BACKGROUND OF THE INVENTION
In 2005 a radically new roller skate design was introduced by LandRoller Inc. of Hermosa Beach, Calif. This skate has a large (approximately five-and-a-half inch) front wheel and an even larger (approximately seven inch) rear wheel, both mounted in an inwardly-canted orientation to an outboard (lateral) side of the skate and in parallel offset planes with the plane of the rear wheel extending down and near the centerline of the roller skate. This design using large wheels provides for a smoother, more maneuverable and more stable ride with increased glide time than the ride provided by the previous in-line skates with their smaller and narrower wheels. The resulting reduced chatter and vibration reduces skater fatigue thereby allowing him to ride more comfortably and for longer sessions. Time Magazine selected this skate as one of the “most amazing inventions” in 2005. This large canted-wheel, out-of-line skate design is disclosed in U.S. Pat. Nos. 5,951,028, 6,273,437 and 6,443,464 (see also U.S. Pat. No. 3,885,804 (Cudmore)), and an improved wheel and tire combination therefor is disclosed in US 2007/0096542 (Van der Palen et al.). The entire contents of these patents and this published application are hereby incorporated by reference.
SUMMARY OF THE PREFERRED EMBODIMENTS
Disclosed herein is an improved large angled-wheel or “out-of-line” roller skate having a frame supporting fore and rear axles extending in a lateral direction from the frame and supporting canted fore and rear wheels, respectively, for rotation thereabout. Also disclosed herein is an improved axle assembly for that roller skate.
According to one preferred embodiment of the present invention the frame is made of an injection-molded engineered plastic. The plastic for lightweight frames can be urethane or nylon-based plastics with at least five percent carbon fiber and for heavier frames it can be urethane or nylon-based plastics with at least twenty-five percent glass fiber, or Long Glass Fiber.
According to another preferred embodiment of the invention, the wheels include hubs made of an engineered plastic and (urethane) tires on the hubs. The plastic for light-weight wheel hubs can be a urethane-based plastic with at least five percent carbon fiber, and for heavier and less expensive wheel hubs, it can be urethane-based plastics with at least five percent glass fiber.
According to a further preferred embodiment of the invention, a retaining clip attached at one end to the frame retains relative to the frame, the axle nut on an end of the fore or aft axle.
According to a still further preferred embodiment of the invention, a boot cradle is attached to the frame, wherein the cradle has a pair of integrally-formed tapered posts extending in a lateral direction outwardly towards the rear wheel. A wheel guard has first and second openings in which the first and second posts are, respectively, positioned and secured thereto.
According to a yet still further preferred embodiment a frame cap is secured to a forward top surface of the frame. The frame cap can be secured with a fastener, which also secures a retaining clip for a front axle nut to the frame.
According to another preferred embodiment of the invention, a wheelwasher is sandwiched between an outside surface of the frame and a bearing race of one of the wheels with the corresponding axle passing through the wheelwasher. The wheelwasher has a flat back face against the frame side surface and a raised inner ring on the front surface. The raised inner ring is dimensioned so that only the inner race of the inboard bearing of that wheel is contacted by the wheelwasher. A properly sized flat washer can also be used.
According to a further preferred embodiment, the axle has a stepped configuration and the corresponding frame opening has a similar stepped configuration. A retaining nut is secured to an end of the axle and abuts a surface of the frame at the opposite end of the opening.
According to a still further preferred embodiment, a brake arm of a brake arm assembly is attached at one end to the frame and at another end to a brake pad, also of the brake arm assembly. The assembly includes a recessed area immediately adjacent to and for the rear wheel, thereby improving skating stability.
According to a yet still further preferred embodiment, the frame has a lateral side protrusion, a frame member secured to, integrally formed with and extending in a lateral direction out from the side edge and including formed therein the downwardly-angled axle opening.
