembly rotates; at least one support surface adapted for supporting and guiding the wheel on a surface; and at least one groove provided on opposing sides of the support surface. The at least one groove may be recessed with respect to the at least one support surface. The grooves may be adapted for engaging an operating structure, such as one or more cables. 
     These and other features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a foldable structure shown in an opened or deployed position in accordance with one embodiment of the present invention; 
         FIG. 2  is a perspective view of the structure shown in  FIG. 1  in a folded or closed position; 
         FIG. 3  is a perspective view of a frame of the foldable child structure shown in  FIG. 1  in an opened position; 
         FIG. 4  is a perspective view of the frame in a partially-opened position; 
         FIG. 5  is a perspective view of the frame in a folded position; 
         FIG. 6  is a side view of one of the upper corners of the frame of  FIG. 3  in the opened position; 
         FIG. 7  is a side view of one of the lower corners of the frame of  FIG. 3  in the opened position; 
         FIG. 8  is a side view of one of the lower corners of the frame of  FIG. 4  in the partially-opened position; 
         FIG. 9  is a side view of one of the lower corners of the frame of  FIG. 5  in the folded position; 
         FIG. 10  is a perspective view of a wheel shown in  FIGS. 7-9 ; 
         FIG. 11  is a front view of a wheel shown in  FIGS. 7-9 ; and 
         FIG. 12  is a front view of a wheel in accordance with another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations, except where expressly specified to the contrary. It is also to be understood that the specific devices illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting. 
     With reference to  FIGS. 1 and 2 , a foldable child enclosure apparatus  10  configured in the form of a play yard or playpen is illustrated. The play yard is portable and, as such, is foldable, closable, or collapsible so as to move between an opened, deployed position, as shown in  FIG. 1 , for use, and a folded, collapsed, or closed position as shown in  FIG. 2 , for transport and/or storage. The play yard may have soft, flexible mesh sides, such as sides  12 ,  14 , fabric coverings, such as fabric coverings  16 ,  18 ,  20 ,  22 , a base pad or mattress  24 , and decorative and protective upper and lower corners, such as the four upper corners  30 ,  31 ,  32 ,  33 , and the four lower corners, of which only three lower corners  34 ,  35 ,  36  are shown. Side padding (not shown) may also be placed around the interior of the play yard for added protection of a child placed on the pad or mattress  24 . Storage devices, child seats, bassinets and the like may also be mounted on and to the play yard although they are not shown here. Under the mesh, the fabric, the pad, and any side padding is a foldable frame, denoted generally as reference numeral  40 , as shown in an opened position in  FIG. 3 , a partially-opened position in  FIG. 4 , and in a folded position in  FIG. 5 . 
     With reference to  FIGS. 3-5 , to better understand the invention, the detailed description of the foldable frame  40  set forth hereafter may best be understood by dividing the foldable frame  40  into four portions. The frame  40  includes a base assembly, denoted generally as reference numeral  42 , forming a lower portion of the frame  40 , an upper assembly, denoted generally as reference numeral  44 , forming an upper portion of the frame  40 , a side structure, denoted generally as reference numeral  46 , and a centrally-located hub assembly, denoted generally as reference numeral  48 . The base assembly  42  is pivotally connected to both the hub assembly  48  and to the side structure  46 , and the upper assembly  44  is pivotally connected to the side structure  46 . 
     The base assembly  42  includes four upper base legs  50 ,  52 ,  54 ,  56 , and four lower base legs  60 ,  62 ,  64 ,  66 , four lower corners  34 ,  35 ,  36 ,  37 , a pair of stability legs  70 ,  72  and pivot rivets, such as the rivets  80 ,  82  around which the upper base leg  50  and the lower base leg  60  pivot or rotate relative to the corner  34 . Each quarter of the frame is constructed in the same manner so that only the left portion of the frame as shown in  FIGS. 3-6  will be detailed. The base legs are configured as shown in an “X” pattern and no side structure or elements are present as in many conventional play yard devices. The lower corners each include a wheel or caster, such as the wheel  86 . 
     The upper assembly  44  includes eight upper arms  140 ,  142 ,  144 ,  146 ,  148 ,  150 ,  152 ,  154 , upper four corner assemblies  30 ,  31 ,  32 ,  33 , and four stiffening members  170 ,  172 ,  174 ,  176 . As was earlier done, only a portion of the frame will be detailed because all other like structures of the frame are identically configured. The upper arm  140  is pivotally connected to a corner by a rivet  180  and to the stiffening member  170  by a rivet  182 . The upper arm  154  that is positioned perpendicular to the upper arm  140  is pivotally connected to the corner by a rivet  184  and to the stiffening member  176  by a rivet  186 . The remaining upper arms are arranged in a similar fashion. 
