AU2021334349A1 - Caster angle adjuster - Google Patents

Abstract

A vehicle may include a frame, a drive wheel, a caster, and at least one adjustable inset. The frame may include a receiver and a pair of substantially parallel lateral frame members disposed on each side of a centerline of the vehicle. The drive wheel may be coupled to the frame. The caster may include a caster wheel, a caster stem including a stem proximal end, a stem distal end, and a stem proximal-distal axis disposed at a caster stem angle relative to the frame. The at least one adjustable inset may be configured alignable in a plurality of configurations with the receiver. Each configuration may correspond to a different caster stem angle. The at least one adjustable inset may be disposed between the receiver and the centerline of the vehicle.

Description

TITLE OF THE INVENTION

[0001] Caster Angle Adjuster

CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63/071,213 filed August 27, 2020 entitled “Caster Angle Adjuster”, which is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

[0003] The present disclosure relates to vehicles and, more particularly, to vehicles with an adjustable wheel or track. Mobility vehicles may include wheels or tracks to move the vehicle. The orientation of the wheels or tracks may influence performance characteristics of the vehicle. It may be desirable to allow orientation adjustment of the wheels or tracks to tailor the performance characteristics of the vehicle to a user’s preference.

BRIEF SUMMARY OF THE INVENTION

[0004] A vehicle may include a frame, a drive wheel, a caster, and at least one adjustable inset. The frame may include a receiver and a pair of substantially parallel lateral frame members disposed on each side of a centerline of the vehicle. The drive wheel may be coupled to the frame. The caster may include a caster wheel, a caster stem including a stem proximal end, a stem distal end, and a stem proximal-distal axis disposed at a caster stem angle relative to the frame. The at least one adjustable inset may be configured alignable in a plurality of configurations with the receiver. Each configuration may correspond to a different caster stem angle. The at least one adjustable inset may be disposed between the receiver and the centerline of the vehicle.

[0005] The pair of substantially parallel lateral frame members may include a first section and a second section. A first lateral side of the first section may lie in a first plane, a second lateral side of the first section may lie in a second plane opposite the first plane, and the at least one adjustable inset may be positioned between the first plane and the second plane. The receiver may be within a housing and the housing may be integral with the frame. The caster stem may be positioned on a first side of the frame and the adjustable inset may be positioned on a second side of the frame opposite the first side. The receiver may comprise a channel and a width of the channel may be approximately a width of the at least one adjustable inset. The plurality of configurations may include up to eight configurations. [0006] The adjustable inset may be a first adjustable inset and the vehicle may further comprise a second adjustable inset alignable in a plurality of configurations with the receiver. Each configuration may correspond to a different caster stem angle. Each of the first adjustable inset and the second adjustable inset may be alignable in a plurality of configurations for a total of 64 configurations. The at least one adjustable inset may be disposable at least partially within the receiver. The at least one adjustable inset may be detachably coupled to the frame.

[0007] The caster may be coupled to the frame by a fastener and the at least one adjustable inset may comprise a bushing configured to receive the fastener. The bushing may include an eccentric opening configured to receive the fastener. The bushing may include a body having a first surface, a second surface opposite the first surface, and a sidewall extending from the first surface to the second surface. The sidewall may define an opening to receive the fastener. An opening center point at the first surface may be offset from a body center point at the first surface. The opening may be disposed about an opening central axis extending from the first surface to the second surface. The body may be disposed about a body central axis. The opening central axis may be offset from the body central axis.

[0008] The frame may include a first section, a second section, and the receiver may be within a housing coupled to each of the first section and the second section. The at least one adjustable inset may be positioned at least partially within the receiver. The housing, the first section, and the second section may be a unitary construct. The housing may include a recess and the at least one adjustable inset may be within the recess.

[0009] In a further embodiment, the vehicle may comprise a cover detachably coupled to the housing. The cover may be configured to cover the at least one adjustable inset when the cover is coupled to the receiver. The receiver may comprise a channel configured to receive the at least one adjustable inset. The at least one adjustable inset may be configured to be positioned at a plurality of positions along a length of the channel, each of the plurality of positions corresponding to at least one of the plurality of configurations. At least one of a rotational orientation and position of the at least one adjustable inset along the channel of one configuration of the plurality of configurations of the at least one adjustable inset may be different than another configuration of the plurality of configurations of the at least one adjustable inset.

[0010] The channel may be defined by a first sidewall and a second sidewall, the first sidewall being generally parallel to the second sidewall. The first sidewall may be generally horizontal when the vehicle is on a generally horizontal surface. The at least one adjustable inset may be sized and shaped to fit within the channel in a plurality of orientations. The caster stem angle may be different when the at least one adjustable inset is positioned within the channel for each orientation of the plurality of orientations.

[0011] In a further embodiment, the vehicle includes a caster stem housing coupled to the frame, the caster stem housing being configured to receive the caster stem. The caster stem housing may be coupled to the frame by a fastener. In a further embodiment, the vehicle includes a restraint bracket coupled to the frame between the caster stem housing and the frame. The restraint bracket may be detachably coupled to the frame. The restraint bracket may be positioned between the frame and the caster stem housing when the caster stem housing and the restraint bracket are coupled to the frame. In a further embodiment, the vehicle includes a first motor coupled to the drive wheel, a second drive wheel coupled to the frame, and a second motor coupled to the second drive wheel. The vehicle may include a controller configured to send a first drive signal to the first motor and a second drive signal to the second motor. The first drive signal may be independent of the second drive signal.

