Conveyor chain for a stepmill

Abstract

A conveyor chain which is designed to be used on a stepmill to form into steps on the side interacting with a user, but which can fold into a generally flat configuration when returning to the top of the tread. Each step is designed to be formed of four generally identical segments where both the segments forming the tread and kickplate can fold relative to each other and each of the tread and kickplate can fold at a midpoint between two segments.

Claims

1. A conveyor chain for a stepmill, the chain comprising: a plurality of segments, each of said segments comprising a main body including: a top surface; a bottom surface smaller than said top surface and generally parallel thereto; an angled face interconnecting said top surface and said bottom surface; and an edge also interconnecting said top surface and said bottom surface; wherein, said edge and said angled face are not parallel to each other; and wherein said edge has a plurality of eyelets arranged thereon; and a plurality of axial rods; wherein, said plurality of segments are arranged into a conveyor chain by: forming multiple units from said plurality of segments by repeatedly connecting a segment to another segment with a hinge arranged so that said angled faces of said segments can alternatively be in contact with each other and not in contact with each other; interconnecting said multiple units into a chain by threading an axial rod through interleaved eyelets from adjacent units.

2. The conveyor chain of claim 1 wherein said plurality of segments includes at least four segments.

3. The conveyor chain of claim 2 wherein said plurality of segments includes at least eight segments.

4. The conveyor chain of claim 1 wherein all said hinges in said plurality of hinges are on an inside of said chain.

5. The conveyor chain of claim 1 wherein each of said segments in said plurality of segments is generally identical to all other segments in said plurality of segments.

6. The conveyor chain of claim 1 wherein each of said edges is generally perpendicular to at least one of said top surface or said bottom surface.

7. The conveyor chain of claim 1 wherein each of said edges is generally perpendicular to both said top surface and said bottom surface.

8. The conveyor chain of claim 1 wherein each of said angled faces is generally flat.

9. The conveyor chain of claim 1 wherein each of said angled faces is sawtoothed.

10. The conveyor chain of claim 1 wherein each of said angled faces is stepped.

11. A step for a stepmill, the step comprising: a plurality segments, each of said segments comprising a main body including: a top surface; a bottom surface smaller than said top surface and generally parallel thereto; an angled face interconnecting said top surface and said bottom surface; and an edge also interconnecting said top surface and said bottom surface; wherein, said edge and said angled face are not parallel to each other; and wherein said edge has a plurality of eyelets arranged thereon; wherein: a first segment from said plurality of segments is connected to a second segment from said plurality of segments to form a tread, said first segment and said second segment being connected by a first hinge so that the angled faces of said first segment and said second segment are in contact with each other; a third segment from said plurality of segments is connected to a fourth segment from said plurality of segments to form a kickplate, said third segment and said fourth segment being connected by a second hinge so that the angled faces of said third segment and said fourth segment are in contact with each other; said tread and said kickplate are connected together by an axial rod through said eyelets on said second segment and said eyelets on said third segment, said eyelets on said second segment and said eyelets on said third segment being interleaved with each other; and said tread and said kickplate are positioned generally perpendicular to each other.

12. The step of claim 11 wherein each of said segments in said plurality of segments is generally identical to all other segments in said plurality of segments.

13. The step of claim 11 wherein each of said edges is generally perpendicular to at least one of said top surface or said bottom surface.

14. The step of claim 11 wherein each of said edges is generally perpendicular to both said top surface and said bottom surface.

15. The step of claim 11 wherein each of said angled faces is generally flat.

16. The step of claim 11 wherein each of said angled faces is sawtoothed.

17. The step of claim 11 wherein each of said angled faces is stepped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a side perspective view of an embodiment of a conveyor chain as it would be on a stepmill, but removed from all other components.

(2) FIG. 2 shows a side perspective view of a single link of a conveyor chain that uses four identical segments to form a single stair.

(3) FIG. 3 shows a side perspective view of a single segment of the conveyor chain of FIG. 2.

(4) FIG. 4 shows an underside view of the link of FIG. 2 illustrating the mating hinges of each of the two segments forming each of the elements of the link.