The present invention is also directed to and includes the individual components of the roller skate, such as the plastic frame, the retaining clip, the plastic hub, the wheel, the cradle, the wheel guard, the front plate, and the brake arm assembly, and various assemblies and subassemblies thereof. An example of a subassembly is the axle assembly of the invention.
Further, the present invention includes the method of making the roller skate and its various components. An example thereof is the method of forming the stepped axle opening in the plastic frame.
Even further, the present invention includes the methods of assembling the roller skate, and/or subassemblies thereof. An example thereof is the method of assembling the frame cap and the front retainer clip using a single fastener. Another example thereof is assembling the axles using a retainer nut held in place by a retainer clip (or similar retaining means) which is secured to the frame.
Other objects and advantages of the present invention will become more apparent to those persons having ordinary skill in the art to which the present invention pertains from the foregoing description taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a roller skate of the present invention;
FIG. 2 is a side elevational view thereof;
FIG. 3 is a top plan view thereof;
FIG. 4 is a bottom plan view thereof;
FIG. 5 is a rear elevational view thereof;
FIG. 6 is a front elevational view thereof;
FIG. 7 is an exploded perspective view thereof;
FIG. 8 is a cross-sectional view taken on line 8-8 of FIG. 3;
FIG. 9 is a cross-sectional view taken on line 9-9 of FIG. 3;
FIG. 10 is a cross-sectional view taken on line 10-10 of FIG. 3;
FIG. 11 is a perspective view of the front or rear hub of the roller skate of FIG. 1 illustrated in isolation;
FIG. 12 is an elevational view of the hub of FIG. 11;
FIG. 13 is an enlarged cross-sectional view of the hub portion of the wheel taken on line 13-13 of FIG. 12;
FIG. 14 is a perspective view of the frame of the roller skate of FIG. 1 illustrated in isolation;
FIG. 15 is a top plan view of the frame of FIG. 14;
FIG. 16 is a side elevational view of the frame;
FIG. 17 is a bottom plan view of the frame;
FIG. 18 is a cross-sectional view taken on line 18-18 of FIG. 17;
FIG. 19 is rear end view of the frame;
FIG. 20 is a front end view of the frame;
FIG. 21 is a perspective view of the brake arm of the roller skate of FIG. 1 illustrated in isolation;
FIG. 22 is a top plan view of the brake arm of FIG. 21;
FIG. 23 is a side elevational view of the brake arm;
FIG. 24 is a bottom plan view of the brake arm;
FIG. 25 is a cross-sectional view taken on line 25-25 of FIG. 24;
FIG. 26 is a front end view of the brake arm;
FIG. 27 is a rear end view of the brake arm;
FIG. 28 is a perspective view of the brake pad of the roller skate of FIG. 1 illustrated in isolation;
FIG. 29 is a top plan view of the brake pad of FIG. 28;
FIG. 30 is a side elevational view of the brake pad;
FIG. 31 is a bottom plan view of the brake pad;
FIG. 32 is a front end view of the brake pad;
FIG. 33 is a rear end view of the brake pad;
FIG. 34 is a perspective view of the frame cap of the roller skate of FIG. 1 illustrated in isolation;
FIG. 35 is a rear end view of the frame cap of FIG. 34;
FIG. 36 is a top plan view of the frame cap;
FIG. 37 is a front end view of the frame cap;
FIG. 38 is a left side elevational view of the frame cap;
FIG. 39 is a right side elevational view of the frame cap;
FIG. 40 is a top plan view of the right side wheelguard of the roller skate of FIG. 1 illustrated in isolation;
FIG. 41 is an elevational view of the right side wheelguard of FIG. 40;
FIG. 42 is a bottom plan view of the right side wheelguard of FIG. 40;
FIG. 43 is an end elevational view of the right side wheelguard of FIG. 40;
FIG. 44 is a perspective view of the front or rear axle of the roller skate of FIG. 1 illustrated in isolation;
FIG. 45 is a rear end view of the axle of FIG. 44;
FIG. 46 is a front end view of the axle;
FIG. 47 is a plan or elevational view of the axle;
FIG. 48 is a cross-sectional view taken on line 48-48 of FIG. 46;
FIG. 49 is a perspective view of the retaining clip of the roller skate of FIG. 1 illustrated in isolation;
FIG. 50 is a top view of the retaining clip of FIG. 49;
FIG. 51 is a left end view of the retaining clip;
FIG. 52 is a side elevational view of the retaining clip;
FIG. 53 is a right end view of the retaining clip;
FIG. 54 is a perspective view of the wheelwasher of the roller skate of FIG. 1 illustrated in isolation;
FIG. 55 is an elevational view of the wheelwasher of FIG. 54;
FIG. 56 is a side view of the wheelwasher;
FIG. 57 is a perspective view of the roller skate of FIG. 1 with a boot therein; and
FIG. 58 is a side elevational view of the roller skate and boot of FIG. 57.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
Referring to the drawings wherein like reference numerals designate like parts, disclosed herein is an improved angled (large) wheel and out-of-line roller skate shown generally at 100. It is shown from various angles in FIGS. 1-6 and informative cross-sectional views are depicted in FIGS. 8-10. Various ones of the individual components of the skate 100 are shown enlarged, in isolation, in detail and from various angles in FIGS. 11-56. Further reference will be made to them when the respective components are discussed in detail later in this disclosure.
To better understand the various components of the roller skate 100 and how they are assembled, an exploded perspective view is provided by FIG. 7. Referring thereto, reference numerals assigned to various of the components are as follows: frame 110, frame sidewall 120, frame fore member 130, frame fore opening 140, frame rib configuration 150, frame vertical fastener-receiving openings 160, 170, 180, 190, 200, fore axle 210, forward wheel 220, fore outer bearing 230, fore bearing spacer 240, fore inside bearing 250, fore wheelwasher 260, fore retainer nut 270, fore retainer clip 280, frame cap 290, cap fastener 300, rear axle 310, rear wheel 320, rear outside bearing 330, rear bearing spacer 340, rear inside bearing 350, rear wheelwasher 354, rear member 360, rear opening 370, rear axle retainer nut 380, rear retainer clip 390, rear fastener 400, cradle 410, lateral opening 420, medial opening 430, front opening 440, front T-nut fastener 450, bottom fasteners 460, 470, rear opening 480, rear T-nut fastener 490, fastener side tapered pegs 500, 510, wheelguard 520 having openings 530, 540, screws 550, 560, brake arm assembly shown generally at 570, brake arm 580, brake arm recessed area 590, brake arm opening 600, brake pad 610, brake pad recessed area 620, brake pad opening 630, brake pad fastener 640, brake arm openings 650, 660, brake arm fasteners 670, 680, brake arm fastener threaded insert caps 690, 700, and brake arm ribs 710.
The front and rear wheels 220, 320 have the same constructions and shapes. The front wheel 220 (hub 720 plus urethane tire 730) has a diameter of between one hundred and ten and two hundred millimeters, or approximately one hundred and fifty millimeters. In contrast, the rear wheel 320 (hub 740 plus urethane tire 750) has a diameter of between one hundred and forty and two hundred and fifty millimeters, or approximately one hundred and eighty millimeters. The large diameter angled wheels 220, 320, as shown in FIGS. 12-13, on the skate 100 of the present invention need to be both strong and rigid (high flexural strength and modulus) to prevent excessive rim flexing during skating under load. Pursuant to the present invention, several urethane based “engineered plastics” can be used in injection molds to make strong, stiff, lightweight, low-cost wheel hubs 720, 740 that bond to the urethane tires 730, 750. For lightweight wheel hubs, urethane-based plastics with at least five percent carbon fiber can be used, and the carbon fiber upper limit can be forty percent. This material also provides for a new construction for lightweight racing wheel hubs for inline skates pursuant to this invention. For heavier, but less expensive wheel hubs, urethane-based plastics with at least five percent glass fiber can be used. For glass fiber the upper limit is sixty percent; there is long and short glass fiber. For the wheel hubs 720, 740, generally any rigid thermoplastic polyurethane with enough carbon fiber or glass fiber loading to provide sufficient stiffness can be used.