     The side structure  46  includes four generally vertically disposed side posts  250 ,  252 ,  254 ,  256 . Each side post  250 ,  252 ,  254 ,  256  is connected to a respective lower corner and to a respective upper corner. This arrangement permits the side posts to pivot or tilt outwardly and, at the same time, pull the upper corner assemblies outwardly or apart from one another. Each side post also encloses an operative structure that may take the form of a cable as described in greater detail hereinafter. Accordingly, the operative structure is in mechanical communication with the upper arms of the upper assembly and the base assembly to move the upper arms to positions consistent with an opened enclosure and positions consistent with a folded enclosure in response to movement of the base assembly. 
     Each corner of the foldable frame  40  includes a latching mechanism  200  as can be seen in  FIG. 6  where the upper corner  30  has been removed. As was earlier done, only one of the latching mechanisms of the frame will be detailed because all other like latching mechanisms of the frame are identically configured. With reference to  FIG. 6 , and with continued reference to  FIGS. 3-5 , the latching mechanism  200  includes a first leg  202  having a first end  204  pivotally connected to and extending from an upper portion of the side post  250  and a second end  206 ; a second leg  208  having a first end  210  pivotally connected to the second end  206  of the first leg  202  and a second end  212  connected to a portion of the upper arm  140  of the upper assembly  44 ; and a locking member  214  having a first end  216  pivotally coupled to the upper portion of the side post  250  between an end of the side post  250  and a position where the first end  204  of the first leg  202  is coupled to the upper portion of the side post  250  and a second end  218  connected between the first leg  202  and the second leg  208 : The locking member  214  includes a central pivoting member  220  that is operatively coupled to the lower corner  34  by an operating structure, such as a first cable  221  and second cable  222 . First cable  221  is secured to a lower end of central pivoting member  220  and extends upward around an upper portion of side post  250  into a hole (not shown) in side post  250  and to the lower corner  34 . The second cable  222  extends from an upper end of the central pivoting member  220  over a wheel  224  provided at the first end  204  of the first leg  202 , into a hole (not shown) in the side post  250 , and to the lower corner  34 . 
     With reference to  FIGS. 7-9 , a side view of one of the lower corners of frame  40  is illustrated in various stages of opening. While a lower corner  34  is used for purposes of illustrating the components in  FIGS. 7-9 , the remaining three lower corners  35 ,  36 ,  37  have identical components and function in an identical way.  FIG. 7  shows the lower corner in an opened position with upper base leg  50  and lower base leg  60  in a deployed configuration.  FIG. 8  shows the same components illustrated in  FIG. 7  in a partially-opened position as frame  40  is advanced from a folded configuration to an opened configuration, or vice versa.  FIG. 9  shows the lower corner in a closed position with upper base leg  50  and lower base leg  60  in a folded configuration. 
     As briefly described hereinabove with regard to  FIG. 6 , the first and second cables  221 ,  222  are connected to the central pivoting member  220  of the locking member  214 . The cables  221 ,  222  then extend downward through the side post  250 . Referring back to  FIGS. 7-9 , first cable  221  extends into the lower corner  34  around wheel  86  and is connected to a lower end  241  of a locking link member  240 . An upper end  242  of locking link member  240  is pivotally coupled to lower base leg  60  at pivot point  243 . Adjacent to the pivot point  243  is a cam  244  provided at a terminal end of lower base leg  60 . Cam  244  has a notch  245  to actuate the locking link member  240  to unlock the upper corner. When lower base leg  60  is moved from the folded to the opened position, cam  244  pivots about pivot point  243 . A tensioning force in the first cable  221  at lower end  241  of locking link member  240  causes further pivoting of cam  244  about pivot point  243 . In a fully opened position, upper end  242  of locking link member  240  slides over the locking notch  245  to lock the lower corner assembly in place. When the lower base leg  60  is moved from the open to the folded position, upper end  242  of locking link member  240  slides over the locking notch  245  to unlock the lower corner assembly, thereby relieving the tensioning force and allowing the latching mechanism  200  to move from the locked position to the nested position discussed hereinabove. 
     With further reference to  FIGS. 7-9 , second cable  222  extends into the lower corner  34  around wheel  86  and is connected to a lower end  225  of a plate  226 . An upper end  227  of the plate  226  is pivotally coupled to a lower end of the side post  250  at pivot point  228 . A camming plate  229  is connected to each upper base leg  50 ,  52 ,  54 ,  56 . The camming plate  229  is shaped and sized such that it comes into contact with the plate  226  as the upper base legs  50 ,  52 ,  54 ,  56  are moved from the folded to the open position. As the camming plate  229  comes into contact with the plate  226 , it causes the plate  226  to rotate about its pivot point  228  and provide a tensioning force to the second cable  222 . This tensioning force is transferred to the latching mechanism  200  to move the latching mechanism  200  to the locked position. When the upper base legs  50 ,  52 ,  54 ,  56  are moved from the open to the folded position, the contact between the camming plate  229  and the plate  226  is removed, thereby relieving the tensioning force and allowing the latching mechanism  200  to move from the locked position to the nested position discussed hereinabove. 