(5) FIG. 5 shows the bend of two adjacent segments about the mating hinge.

(6) FIG. 6 shows side view of the chain of FIG. 1 with an illustration of the location of support tracks to carry and support the chain.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

(7) It is helpful to provide some general terminology that will be used herein. Generally, this disclosure is concerned with a conveyor chain that can be formed into stair steps. Stair steps are well understood by one of ordinary skill in the art and generally have two surfaces that are visible to a user, a “tread”, which is generally horizontal and upon which a user will place their foot when climbing the steps and a “kickplate” that serves to interconnect adjacent treads and provides the vertical separation between them. The kickplate also serves to prevent a user's foot from extending underneath the next tread. It should be recognized that is some forms of stairs, the kickplate is not present for aesthetic reasons. However, a stepmill will generally have a kickplate to eliminate a potential pinch hazard between adjacent treads and to provide for a continuous chain shape. Further, one of ordinary skill in the art generally understands what the top of a staircase is and the bottom of a staircase is.

(8) A stepmill is an exercise device which provides for a moving belt or chain which provides a small staircase (generally having between 3 and 5 treads of steps) where the belt or chain which forms the steps can move backwards (downwards) making the staircase effectively endless. Stairs will generally become available to the user at the top of the staircase and the steps will disappear under the staircase at the bottom. The user will walk on treads that are within the middle which provide a sturdy base and generally hold their relative positions to each other.

(9) To provide for the endless loop operation, the belt or chain of the stepmill causes the elements forming the staircase to return from the bottom of the staircase to the top of the staircase generally underneath the staircase as visible to the user. This makes the staircase “endless” from the point of view of the user. As the user steps up a step, the step simultaneously moves downward. Generally, the user will walk forwards up the staircase formed by a stepmill, but this is by no means required.

(10) A conveyor chain of the type used in a stepmill is an endless loop comprising a series of links that are connected together. This is as opposed to a belt comprising a single looped piece of material. Each link of a conveyor chain will be connected to the next and prior link via a rotational connection with the first and last link interconnected to form a loop. This allows the links to freely rotate relative to each other. It should be recognized that links are considered to repeat in a chain, thus, a link may be made up of one or more components which also rotate relative to each other, but which do not repeat. That is, a “link” as used herein comprises one piece of the chain that, when multiple identical links are interconnected, form the conveyor chain.

(11) In the present disclosure, each link of the conveyor chain (100) will correspond to a single “step” of the system. Thus, the chain (100) of FIG. 1 comprises eight links (200), each of those links is formed of two elements (a tread (201) and a kickplate (203)) and each of the two elements is comprised of two segments (300). A single link (200) is shown in FIG. 2 and a single segment (300) is shown in FIG. 3.

(12) A step, as used herein, generally will comprise two elements. The first element will generally be substantially horizontal and will comprise a tread (201) that the user will step onto by placing their foot flat on it. The step then also comprises a substantially vertical element that is the kickplate (203). It should be recognized that the generally horizontal and generally vertical positions of the tread (201) and kickplate (203) are when the link forms a step as in FIG. 2. At alternative times, the relative positions and arrangements of the tread (201) and kickplate (203) are different, but the elements (201) and (203) will always be arranged in the same arrangement when the link (200) forms a step.

(13) In forming the conveyor chain, a lower step's tread (201) element will be connected toward the bottom (231) of the lower step's kickplate (203) at a first end (213) of the tread (201) while the top (233) of the kickplate (203) will be connected to the immediately higher step's tread (201) element at the second end (211), which is opposite the first (213). In this way, the series of links, when in their step configuration, will essentially form a series of interconnected “L's” when viewed from the side.

(14) FIG. 2 provides for a detailed view of a single link (200) of an embodiment of the conveyor chain. As can be seen in FIG. 2, each link (200) forms a tread (201) and kickplate (203), but each of the tread (201) and kickplate (203) are formed from two segments (300a), (300b), (300c), and (300d). Each segment (300a), (300b), (300c), and (300d) however is generally identical to each other segment (300a), (300b), (300c), and (300d) and each comprises the segment (300) of FIG. 3. As should be apparent from FIG. 2, the segments (300a), (300b), (300c), and (300d) are simply multiples of segment (300) arranged in different positions.

(15) As shown in FIG. 3, each segment (300) will generally be comprised of a main body (302) that is generally in the shape of a trapezoidal prism. The two generally parallel major surfaces of the prism are referred to as the top (303), which is the larger of the parallel surfaces, and the bottom (301) which is the smaller. With regards to the non-parallel surfaces, one of these will generally be arranged to be generally perpendicular to at least one of the two major surfaces and is referred to as the edge (305).

(16) The edge (305) has a plurality of repeating eyelets (351) extending therefrom. Each of the eyelets (351) comprises a generally rounded surface (353) on the end opposing the edge (305) and a single hole (355) therethrough. The eyelets (351) will be arranged in a spaced arrangement from each other with gaps (357) between. Each gap (357) is of generally the same width as the width of the each eyelet (351) where the width is measured in the dimension parallel to the edge (305). The plurality of eyelets (351) are also offset from one side of the prism along the width of the edge (305) so that on one side (307) an eyelet (305) is generally flush with the side (307) of the prism, while on the other side (309) a gap (357) is generally flush with the side (309) of the prism.

(17) The other non-parallel surface of the segment (300) extends outward at a first angle (A) from the bottom surface (301) and is referred to as the angled face (311). In an embodiment, angle (A) is around 135 degrees but alterative angles of virtually any amount can be used in alternative embodiments so long as the angle (A) is greater than 90 degrees. The angled face (311) will generally have a greater surface area than the edge (309), but this is not required. The angled face (311) will generally not be planar to the edge (305) to the extent that the edge is, in many respects, a conceptual surface in the main body (302).

(18) While the angled face (311) will generally comprise a generally planar flat surface, this is by no means required. In an alternative embodiment, the angled face (311) may comprise a stepped or sawtoothed pattern formed from virtually any shape extending from the generally planar surface. The angled face (311) is generally only required to be able to effectively interface with another angled face (311) on an opposing arranged segment (300) as discussed in conjunction with FIG. 2.

(19) The segments (300) of FIG. 3 are designed to interface with each other as shown in FIG. 2. Specifically, four segments (300a), (300b), (300c), and (300d) are positioned as shown in FIG. 2 to form a single link (200). The first segment (300a) is arranged with the top (303) upward (that is toward the upper portion of the page) and side (307) toward the viewer so that the angled face (311) is directed downward. The second segment (300b) is then arranged vertically flipped so that the bottom (301) is toward the upper portion of the page and the angled face (311) is facing upward. However, the second segment (300b) is not horizontally flipped relative to the first segment (300a) as the side (307) still faces the user. The angled face (311) of the first segment (300a) is adjacent to and in contact with the angled face (311) of the second segment (300b) which essentially intermesh due to the relationship of the angles (A) and any toothed or similar pattern thereon.

(20) The second segment (300b) is then connected via its eyelets (351) by an axial rod (391) being placed through the eyelets (351) of the second segment (300b) and the eyelets (351) of the third segment (300c) which are interleaved with each other. Because the eyelets (351) are offset on the edges (309), the third segment (300c) is horizontally flipped, but not vertically flipped, compared to the second segment (300b) and has the side (309) facing the user. The third segment (300c), however, is still positioned with the bottom (301) upward which in the FIG. is toward the left of the page due to the third segment (300c) being rotated generally 90 degrees to the second segment (300b) about the axial rod (391). As should be apparent, the third segment (300c) can freely rotate about the axis defined by the axial rod (391) relative to the second segment (300b).

(21) The fourth segment (300d) is arranged vertically flipped, but not horizontally flipped, relative to the third segment (300c) with the angled face (311) of the fourth segment (300d) in contact with the angled face (311) of the third segment (300c). This results in the top (303) being upward or toward the left of the page in FIG. 2 with the side (309) being toward the viewer.

(22) It should be apparent from FIG. 2 that the positions of the eyelets on the fourth segment (300d) are such that they would intermesh with the eyelets (351) on the first segment (300a). This interconnection between the fourth segment (300d) of a first link (200a) and the first segment (300a) of a second link (200b) allows two consecutive links to be connected with another axial rod (391) as can be seen in FIG. 1. As is also shown in FIG. 1, the pattern of links (200) is repeated until a chain (100) with the desired number of links (200) is assembled. At this time, the fourth segment (300d) of the last link is connected with the first segment (300a) of the first link to form an endless chain (100). As should be apparent from FIG. 1, the upward side of each link (200) in FIG. 2 generally forms the outer surface of the chain (100) while the downward side generally forms the inner surface of the chain (100).

(23) As can be best seen in FIG. 4, the angled faces within the two segments (300) in each element are further interconnected by a hinge (501). The hinges (501) are generally on the inside surface of the chain (100) (the downward surfaces of FIG. 2) and provide the chain (100) strength. The hinges (501) are of generally similar design and the first hinge (501a) interconnects the first segment (300a) with the second segment (300b) while the second hinge (501b) interconnects the third segment (300c) with the fourth segment (300d). Each hinge (501) is arranged to bend at the line of intersection at the downward sides of the angle faces (311) of the two segments so their angled faces (311) are alternatively in contact with each other and not in contact with each other. The first hinge (501a) is attached to the bottom surface (301) of the first segment (300a) and the top surface (303) of the second segment (300b) with the hinge (501a) positioned to bend at the line of intersection between to the bottom surface (301) of the first segment (300a) and the top surface (303) of the second segment (300b). The second hinge (501b) is attached to the bottom surface (301) of the fourth segment (300d) and the top surface (303) of the third segment (300c) with the hinge (501b) positioned to bend at the line of intersection between to the bottom surface (301) of the fourth segment (300d) and the top surface (303) of the third segment (300c).

(24) As should be apparent from FIG. 4, the positioning of the hinges (501) allows for each of the segments (300) within each element (the tread (201) and the kickplate (203)) to rotate in only one direction relative to the other segment (300) in the same element. This direction, as shown in FIG. 5 is where the two angled faces (311) move away from each other and, as can be best seen from FIG. 1, allows the segments (300) to bend generally downward in the directionality of FIG. 2 to be able to form the loop of FIG. 1. Further, because of the axial rod (391) and eyelet (351) arrangement both within a link (300) (between second segment (300b) and third segment (300c)) and between links (300) (between the first segment (300a) on a second link (200b) and the fourth segment (300d) on a first link (200a)) each tread element (201) can freely rotate either direction relative to the kickplate element (203) within a link (300), and each link can freely rotate in either direction relative the two other links (300) to which it is attached. This should be apparent by the myriad of different relative positions of the eight links (200) shown in FIG. 1.

(25) FIG. 1 best illustrates the movement of the chain (100) in creating a stair arrangement for exercising. In FIG. 1, there are shown three links (200a), (200b) and (200c) which are positioned in their “L” position of FIG. 2. Each of these links forms a stair of the chain (100) where a user can place their foot on the tread surfaces (201a), (201b), and (201c). Further, a fourth tread surface (201d) is in the process of forming at the top of the staircase. Each of the tread surfaces (201a), (201b), (201c), and (201d) is interconnected by a kickplate (203a), (203b), and (203c). There are then five additional links (200d), (200e), (200f), (200g), and (200h) which are arranged in various states of bending at their hinges (501) and/or eyelet (351) and rod (391) connections.

(26) As can be seen in FIG. 1 the fourth kickplate (203d) is currently bent downward (inward on the chain (101)) within the kickplate element (203d) as the fourth link (200d) is coming over the top of the stepmill and a eighth kickplate (203g) is also bent inward on the chain (101) as the eighth link (200h) is turning under the bottom of the stepmill. The remaining links (200e), (200f) and (200g) are arranged to form a roughly flat arrangement when they are under the stair area moving from the bottom sprocket to the top. This arrangement is much thinner than the step arrangement of links (200a), (200b), and (200c).

(27) As should be apparent from FIG. 1, the chain (100) allows for a substantial reduction in the height of the lowest portion of the chain (100) when it is mounted in a housing. In particular, the link at the very bottom (the eighth link (200h) of FIG. 1) allows the link to turn in a space generally equal to or less than the combined depth of two segments (300) (although slightly larger amounts may be used in an embodiment due to other requirements of the stepmill). This allows for the bottom tread of the stepmill to generally be closer to the ground than with designs where the tread and kickplate are each a monolithic piece, or where the step link (tread and kickplate combined) are each formed as a monolithic piece.

(28) In order to provide good support for the weight of a user walking on the links (200) in the step configuration, the links (200) will generally be carried on two independent tracks (601) and (603) as shown in FIG. 6. The tracks (601) and (603) are mounted to a support structure (not shown) of a typical type to support a conveyor chain stairmill belt. In the arrangement of FIG. 6, each of the axial rods (391) within the links (200) are connected to track (601) while each of axial rods (391) between links (200) are connected to track (603). This means that as each link (200) comes into position at the top of the device, the links (200) will naturally be positioned in the step arrangement shown due to the distance between the tracks (601) and (603) at that point. Further, when a user stands on the tread (201) of a link (200), their weight is distributed between the two tracks (601) and (603) and two rods (391) with each of the treads (201) supported at each end (211) and (213) by a separate track (601) and (603) respectively.

(29) Further, as can be best seen in FIGS. 2-5, in the tread arrangement, the two segments (300a) and (300b) of the tread (201) will push against each other and resist splitting at their angled faces (311) as the faces (311) are compressed together by the mass of the user. Splitting between the segments of the tread (201) is actually resisted by two separate components, firstly by the angled faces (311) compressing together and secondly by the hinge (501a) which will generally not be designed to rotate in that direction. However, the hinge (501a) is not under extreme duress from the mass of the user trying to rotate it in an opposing direction. Instead, the angled faces (311) (along with the surface of the tread itself) spread the mass of the user across a fairly wide area. It should be recognized that while the embodiments of the drawings provide for a fairly steep angle (A) for the angled faces (311), these faces can be a lot longer by using an angled face (311) with a greater surface area and a more shallowly angled face (311).

(30) Throughout this disclosure, relative terms such as “generally,” “about,” and “approximately” may be used, such as, but not necessarily limited to, with respect to shapes, sizes, dimensions, angles, and distances. One of ordinary skill will understand that, in the context of this disclosure, these terms are used to describe a recognizable attempt to conform a device to the qualified term. By way of example and not limitation, components such as surfaces described as being “generally planar” will be recognized by one of ordinary skill in the art to not be, in a strict geometric sense, planar, because in a real world manufactured item a surface is generally never truly planar as a “plane” is a purely geometric construct that does not actually exist, and no component is truly “planer” in the geometric sense. Thus, no two components of a real item are ever truly planar, as they exist outside of perfect mathematical representation. Variations from geometric descriptions are inescapable due to, among other things: manufacturing tolerances resulting in shape variations, defects, and imperfections; non-uniform thermal expansion; design and manufacturing limitations, and natural wear. There exists for every object a level of magnification at which geometric descriptors no longer apply due to the nature of matter. One of ordinary skill will understand how to apply relative terms such as “generally,” “about,” and “approximately” to describe a range of variations from the literal meaning of the qualified term in view of these and other considerations.

(31) Further, use in this description of terms such as “upward” and “downward” do not actually require that certain surfaces or objects be closer or further away from a surface upon which an exercise machine is resting at any given time. Instead, they are generally used to denote opposite directions in conjunction with the standard arrangement of the FIGS. provided herein so as to give relative positioning of elements. Similarly, terms such as “inward” and “outward”, “left” and “right”, and “top” and “bottom” are used to show relative directions or positions as opposed to absolute location.

(32) While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be merely illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.