Referring to FIGS. 14-20, the frame 110 of the skate 100 needs to be both strong and rigid, having high flexural strength and modulus to prevent excessive flexing during skating under load. Because both wheels 220, 320 are only on one side of the boot 760 (see FIGS. 57 and 58), flexing under load will tend to twist the frame 110, which will then cause the wheels to turn so that they are no longer parallel to the centerline of the frame. Specifically, the front wheel 220 will turn in and the rear wheel 320 will turn out. This will cause the skate 100 to steer across the centerline of the skater's intended path. To compensate for this, the skater would have to continuously correct his direction of travel, resulting in an unsatisfactory skating experience.
The present invention provides for a novel construction which uses especially rigid (high flexural modulus) materials to resist this undesirable twisting of the frame 110 under load. The shape, construction and curvature of this frame 110, as depicted in FIGS. 14-20, are completely different than the diecast aluminum frame used in the above-discussed prior art out-of-line skate. The materials that were discovered by the applicant to provide the desired attributes of the frame 110 are urethane or nylon-based plastics with at least five percent carbon fiber (and less than forty percent) for lightweight frames. Urethane or nylon-based plastics with at least twenty-five percent glass fiber, or Long Glass Fiber, can be used for heavier, but less expensive frames. The weight of the frames 110 for thirty percent carbon-filled plastic is approximately two hundred and ten grams. The fifty percent long glass fiber-filled nylon frames weigh approximately two hundred and fifty grams. The “rigid” materials can have a flexural modulus of generally 2,400,000 psi for thirty percent carbon-filled polyurethane and 2,200,000 psi for fifty percent long-glass fiber-filled nylon.
The plastic frame 110 has a peripheral sidewall 120, a rib configuration 150 within the sidewall, and a plurality of vertically-disposed, fastener-receiving openings 160, 170, 180, 190, 200 within the rib configuration. On the outboard side of the sidewall 120 and extending in lateral directions out therefrom are a fore member 130 and an aft member 360. Each defines therein the fore and aft downwardly-angled openings 140, 370, respectively, for the fore and aft axles 210, 310, respectively.
Referring to FIGS. 14 and 15, for example, the frame 110 has a generally hourglass shape configuration when viewed from the top, similar to that of the user's footprint, with a wide forward area, a slightly smaller rear area, and a thinner connecting neck. The total length of the frame 110 can be between one hundred and fifty and three hundred and fifty millimeters, or approximately two hundred and ninety millimeters. The maximum width at the wide forward area can be between forty and one hundred millimeters, or approximately seventy millimeters; the maximum width at the rear area can be between twenty and one hundred millimeters, or approximately fifty millimeters; and the minimum width at the neck can be between ten and eighty millimeters, or approximately thirty-five millimeters. Referring to FIG. 16, the vertical distance between the uppermost and lowermost points can be between twenty-five and one hundred millimeters, or approximately fifty millimeters.
An improved means for retaining the axles 210, 310, as depicted in isolation in FIGS. 44-48, more securely relative to the frame 110, at the correct angle, and with a tight fit for the axles can be used pursuant to the present invention. The engineered plastic frame 110 is injection molded with only a conical indentation at each axle hole location (in the respective frame member). After the frame is injection molded, it is positioned in a “fixture” which allows the axle holes to be drilled at a precise angle and location and to tight tolerances. Since the threaded length of the axle is a much smaller diameter than the main or load bearing part of the axles 210, 310 (six millimeters versus ten millimeters), the axle hole diameter can be “stepped” with steps 780, 790, and plate 800 having a hole, to allow the nuts 270, 380 to contact the maximum surface area of the plastic frame. This can be done by using a precision step drill, or a non-precision step drill with a reaming follow-up step. If necessary, another third diameter to a step drill can be used to “clean up” the outer surface of the frame. This method forms dimensionally-precise axle holes 140, 370 without weakening the plastic in critical areas of the frame 110. (Instead of using the above-described method, a stepped slide pin alternatively can be used.) The front axle 210 is held in hole 140 at an angle of between fifteen and forty degrees, or approximately twenty-seven degrees, angled downwardly from the horizontal. Similarly, the rear axle 310 is held in hole 370 at an angle of between fifteen and forty degrees, or approximately twenty-seven degrees, angled downwardly from the horizontal.
Due to the angle of the axle, relative to the frame, that is necessary in an “out-of-line” skate similar to the above-discussed prior art skate, it has been found by the applicant that the axle nuts 270, 380 cannot be easily retained in any simple injection-molded frame design. And if the nut is not held in its place at all times, the nut may be pushed out of position during any operation that involves completely unscrewing the axle, such as when the user decides to change a wheel or a bearing. If the axle is not retained, the nut may be pushed out of its proper position when the axle is reinserted into the axle hole and it may fail to engage the threads of the nut.
Accordingly, novel nut retaining clips 280, 390 (or resilient retaining members or retaining means) are provided by the present invention which keep the nuts 270, 380 in their proper location when the axle 210, 310 is removed and then reinserted. The clips 270, 380 are shown in isolation and from various angles in FIGS. 49-53. Without this clip, the user will most likely have to remove the boot 760 (see FIGS. 57 and 58) from the frame 110 to realign the nut to engage the axle threads. This would be a frustrating and time consuming step by the user.
Referring to FIGS. 49-53, it is seen that each of the clips 270 or 380 is formed from a single strip of metal, such as steel or aluminum, bent to form first, second, third, fourth and fifth portions, 810, 820, 830, 840, 850, each disposed at a different angle relative to the portion or portions adjacent thereto. The first portion 810 has a hole 860 for receiving therein a fastener 300 or 440 which secures the retaining clip to the frame 110, and the fourth portion 840 has a hole 870 for receiving an end of the respective axle 210 or 310. Referring to FIG. 52, the retainer clip 270 or 380 can have a horizontal dimension between tips of 19.82 millimeters, and referring to FIG. 58, it can have a width dimension of ten millimeters.
“Stepped” wheelwashers 260, 354 placed against the frame 110 at the members 130, 360 and around the axle hole provide significant advantages. The wheelwashers 260 or 354 is shown in isolation in FIGS. 54-56. The “step” formed by an inner ring 880 on the ring 890 allows only the inner race of the innermost wheel bearing race 250 or 350 to contact the wheelwasher. The outer diameter of the wheelwasher is twenty millimeters, the inner diameter is ten millimeters, the outer diameter of the inner ring is fifteen millimeters, the thickness of the ring is 1.0 millimeter and the additional thickness of the inner ring is 0.50 millimeter. Although a much smaller diameter wheelwasher could allow the same limited contact (which allows the bearing to free spin), it would have the disadvantage of not spreading the compression force loads acting on the plastic frame surface. The large diameter of the specially-shaped axle wheelwashers 260, 354 distributes the compression forces over a large surface area on the plastic frame 110 thereby minimizing stress concentration and localizing plastic deformation. The step portion (inner ring 880), which is sized to ensure that only the inner race 250, 350 of the inboard bearing is contacted by the wheelwashers 260, 354 allows for smooth, unbinding bearing operation. The wheelwashers 260, 354 can be made of zinc-plated steel alloy, or similar material. A properly sized flat washer can also be used.
The stepped axle 210 (or 310) thus passes through the outer race 230 (or 330), the center opening of the bearing spacer 240 (or 340) (in the center of the hub of the wheel 220 (or 320)), the inside bearing 250 (or 350), the wheelwasher 260 (or 354), the stepped frame opening 140 (or 370), and the retainer nut 270 (or 380) which is screwed onto or otherwise secured to the end tip of the axle. The step of the axle abuts the step at the end of the opening. The retainer clip 280 (or 390) is secured at one end by a fastener 300 (or 400) to the frame. The axle end passes through the opening 870 in the clip 280 and the end portion 850 of the clip wraps around the nut.
The wheelguard 520 for the cradle 410 helps to prevent the users pant legs, boot laces, fingers and the like from getting caught in the wheels 320. Pursuant to the present invention the wheelguard 520, as shown in isolation in FIGS. 40-43, is attached to the cradle 410. Openings 530, 540 in the wheelguard 520 slip over tapered pins or pegs 500, 510 that are integrated into the boot cradle 410, which can be formed of plastic, for example. Screws 550, 560 are then passed through the wheelguard 520 and into the tapered pins 500, 510, providing a more secure connection. The wheelguard 520 can be made of plastic, for example.
The boot cradle 410 is secured to the frame 110 by the fastener 554 passing up through frame opening 170, through cradle opening 400 and secured at its end by T-nut fastener 450, and also by fastener 470 extending up through frame hole 190, through a cradle hole and secured at an end by T-nut fastener 570. The boot cradle 410 has weight reducing and decorative holes 460, 470.
For example, two frame sizes can be used to cover multiple sizes of the boots 760. Over the size range for each frame size, different length boot cradles with varying toe cap positions are used to allow for greater size flexibility over a given frame size. The smaller boot sizes for a given frame size use a toe cap positioned in a manner that does not fully cover the end of the frame, that is, the forward open end of the frame is exposed. This exposure creates an unfinished and unattractive appearance, and more importantly, potentially allows dirt and water to accumulate in the front end of the frame. A tight fitting frame cap 290, as shown in isolation in FIGS. 34-39, is secured by a screw 300 through the cap hole 890 into the frame 110 (which simultaneously secures the nut retaining clip 280), solves both cosmetic and practical functions. The frame cap 290 can be made generally of any rigid plastic.
The brake arm assembly 530 is attached at one end of the brake arm 580 (see FIGS. 21-27) and the (rubber) brake pad 610 (see FIGS. 28-33) extends out from the other end. The brake arm assembly 530 has a continuous recessed area 900 formed by recessed part 590 in the brake arm 580 and recessed part 620 in the brake pad 610. The brake arm 580 can be made, for example, of nylon 6/6 with fifty percent glass fiber fill. The recessed area 900 allows the rear wheel 320 to be moved closer to the centerline of the boot 760 than in the prior art brake arm. This improves skating stability by positioning the ground contact point of the rear wheel 320 as close to the centerline of the boot 760 as possible. In other words, skating stability is improved by being able to position the contact point of the rear wheel 320 closer to the boot centerline. Variations in distances of the rear wheel 320 from the centerline can be caused by the design of the boot and particularly the width of the rear third of the boot.
The brake arm 580 is secured to the frame by fasteners 670, 680 passing through arm holes 650, 660, respectively, and frame holes 200, 180, respectively, and secured by insert caps 690 and 700, respectively. Ribs 710 on the top of the arm fit into openings in the bottom of the frame. Fastener 640 passes through arm hole 600 and onto pad peg 630 to secure the pad to the arm.
FIGS. 57 and 58 show a boot 760 fastened in and to the frame 110 of the roller skate 100. It is held in place by front and rear T-nut fasteners which slip fit into the fastener opening in the cradle 400 as shown for example in FIG. 1.
From the foregoing detailed description, it will be evident that there are a number of changes, adaptations and modifications of the present invention which come within the province of those skilled in the art. For example, the roller skate can be an in-line skate, or the wheel can be for skates other than the present out-of-line skate. Further, the scope of the invention includes any combination of the elements from the different species or embodiments disclosed herein, as well as subassemblies, assemblies, and methods of using and making thereof. For example, the axle assembly can form a separate invention. It is intended though that all such variations not departing from the spirit of the invention be considered as within the scope thereof.
Patent Application
20090079147