[0012] In a further embodiment, a vehicle may include a frame having a first section, a second section, a housing, a drive wheel, a caster, an adjustable inset, and a cover. The first section may be disposed on a first side of a centerline of the vehicle. The second section may be disposed on a second side of the centerline of the vehicle opposite the first side. The housing may be fixed to each of the first section and the second section. The housing may include a receiver. The drive wheel may be coupled to the frame. The caster may include a stem disposed along a longitudinal axis oriented at a selected caster stem angle relative to the frame. The adjustable inset may be within the receiver. The adjustable inset may be disposed between the receiver and the centerline of the vehicle. The adjustable inset may be configured to selectively adjust the selected caster stem angle. The cover may be coupled to the housing. The cover may cover the at least one adjustable inset. [0013] In a further embodiment, the vehicle may include a caster stem housing configured to receive the caster stem. The caster stem housing may be coupled to the frame. In a further embodiment, the vehicle may include a restraint bracket coupled to the frame between the caster stem housing and the frame. The restraint bracket may be detachably coupled to the frame. The caster stem may be positioned on a first side of the first section and the at least one adjustable inset may be positioned on a second side of the first section opposite the first side.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0014] The foregoing summary, as well as the following detailed description of embodiments of the caster angle adjustment mechanism, will be better understood when read in conjunction with the appended drawings of an exemplary embodiment. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. For example, although not expressly stated herein, features of one or more various disclosed embodiments may be incorporated into other of the disclosed embodiments.

[0015] In the drawings:

[0016] Fig. l is a perspective view of a vehicle including a caster angle adjustment mechanism in accordance with an exemplary embodiment of the present invention;

[0017] Fig. 2 is a side elevational view of the vehicle of Fig. 1;

[0018] Fig. 3 is a front perspective view of a frame of the vehicle of Fig. 1;

[0019] Fig. 4 is a side elevational view of a frame member of the vehicle of Fig. 1;

[0020] Fig. 5 is a bottom perspective close-up view of the frame of the vehicle of Fig. 1;

[0021] Fig. 6 is a side elevational view of the caster angle adjustment mechanism of the vehicle ofFig. 1;

[0022] Fig. 7 is an exploded view of the caster angle adjustment mechanism of the vehicle shown in Fig. 1;

[0023] Fig. 8 is a close up exploded view of the caster angle adjustment mechanism of the vehicle shown in Fig. 1;

[0024] Fig. 9 is a cross-sectional view of a stem housing of the vehicle of Fig. 1;

[0025] Fig. 10 is a side elevational view of an inset of the caster angle adjustment mechanism of the vehicle shown in Fig. 1;

[0026] Fig. 11 is a side elevational view of a portion of the vehicle shown in Fig. 1;

[0027] Fig. 12 is a chart depicting different orientations of insets;

[0028] Fig. 13 is a side elevational view of in accordance with another embodiment of the present invention; and

[0029] Fig. 14 is a side elevational view of the frame shown in Fig. 13 and caster angle adjustment mechanism.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION

[0030] Some vehicles include a frame, a seat for a user, and a plurality of wheels. The orientation of the frame relative to the ground may be influenced by the size or orientation of the wheels relative to the frame. Certain drive characteristics of the vehicle may be adjusted by selectively changing the orientation of the wheels relative to the frame. [0031] Referring to the drawings in detail, wherein like reference numerals indicate like elements throughout, there is shown in Figs. 1-14 a vehicle (e.g., a wheelchair or scooter), generally designated 30, including a caster angle adjustment system in accordance with an exemplary embodiment of the present invention.

[0032] In some embodiments, the vehicle 30 may be a wheelchair. In some embodiments, the vehicle 30 includes a means for moving the vehicle 30. The means for moving the vehicle may include one or more first wheels or drive wheels 32 and one or more second wheels or casters 34. In some embodiments, the vehicle 30 includes a receiving area 102 for a user. In some embodiments, a user can at least one of sit, stand, or lie in the receiving area 102 while the vehicle 30 moves. In some embodiments, the receiving area is supported by a frame 40. In some embodiments, the means for moving the vehicle 30 is coupled to the frame 40 such that a force applied to one of the wheels (e.g., a force applied to drive wheel 32 by a user or a motor) or the frame 40 (e.g., by someone pushing the vehicle) moves the vehicle 30.

[0033] Referring to Fig. 1, in some embodiments, the receiving area 102 is a seat 36 on which a user can sit, stand, or kneel. The seat 36 may include a seat back 38. The seat 36 and/or seat back 38 may be pliable to allow the vehicle 30 to be folded into a compact configuration for transport and storage, as explained in greater detail below. In some embodiments, the seat back 38 may include additional a storage pouch disposed on one or more sides of the seat back 38. In some embodiments, handles 46 extend from the seat back 38. Handles 46 may be configured to be engaged by someone pushing or pulling the vehicle 30.

[0034] In mobility devices, such as vehicle 30, it may be desirable to provide a support structure or frame 40 to which various components can be coupled. Referring to Figs. 1-6, in some embodiments, the frame 40 may include one or more frame members. Frame 40 may include a pair of substantially parallel lateral frame members disposed on each side of a centerline C-C of the vehicle (Fig. 3). Frame 40 may include a first frame member 48 and a second frame member 50. First frame member 48 may be disposed opposite the second frame member 50. First frame member 48 may be spaced from second frame member 50. First frame member 48 may be coupled to second frame member 50 by cross member 52, as explained in greater detail below.

[0035] In some embodiments, the shape of frame 40 provides greater clearance for a wheel (e.g., caster 34) than existing frames. In some embodiments, frame 40 is sized and dimensioned such that the orientation of the caster 34 relative to the frame may be adjusted, as explained in greater detail below. In some embodiments, frame 40 is sized and dimensioned such that the orientation of the caster 34 relative to the frame may be adjusted to a greater degree than existing designs. [0036] The pair of substantially parallel lateral frame members may include a first section and a second section. In some embodiments, at least one of first frame member 48 and second frame member 50 includes a first section 68 and a second section 70. In some embodiments, first section 68 and second section 70 are tubular metal elements (e.g., steel, magnesium, or aluminum). In other embodiments, first section 68 and second section 70 are reinforced polymer or plastic. A first lateral side of the first section 68 may lie in a first plane Pi (Fig. 3). A second lateral side of the first section 68 may lie in a second plane P2. The first plane Pi may be opposite the second plane P2. [0037] Referring to Fig. 4, in some embodiments, the first section 68 of frame 40 includes a first portion 105 and a second portion 107. In some embodiments, the first portion 105 includes a first longitudinal axis 104. In some embodiments, the second portion 107 includes a second longitudinal axis 106. In some embodiments, first section 68 includes a third portion 109. In some embodiments, the third portion 109 includes a third longitudinal axis 108. In some embodiments, the first longitudinal axis 104 and third longitudinal axis 108 are generally parallel to each other. In other embodiment, the first longitudinal axis 104 and third longitudinal axis 108 are transverse to each other. In some embodiments, angle 110 defines the intersection of the first longitudinal axis 104 and the second longitudinal axis 106. In some embodiments, the angle 110 is about 10°, 20°, 30°, 40°, 50°, 60°, 70°, or 80°

[0038] In some embodiments, second section 70 includes second section axis 90. In some embodiments, second section axis 90 is perpendicular to at least one of first longitudinal axis 104 and third longitudinal axis 108. In some embodiments, first frame member 48 includes a third section 150. In some embodiments, third section 150 includes a third section axis 152. In some embodiments, the third section axis 152 may be generally parallel with the third longitudinal axis 108. In some embodiments, first frame member 48 includes an angled portion 154 which includes an angled portion axis 155. In some embodiments, the angled portion 154 connects to second section 70 and third section 150. In some embodiments, angle 153 defines the intersection of the second section axis 90 and angled portion axis 155. In some embodiments, the angle 153 is about 10°, 20°, 30°, 40°, 50°, 60°, 70°, or 80°

[0039] In some embodiments, at least one of the first section 68 and second section 70 are coupled to a receiver housing 66. In some embodiments, the first section 68 and second section 70 are each coupled to the receiver housing 66. In some embodiments, the receiver housing 66 has a generally circular outer shape and is defined by an outer surface which extends circumferentially around the receiver housing 66. In other embodiments, the receiver housing 66 may have a generally rectangular, square, or hexagonal shape. In some embodiments, the receiver housing 66 forms the junction of the first section 68 and the second section 70. In some embodiments, the receiver housing 66 forms the junction of the first section 68 and the second section 70 such that the first section 68 and second section 70 do not directly contact each other. In some embodiments, the receiver housing 66 includes at least one member recess 118 (Fig. 7) configured to receive at least one of the first section 68 and second section 70. Receiver housing 66 may be integral with frame 40.

[0040] Receiver housing 66 may include an aperture configured to receive at least one fastener that may be used to couple a caster stem housing to the frame 40. Referring to Figs. 6-9, in some embodiments, the receiver housing 66 includes a recess 67. In some embodiments, recess 67 is configured to receive a fastener 72. In some embodiments, recess 67 is configured to receive an eccentric fastener (c.g, inset 82), as explained in greater detail below. In some embodiments, the recess 67 defines an area to receive fastener 72 such that a cap 92 can be coupled to the receiver housing 66 while avoiding contact between the cap and fastener. In some embodiments, the cap 92 is detachably coupled to the receiver housing 66 (e.g., via clip, snap fit, interference fit, magnet, or threaded connection). In some embodiments, the cap 92 may be coupled to the recess 67 such that the outer surface of the cap 92 is flush with the outer surface of the receiver housing 66. Cap 92 may provide a cleaner aesthetic appeal compared to existing designs. Cap 92 may prevent contact between a user or user’s clothing and portions of the frame 40 (e.g., fastener).

[0041] In some embodiments, the recess 67 has a generally circular shape. In some embodiments, the recess 67 has a generally square, rectangular, or hexagonal shape. In some embodiments, the recess 67 is sized to receive fasteners 72 in any of a variety of positions, as explained below. In some embodiments, the recess 67 is bounded on at least a portion of one side by a recess surface 115 (Fig. 9). In some embodiments, the distance from the outer surface 111 of the receiver housing 66 to the recess surface 115 is sized to receive a head of the fastener 72. In some embodiments, the cap 92 seals the recess 67 when the cap 92 is coupled to the receiver housing 66. [0042] The receiver housing 66 may include an alignment means configured to receive an inset. In some embodiments, the alignment means is a channel 120 within recess 67. In some embodiments, the channel 120 is configured to receive an inset 82. In some embodiments, the channel 120 is disposed at least partially in the recess surface 115 (Fig. 9). In some embodiments, the channel 120 is defined by a first sidewall 146 and a second sidewall 148 (Fig. 9). The width of the channel 120 may be the distance between first sidewall 146 and second sidewall 148. The width of the channel may be approximately the width of the inset. In some embodiments, the first sidewall 146 is generally parallel to the second sidewall 148. In some embodiments, the first sidewall 146 may be generally horizontal when the vehicle 30 is on a generally horizontal surface. In some embodiments, first sidewall 146 is spaced from second sidewall 148 such that inset 82 cannot rotate relative to the receiver housing 66 when inset 82 is within channel 120.

[0043] In some embodiments, channel 120 has a depth such that a surface of the inset 82 is flush with the recess surface 115. In some embodiments, channel 120 a depth that is normal to the frame. The depth of the channel 120 may terminate proximate an outer surface of the frame such that the channel 120 is accessible from an interior of the frame and the caster 34 is fixed to an outer part of the frame. In some embodiments, the depth of the channel 120 is selected such that at least a portion of the inset 82 extends closer to the outer surface of the receiver housing 66 than the recess surface 115 such that the inset can be grasped for ease of removal (e.g., manually or with a tool such as pliers or tweezers).

[0044] Referring to Fig. 4, in some embodiments, the first section 68, second section 70, and receiver housing 66 are a unitary construct. In other embodiments, at least one of the first section 68 and the second section 70 are detachable from the receiver housing 66. In some embodiments, the first section 68, second section 70, and receiver housing 66 are manufactured from the same material. In other embodiments, at least one of the first section 68, second section 70, and receiver housing 66 are made out of a different material than another of first section 68, second section 70, and receiver housing 66. In some embodiments, the first section 68 and second section 70 have a fixed position relative to the receiver housing 66. In some embodiments, the orientation of the receiver housing 66 is adjustable relative to at least one of first section 68 and second section 70 while the orientation of the first section 68 relative to second section 70 remains fixed.

[0045] Referring to Fig. 5, in some embodiments at least one of the first section 68 and third section 150 includes an index 122 configured to couple drive wheels 32 to frame 40 in a plurality of positions. In some embodiments, the index 122 includes a plurality of indexing components (e.g., indents, tabs, etc.) that allow adjustment of the position of the drive wheels relative to frame 40. In some embodiments, index 122 includes a crenelated surface configured to mesh with a crenelated surface on frame engaging portion 128.

[0046] Referring to Figs. 4-5, in some embodiments, at least one of first frame member 48 and second frame member includes a span 112. In some embodiments, span 112 may be generally parallel to second section (or segment) 70. In some embodiments, span 112 includes one or more apertures 119 . In some embodiments, the apertures 119 are configured to receive fasteners coupled to additional elements (e.g., an oxygen tank holder, an anti-tip bar). In some embodiments, the first section 68, second section 70 and span 112 are a unitary construct. [0047] It may be desirable for a vehicle to be selectively folded and unfolded. In such a vehicle, it is desirable to ensure that the vehicle remains in the unfolded or expanded configuration during use. Referring to Fig. 3, in some embodiments, the frame 40 may include one or more cross members 52. Cross members 52 may extend from first frame member 48 to second frame member 50 of frame. In some embodiments, cross members 52 maintain the position of the first frame member 48 relative to the second frame member 50. In some embodiments, the cross members 52 are telescopic members that extend to allow a user to selectively adjust the effective width of frame 40 to one of a selected plurality of widths. In some embodiments, the cross members 52 are detachably coupled to at least one of first frame member 48 and second frame member 50 such that the vehicle 30 can be folded into a compact configuration. In some embodiments, cross members 52 includes a first cross member 124 and a second cross member 126. In some embodiments, the first cross member 124 and second cross member 126 are pinned to each other in a scissor configuration. In some embodiments, cross members 52 are fixed to frame 40. In some embodiments, cross members 52 and frame 40 are a unitary construct.

[0048] In some embodiments, the cross members 52 includes a locking mechanism 54 configured to prevent unintentional folding of frame 40. In some embodiments, the locking mechanism 54 may be configured to be released (e.g., manually or via a powered actuator) from a locked state where the frame 40 is prevented from folding to an unlocked state where the frame 40 can be folded. In some embodiments, locking mechanism 54 is attached to second frame member 50 of frame 40. In some embodiments, locking mechanism 54 is attached to first frame member 48 of frame 40. In some embodiments, the locking mechanism may be attached to both the first frame member 48 and second frame member 50 of frame 40.

[0049] In mobility devices, such as vehicle 30, it can be desirable to include a means for propulsion. Such means for propulsion may include wheels (e.g., drive wheels 32) or a track system (not shown). Referring to Figs. 1-5, in some embodiments, drive wheels 32 may be attached on opposing sides of frame 40. In other embodiments, vehicle 30 may include a single drive wheel 32 on one side or in the middle of frame 40. In some embodiments, drive wheels 32 may have a diameter greater than the diameter of caster wheels 34. In some embodiments, the greater diameter of the drive wheels 32 relative the caster wheels 34 provides greater stability to the vehicle when the majority of the weight is distributed over the drive wheels 32. In some embodiments, the greater diameter of the driver wheels 32 relative to the caster wheels 34 makes it easier to turn the vehicle. In some embodiments, the drive wheels 32 are attached to a rear portion of frame 40. In other embodiments, drive wheels 32 are attached to a front portion of frame 40. In some embodiments, drive wheels 32 include drive handles 56 configured to be manually engaged by a user. In some embodiments, each drive wheel 32 is rotatable independently of the other drive wheel.

[0050] Referring to Figs. 2 and 5, in some embodiments vehicle 30 includes a drive wheel coupling mechanism 88 attached to the frame 40. In some embodiments, the drive wheel coupling mechanism 88 provides for adjustment of the position of the drive wheel relative to the frame. In some embodiments, the drive wheel coupling mechanism 88 extends at least partially between the first section 68 and third section 150. In some embodiments, the drive wheel coupling mechanism 88 includes a frame engaging portion 128. In some embodiments, the frame engaging portion 128 is configured to couple (e.g., directly couple) to at least one of the first section 68 and third section 150. In some embodiments, frame engaging portion 128 couples to indexing features 122 of the frame 40 such that the position of the drive wheel 32 can be adjusted along two axes (e.g., horizontally and vertically).

[0051] In some embodiments, the drive wheel coupling mechanism 88 may include a receiving component 130 (e.g., a pillow block bearing) to couple drive wheels 32 to drive wheel coupling mechanism 88. In some embodiments, the drive wheel 32 is configured to rotate about a drive wheel axle 113. In some embodiments, the receiving component 130 receives at least a portion of the drive wheel axle 13. In some embodiments, the receiving component 130 includes a flange configured to receive a fastener to couple the receiving component to the frame 40.

[0052] In some embodiments the drive wheel coupling mechanism 88 includes an opening 117. Drive wheel axle 113 may extend through the opening 117. Opening 117 may be an elongated opening such that drive wheel axle 113 can extend through the opening at any one of a plurality of positions. In some embodiments, the drive wheel coupling mechanism 88 includes one or more apertures 137 adjacent the opening 117. Apertures 137 may be configured to receive a fastener to detachably couple receiving component 130 to the drive wheel coupling mechanism 88 in a plurality of positions. In some embodiments, the drive wheel coupling mechanism 88 allows a user to adjust the position of the drive wheel 32 with respect to the seat 36 to allow a user to adjust the height and/or angle of the seat 36 relative to the ground. In some embodiments, the position of each drive wheel 32 relative the seat 36 may be adjusted independently of one another. In some embodiments, the drive wheel coupling mechanism 88 may include notches or indicia to indicate the relative position of the respective drive wheel 32 to the seat 36.

[0053] In some embodiments, the vehicle 30 may include a first drive wheel and a second drive wheel. In some embodiments, the vehicle 30 includes a drive motor coupled to at least one of first drive wheel and second drive wheel. In some embodiments, vehicle 30 includes a first motor coupled to the first drive wheel and a second motor coupled to the second drive wheel. In some embodiments, the first motor and second motor may be configured to drive the first and second drive wheels respectively such that the vehicle 30 is propelled in a selected direction. In some embodiments, the vehicle 30 may include a controller configured to send a first drive signal to the first motor and a second drive signal to the second motor. In some embodiments, vehicle 30 includes a steering input mechanism (e.g., steering wheel joystick, directional pad, or sip and puff controller) to send a steering signal to the controller indicative of a desired direction of travel. In some embodiments, the controller is configured to send a signal to at least one of the first motor and the second motor in response to receiving the steering signal. In some embodiments, the first motor and the second motor are configured to cause rotation of the respective drive wheels in response to receiving the signal from the controller. In some embodiments, the first drive signal is independent of the second drive signal. In some embodiments, the first drive wheel and second drive wheel may be rotated by the respective first and second motors in the same direction. In some embodiments, the first drive wheel and second drive wheel may be rotated by the respective first and second motors in opposite directions. In some embodiments, the first drive wheel and second drive wheel may be rotated by the respective first and second motors in the same direction but at different rotational velocities.

[0054] Some mobility vehicles include drive wheels to move the vehicle and one or more additional wheels (e.g., caster wheels) that allow the vehicle to move and change directions. In some embodiments, adjusting the orientation of the caster wheel relative to the frame may affect performance characteristics of the vehicle (e.g., stability or the force required to move the vehicle). Referring to Figs. 6-11, in some embodiments, a caster 34 is coupled to one or both of first frame member 48 and second frame member 50. In some embodiments, caster 34 is detachably coupled to receiver housing 66. In some embodiments, caster 34 is detachably coupled to first frame member 48 or second frame member 50 via receiver housing 66. In some embodiments, caster 34 is coupled to a first side of receiver housing 66 and the caster stem angle adjustment mechanism 80 is coupled to an opposite side of the receiver housing 66.

[0055] In some embodiments, caster 34 includes a caster wheel 58 and a wheel coupling component 64 (Figs. 2 and 11). In some embodiments, caster wheel 58 is detachably coupled to wheel coupling component 64. In some embodiments, wheel coupling component 64 has a forked shape defined by an upper surface 140 and two legs 132 extending from the upper surface 140. In some embodiments, caster wheel 58 is coupled to each of legs 132 such that caster wheel 58 is positioned between legs 132. In some embodiments, when caster wheel 58 is coupled to legs 132, there is a clearance between an upper end of caster wheel 58 and a lower end of upper surface 140 such that the caster wheel 58 is able to rotate about an axle coincident with caster wheel axis 43 (Fig. 1). In some embodiments, each of the legs 132 includes a plurality of openings 133, each configured to receive wheel axle. In some embodiments, the plurality of openings to allow the height of caster wheel 58 relative to legs 132 to be adjusted.

[0056] In some embodiments, a caster stem 60 is coupled to wheel coupling component 64. In some embodiments the caster stem 60 extends from wheel coupling component 64 along a stem axis 138. In some embodiments the caster stem 60 includes a stem proximal end 76 and a stem distal end 78. A bearing (e.g., plain bearing, ball bearing, roller bearing, or bushing) may be coupled to one or both of the stem proximal end 76 and stem distal end 78.

[0057] In some embodiments, the stem axis 138 extends along the proximal-distal axis of the caster stem 60. In some embodiments, the caster 34 is configured to rotate about the stem axis 138. In some embodiments, the stem axis 138 is perpendicular to the upper surface 140 of the wheel coupling component 64. In some embodiments, the orientation of the stem axis 138 relative to the frame 40 is adjustable, as explained in greater detail below. In some embodiments, the wheel coupling component 64 extends at an angle relative to the stem axis such that a vertical center of the caster wheel 58 is offset from the stem axis 138. In some embodiments, the caster wheel 58 being offset from the stem axis allows for easier rotation of the caster 34 about the stem axis 138 compared to a caster wheel that is not offset.

[0058] In some embodiments, stem 60 is coupled to stem housing 62. In some embodiments the caster stem 60 is sized and shaped to fit within an opening 116 of the stem housing 62. In some embodiments, the stem is rotatably coupled to stem housing 62 such that the caster stem 60 can rotate about the stem axis 138 while caster stem 60 is coupled to stem housing 62. In some embodiments, the caster wheel is rotatable about a first axis (e.g., caster wheel axis 43) and about a second axis (e.g., caster stem axis 138). In some embodiments, caster wheel is also rotatable about a third axis (e.g., fastener axis 42), as explained in greater detail below.

[0059] In some embodiments, the stem opening 116 extends from a proximal surface 142 to distal surface 144 of stem housing 62. In some embodiments, stem opening 116 is sized and shaped to receive caster stem 60. In some embodiments, stem opening 116 is defined by a sidewall that extends circumferentially around the stem axis 44 when the caster stem 60 is coupled to stem housing 62. In some embodiments, stem 60 is able to rotate freely about the stem axis 44 when the caster stem 60 is received within stem opening 116. In some embodiments, cap 135 is received in a proximal end of stem opening 116 (Fig. 3). In some embodiments, stem opening 116 is sized such that there is a space between stem 60 and cap 134 when the cap is coupled to stem housing 62 such that no interference to the rotation of caster stem 60 is caused by cap 134. In some embodiments, bearings and/or bushings are positioned within stem opening 116 such that caster stem 60 does not contact stem housing 62.

[0060] Referring to Fig. 9, in some embodiments, stem opening 116 includes at least one ridge 136. Ridge 136 may be a bearing shoulder or stop. Ridge 136 may have an extruded spline form for weight savings compared to other designs. In some embodiments, the caster stem 60 is detachably coupled to the stem housing 62. In some embodiments, stem opening 116 is symmetrical about a vertical axis such that the stem housing 62 can be flipped about the horizontal axis relative to the frame 40 and still receive the caster stem 60 within the stem opening 116.

[0061] Caster 34 or stem housing 62 may be detachably coupled to the frame 40. In some embodiments, caster 34 is coupled to the receiver housing 66 by a fastener 72. In some embodiments the fasteners 72 are bolts. In other embodiments, the fasteners are rivets, dowels, or cotter pins. In some embodiments, the fasteners 72 have a threaded portion configured to threadably engage threaded openings 74 in the stem housing 62. In some embodiments, the more than one fastener 72 couples the caster stem housing to the receiver housing 66. In some embodiments, each fastener 72 has the same diameter and/or length. In some embodiments, the fastener 72 extends through inset 82 within the receiver housing 66.

[0062] It may be desirable to change the caster stem angle Ai to adjust performance characteristics of the vehicle 30 (e.g., force required to move the vehicle or vehicle stability) or for user comfort (e.g., by adjusting the orientation of the seat 36 relative to the ground). With further reference to Fig. 6-12, in some embodiments, the vehicle 30 may include caster stem angle adjustment mechanism 80 to adjust the angle of the caster stem 60. In some embodiments, the caster stem angle adjustment mechanism includes one or more of the receiver housing 66, at least one fastener 72, inset 82, and the caster stem housing 62.

[0063] In some embodiments, the caster stem angle adjustment mechanism 80 is configured to allow a user to selectively set the angle Ai of the caster stem 60 relative to the second section axis 90 (Fig. 6) at one of a plurality of caster stem angles. In some embodiments, the angle Ai of the caster stem 60 is defined by the offset angle of the stem axis 138 with respect to the second section axis 90. In some embodiments, the angle of the caster stem 60 relative to the second section axis 90 can influence the resistance to movement of the casters 34. In some embodiments, the caster stem 60 remains vertical regardless of the orientation of the frame relative to the ground, the caster wheel size, or the caster fork size. The angle Ai may increase the resistance to rotation of the caster. At least a portion of the frame 34 may be lifted or elevated each time the caster rotates about the caster stem axis when the seat 36 or frame 40 are oriented other than parallel to the ground.

[0064] In some embodiments, orientation of the caster stem housing 62 is influenced by the orientation of the inset 82 within the alignment means. In some embodiments, the orientation of inset 82 determines the angle of the caster stem 60. Referring to Figs. 9-12, in some embodiments, the inset 82 includes a plurality of opposing exterior sidewalls 156 that are sized and shaped to fit within channel 120 in alignment means. Exterior sidewalls 156 may be opposing surface generally aligned (e.g., parallel) such that two sidewalls 156 engage sidewall of channel 120. In some embodiments, inset 82 includes 8 sidewalls 156. In other embodiments, inset 82 includes 4, 6, 10, or 12 sidewalls. The inset may be disposed between the alignment means and the centerline C-C of the vehicle 30.

[0065] In some embodiments, the inset sidewalls 156 are sized and shaped to engage the first sidewall 146 and second sidewall 148 of the channel 120. In some embodiments, the inset sidewalls 156 engage the sidewalls of the channel 120 such that the inset is prevented from rotating when the inset is within the channel 120. In some embodiments, the exterior sidewalls 156 have generally the same size and are equally spaced about inset 82. Inset may include a selected number of exterior sidewall segments. An inset with a greater number of sidewalls may allow for smaller incremental changes in the caster stem angle, as explained in greater detail below. An inset with a smaller number of sidewalls may provide greater resistance to rotation because of the increased surface area of the inset sidewall engaged with the sidewalls of the channel. In some embodiments, the engagement of fastener 72 with stem housing 62 and the shape of the fastener head in contact with the inset 82 keeps inset 82 within channel 120.

[0066] Referring to Fig. 10, in some embodiments, inset 82 comprises a bushing configured to receive fastener 72. Inset may include an opening 86 to receive fastener 72. In some embodiments, opening 86 is an eccentric opening relative to the body 94 of inset 82. In some embodiments, the opening is defined by an opening sidewall 98. In some embodiments, the opening sidewall 98 is configured to engage a non-threaded portion of the fastener 72. In other embodiments, the opening sidewall 98 is threaded to engage threads on the fastener 72.

[0067] Still referring to Fig. 10, in some embodiments, inset 82 includes body 94 having a first surface 96 and a second surface (not shown) opposite the first surface 96. In some embodiments, the opening sidewall 98 extends from the first surface 96 to the second surface. In some embodiments, the opening 86 includes an opening central axis Oi at the first surface 96. In some embodiments, the body 94 includes a body central axis Bi at the first surface 96. In some embodiments, the opening central axis Oi is offset from the body central axis Bi. In some embodiments, the offset of the opening central axis Oi from the body central axis Bi causes the opening central axis Oi to change relative to channel 120 as the inset 82 is rotated about the body central axis Bi. In some embodiments, inset 82 includes indicia 100 to allow a user to easily identify the orientation (e.g., rotational alignment about body central axis Bi) of the respective inset 82. In some embodiments, the indicia 100 may be a notch or visual indicator.

[0068] In some embodiments, inset 82 may be positioned in a one of a plurality of positions relative to the receiver housing 66. Each position may be associated with one or more particular caster stem angles Ai. It will be understood that additional positions not shown here may be used corresponding to additional caster stem angles. In some embodiments, the position or orientation of the inset 82 is changed or adjusted by removing the inset 82 from the channel 120, rotating the inset 82 about the body central axis Bi, and reinserting the inset 82 into the channel 120.

[0069] Referring to Fig. 8, in some embodiments, first inset 82A and second inset 82B are disposed between the caster stem housing 62 to the frame 40. As the orientation of the first inset 82A or the second inset 82B is changed, the orientation of the respective opening central axis Oi of the inset changes relative to the channel 120. In some embodiments, the position of the fastener 72 extending through the opening 86 relative to the frame is influenced by the position of the opening central axis Oi of the inset 82. Angle Ai is influenced by the position of the fastener 72 relative to the frame when the fastener 72 is coupled to caster stem housing 62. In some embodiments, each different position of the central opening axis Oi corresponds to a different angle Ai when the fastener 72 is coupled to caster stem housing 62.

[0070] In some embodiments, the first inset 82A and second inset 82B may be selectively oriented into one or more orientations or combinations of orientations. Some of these orientations are shown in Fig. 12. Each orientation may correspond to a different angle Ai. Table 1 describes some combinations of the orientations of first inset 82 A and second inset 82B.

Table 1

[0071] At least one of a rotational orientation and position of inset 82 along the channel 120 of one configuration of the plurality of configurations of the inset 82 may be different than another configuration of the plurality of configurations of the inset 82. The combination of first inset 82A and second inset 82B may be positioned in up to sixty -four different configurations. The caster stem angle Ai may be different when the inset 82 is within the channel 120 for each orientation of the plurality of orientations.

[0072] In some embodiments, the first inset 82A may be forward and/or downward of second inset 82B when the vehicle 30 is on a horizontal surface. In some embodiments, second inset 82B may be rearward and/or upward of first inset 82A when the vehicle 30 is on a horizontal surface. In some embodiments, first inset 82 A and second inset 82B are horizontally aligned (e.g., parallel) when the vehicle is on a horizontal surface such that the fasteners 72 are generally horizontally aligned. The fasteners 72 being horizontally aligned may provide greater resistance to rotation of the caster stem housing 62 compared to designs where the fasteners 72 are vertical or horizontally offset.

[0073] In some embodiments, the caster stem angle changes by discrete increments corresponding to the number of exterior sidewalls 158 of each inset 82. In some embodiments, first inset 82A and second inset 82B each have the same number of exterior sidewalls 158 such that rotation of either of first inset 82A or second inset 82B changes angle Ai by the same increment. In other embodiments, first inset 82A and second inset 82B have a different number of exterior sidewalls 158 such that angle Ai changes by a different increment when first inset 82A is rotated compared to when second inset 82B is rotated.

[0074] In some embodiments, each time at least one of the first inset 82A or second inset 82B is rotated, angle Ai is adjusted in increments which may be about 0.5 degrees per rotation, about 1.0 degree per rotation of the inset, 1.5 degrees per rotation, about 2 degrees per rotation, about 3 degrees per rotation, about 4 degrees per rotation, about 5 degrees per rotation, about 0.25 degrees to about 1 degree per rotation, about 1 degree to about 2 degrees per rotation, about 2 degrees to about 3 degrees per rotation, about 3 degrees to about 4 degrees per rotation, about 4 degrees to about 5 degrees per rotation, or less than 5 degrees per rotation.

[0075] Inset 82 may be positioned at various positions along the length of the channel 120. The position of the inset 82 along the length of the channel 120 may correspond to the orientation of the opening 86 of the inset. The position of the opening 86 along the length of the channel 120 may be different for one or more orientations of the inset 82 relative to the channel 120. The inset may move along the length of the channel 120 to accommodate for the change in position of the opening 86 such that the fasteners 72 are still coupleable to the opening 74 in the stem housing 62.

[0076] In some embodiments, a restraint bracket 84 is detachably coupled to the frame 40 by fasteners 72. In some embodiments, the restraint bracket 84 is positioned between the receiver housing 66 and the caster stem housing 62. In some embodiments, restraint bracket 84 is interior to the frame 40. In other embodiments, restraint bracket 84 is exterior to frame 40. In other embodiments, restraint bracket 84 is positioned exterior to caster stem housing 62. In some embodiments, the restraint bracket 84 is configured to receive a restraint (e.g., a strap or seatbelt) to secure the vehicle 30 to another structure. In some embodiments, the restraint bracket 84 includes a closed loop. In some embodiments, a closed loop restraint bracket may receive a strap or be engaged by a clip (e.g., a carabiner). In other embodiments, the restraint bracket 84 is a clip, buckle, shackle, chain, rope, or strap. In some embodiments, the orientation of the restraint bracket 84 changes as the caster stem angle changes.

[0077] Referring to Figs. 13-14, there is shown another embodiment of a frame member, generally designated 248. Frame member 248 is similar to first frame member 48, but includes a generally straight first section 68. Frame member 248 may provide a higher seat height compared to frame member 48. [0078] Frame member 48 may be designed for users with hemiplegia. Frame member 48 may be designed for users with one side paralyzed or having limited functionality. Frame 48 may be designed for users who utilize a foot to propel the vehicle.

[0079] It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concepts thereof. It is understood, therefore, that this invention is not limited to the exemplary embodiments shown and described, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the claims. For example, specific features of the exemplary embodiments may or may not be part of the claimed invention and various features of the disclosed embodiments may be combined. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”.

[0080] It is to be understood that at least some of the figures and descriptions of the invention have been simplified to focus on elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention. However, because such elements are well known in the art, and because they do not necessarily facilitate a better understanding of the invention, a description of such elements is not provided herein.

[0081] Further, to the extent that the methods of the present invention do not rely on the particular order of steps set forth herein, the particular order of the steps should not be construed as limitation on the claims. Any claims directed to the methods of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the steps may be varied and still remain within the spirit and scope of the present invention.

Claims (38)

CLAIMS I/we claim:

1. A vehicle including a caster wheel comprising: a frame having a receiver, the frame including a pair of substantially parallel lateral frame members disposed on each side of a centerline of the vehicle; a drive wheel coupled to the frame; a caster having a caster stem including a stem proximal end, a stem distal end, and a stem proximal-distal axis disposed at a caster stem angle relative to the frame; and at least one adjustable inset alignable in a plurality of configurations with the receiver, each configuration corresponding to a different caster stem angle, the at least one adjustable inset disposed between the receiver and the centerline of the vehicle.

2. The vehicle of claim 1, wherein the pair of substantially parallel lateral frame members includes a first section and a second section, wherein a first lateral side of the first section lies in a first plane, a second lateral side of the first section lies in a second plane opposite the first plane, and the at least one adjustable inset is positioned between the first plane and the second plane.

3. The vehicle of claim 1, wherein the receiver is within a housing and the housing is integral with the frame.

4. The vehicle of claim 1, wherein the caster stem is positioned on a first side of the frame and the adjustable inset is positioned on a second side of the frame opposite the first side.

5. The vehicle of claim 1, wherein the receiver comprises a channel and a width of the channel is approximately a width of the at least one adjustable inset.

6. The vehicle of claim 1, wherein the plurality of configurations includes up to eight configurations.

7. The vehicle of claim 1, wherein the adjustable inset is a first adjustable inset and the vehicle further comprises: a second adjustable inset alignable in a plurality of configurations with the receiver, each configuration corresponding to a different caster stem angle.

8. The vehicle of claim 7, wherein each of the first adjustable inset and the second adjustable inset are alignable in a plurality of configurations for a total of 64 configurations.

9. The vehicle of claim 1, wherein the at least one adjustable inset is disposable at least partially within the receiver.

10. The vehicle of claim 1, wherein the at least one adjustable inset is detachably coupled to the frame.

11. The vehicle of claim 1, wherein the caster is coupled to the frame by a fastener and the at least one adjustable inset comprises a bushing configured to receive the fastener.

12. The vehicle of claim 11, wherein the bushing includes an eccentric opening configured to receive the fastener.

13. The vehicle of claim 11, wherein the bushing includes a body having a first surface, a second surface opposite the first surface, and a sidewall extending from the first surface to the second surface, the sidewall defining an opening to receive the fastener.

14. The vehicle of claim 13, wherein an opening center point at the first surface is offset from a body center point at the first surface.

15. The vehicle of claim 13, wherein the opening is disposed about an opening central axis extending from the first surface to the second surface, wherein the body is disposed about a body central axis, and wherein the opening central axis is offset from the body central axis.

16. The vehicle of claim 1, wherein the frame includes a first section, a second section, and the receiver is within a housing coupled to each of the first section and the second section, the at least one adjustable inset being positioned at least partially within the receiver.

17. The vehicle of claim 16, wherein the housing, the first section, and the second section are a unitary construct.

18. The vehicle of claim 16, wherein the housing includes a recess and the at least one adjustable inset is within the recess.

19. The vehicle of claim 18, further comprising a cover detachably coupled to the housing, the cover configured to cover the at least one adjustable inset when the cover is coupled to the receiver.

20. The vehicle of claim 18, wherein the receiver comprises a channel configured to receive the at least one adjustable inset.

21. The vehicle of claim 20, wherein the at least one adjustable inset is configured to be positioned at a plurality of positions along a length of the channel, each of the plurality of positions corresponding to at least one of the plurality of configurations.

22. The vehicle of claim 20, wherein at least one of a rotational orientation and position of the at least one adjustable inset along the channel of one configuration of the plurality of configurations of the at least one adjustable inset is different than another configuration of the plurality of configurations of the at least one adjustable inset.

23. The vehicle of claim 20, wherein the channel is defined by a first sidewall and a second sidewall, the first sidewall being generally parallel to the second sidewall.

24. The vehicle of claim 23, wherein the first sidewall is generally horizontal when the vehicle is on a generally horizontal surface.

25. The vehicle of claim 20, wherein the at least one adjustable inset is sized and shaped to fit within the channel in a plurality of orientations.

26. The vehicle of claim 25, wherein the caster stem angle is different when the at least one adjustable inset is positioned within the channel for each orientation of the plurality of orientations.

27. The vehicle of any of claims 1 to 26, further comprising a caster stem housing coupled to the frame, the caster stem housing being configured to receive the caster stem.

28. The vehicle of claim 27, wherein the caster stem housing is coupled to the frame by a fastener.

29. The vehicle of claim 27, further comprising a restraint bracket coupled to the frame between the caster stem housing and the frame.

30. The vehicle of claim 29, wherein the restraint bracket is detachably coupled to the frame.

31. The vehicle of claim 29, wherein the restraint bracket is positioned between the frame and the caster stem housing when the caster stem housing and the restraint bracket are coupled to the frame.

32. The vehicle of any of claims 1 to 30, further comprising: a first motor coupled to the drive wheel; a second drive wheel coupled to the frame; and a second motor coupled to the second drive wheel.

33. The vehicle of claim 32, further comprising: a controller configured to send a first drive signal to the first motor and a second drive signal to the second motor, wherein, the first drive signal is independent of the second drive signal.

34. A vehicle comprising: a frame including: a first section disposed on a first side of a centerline of the vehicle;

22 a second section disposed on a second side of the centerline of the vehicle opposite the first side; and a housing fixed to each of the first section and the second section, the housing including a receiver; a drive wheel coupled to the frame; a caster having a stem disposed along a longitudinal axis oriented at a selected caster stem angle relative to the frame; at least one adjustable inset within the receiver, the at least one adjustable inset disposed between the receiver and the centerline of the vehicle, the at least one adjustable inset configured to selectively adjust the selected caster stem angle; and a cover coupled to the housing, the cover covering the at least one adjustable inset.

35. The vehicle of claim 34, further comprising a caster stem housing configured to receive the caster stem, the caster stem housing coupled to the frame.

36. The vehicle of claim 35, further comprising a restraint bracket coupled to the frame between the caster stem housing and the frame.

37. The vehicle of claim 36, wherein the restraint bracket is detachably coupled to the frame.

38. The vehicle of any of claims 34 to 37, wherein the caster stem is positioned on a first side of the first section and the at least one adjustable inset is positioned on a second side of the first section opposite the first side.

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