     With reference to  FIGS. 10-11 , the wheel  86  is illustrated separate from the remaining components of the foldable child enclosure apparatus  10 . Each wheel  86  is adapted for movably supporting the foldable child enclosure apparatus  10  on a surface, such as flooring or carpeting. The wheel  86  generally includes a wheel body  300  and a central axis  302  about which the wheel  86  rotates. The wheel body  300  has a generally cylindrical shape with the central axis  302  extending through a longitudinal extent of the wheel body  300 . An axle opening  304  extends coaxially through the center of the wheel body  300 . The axle opening  304  is adapted for receiving an axle (not shown) about which the wheel  86  rotates. 
     In order to facilitate movement of the foldable child enclosure apparatus  10  across various surfaces, such as thick carpeting or a hard floor surface, the wheel  86  has a plurality of support surfaces  306  adapted for guiding the wheel  86  on the floor surface. As shown in  FIGS. 10-11 , the support surfaces  306  are provided at an outer periphery of the wheel  86  at an interface between the wheel  86  and a surface, such as carpeting or flooring. The support surfaces  306  are adapted for providing traction so that the wheel  86  can rotate, and the foldable child enclosure apparatus  10  can move, across a plurality of different surfaces. Desirably, at least one support surface  306  is provided for engaging the floor. Each support surface is desirably narrow enough to cut between the fibers of thick carpeting in order to provide adequate traction for moving the wheel  86  through carpeting. Additionally, the plurality of support surfaces desirably have a sufficient footprint to balance the wheel  86  on a smooth and hard surface, such as hardwood flooring or concrete, and evenly distribute the weight of the foldable child enclosure apparatus  10  on such surface. 
     With continuing reference to  FIGS. 10-11 , the plurality of support surfaces  306  are separated by a plurality of grooves  308 . The grooves  308  are recessed with respect to the support surfaces  306  such that the grooves  308  have a smaller diameter compared to the support surfaces  306 . The grooves  308  are adapted for engaging the operating structure, such as the first cable  221  and the second cable  222 . The first and second cables  221 ,  222  are desirably wrapped about at least a portion of the grooves  308 . In one embodiment, at least one of the first and second cables  221 ,  222  engages the grooves  308 . 
     Each support surface  306  desirably has a pair of faces  310  extending on opposing sides of the support surfaces  306 . Each face  310  extends between the support surface  306  and the groove  308 . One or both faces  310  may be linear or radiused and may be generally angled with respect to the plane of the support surface  306 , as shown in  FIG. 11 . In the embodiment shown in  FIG. 12 , each face  310  is substantially perpendicular to a plane of the support surface  306 . A narrower profile (i.e., a smaller contact patch or footprint) of the support surface  306  is more suitable for enabling wheel  86  to rotate on thick carpeting because the support surface  306  can cut between the carpet fibers. On the other hand, a wider profile (i.e., a larger contact patch or footprint) of the support surface  306  (shown in  FIG. 12 ) is more suitable for enabling wheel  86  to rotate on a smooth, hard surface, such as hardwood flooring or concrete, by providing sufficient traction to the wheel  86  without damaging the floor surface. The number of support surfaces  306  and their profiles are desirably selected for providing a wheel  86  that be rolled through thick carpeting and smooth flooring. 
     The base legs, upper arms, and side posts may be formed of any suitable tubes, rails, bars, beams, shafts, spars, rods, or the like. Where applicable, any suitable cross-sectional configurations may be used, such as tubular, square, rectangular, I-beam, L-shaped, H-shaped, and C-shaped. Desirably, the side posts have a C-shaped cross-section as shown in the figures. An extrusion of sufficient strength and stiffness should suffice and the material may be plastic or metal or any other suitable material. The upper and lower corners may also be formed of plastic or metal or any other suitable material. 
     As discussed hereinabove, the operation of the foldable frame  40  can be described as a three-phase process through a single interface. Initially, there is a “spreading” phase, followed by a “lift” phase, and then the last “locking” phase. In the first phase, the user pushes down on the centrally-located hub assembly  48  which causes the legs of the base assembly  42  to spread apart. In the last phase, the legs of the base assembly  42  maintain the side posts of the enclosure at a substantially vertical position. In the final phase, latches provided in the upper corners of the enclosure lock the enclosure in the unfolded or open state. 
     When the frame is in the opened position, as shown in  FIG. 3 , the base legs and the upper arms are generally in horizontal positions, and the side posts are generally in vertical positions. When the frame is in the folded position for storage and/or transport, as shown in  FIG. 5 , the side posts remain in generally vertical positions, and the base legs and the upper arms are pivoted or rotated to more generally vertical positions. It is to be noted that the terms “generally horizontal” and “generally vertical” are meant to indicate approximation and that the referenced structures are at, or near, or about horizontal or vertical. 
     While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof