Abstract:
A wagon includes a wagon pan including a wagon pan sidewall and a footwell including a footwell sidewall and a bottom. The wagon pan and footwell are adapted to be shipped in a nesting configuration and fastened together with the wagon pan on top of the footwell to form a body of the wagon. A handle and a number of are wheels adapted to be connected to the body of the wagon. The handle and wheels may also be shipped in a nested configuration with respect to the footwell.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 61/447,220, filed Feb. 28, 2011, currently pending. 
     
    
     FIELD OF THE INVENTION AND BACKGROUND 
       [0002]    The present invention relates to wagons and, more particularly, to the construction of a plastic wagon. 
         [0003]    Wagons are popular with both children and parents. While children enjoy playing with wagons as toys, parents appreciate the utility offered by wagons and often use them to transport children and cargo. 
         [0004]    A difficulty facing manufacturers and shippers of wagons is that the products are bulky and sometimes heavy. This causes packaging difficulties and increases the shipping costs for manufacturers. In addition, the products consume valuable inventory space for distributors and retailers. A need exists for a wagon that provides a compact profile when packaged, shipped and stored in inventory. A need also exists for such a wagon to be economical to construct, durable and lightweight. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is a top front perspective view of an embodiment of the wagon of the present invention; 
           [0006]      FIG. 2  is a bottom front perspective view of the wagon of  FIG. 1 ; 
           [0007]      FIG. 3  is top plan view of the wagon of  FIGS. 1 and 2 ; 
           [0008]      FIG. 4  is a sectional view of the wagon of  FIGS. 1-3  taken along line  4 - 4  of  FIG. 3 ; 
           [0009]      FIG. 5  is a top front partial perspective view showing the rear portion of the interior of the wagon of  FIGS. 1-4 ; 
           [0010]      FIG. 6  is an exploded perspective view of the body of the wagon of  FIGS. 1-5 ; 
           [0011]      FIGS. 7A and 7B  are enlarged bottom perspective views showing insertion of a nut into one of the nut recesses formed in the rim of the footwell of the body of the wagon of  FIGS. 1-6 ; 
           [0012]      FIG. 8  is a bottom front perspective view of the wagon body of  FIG. 6  in an assembled condition showing insertion of screws to further secure the wagon pan to the footwell; 
           [0013]      FIG. 9  is a top front perspective view of the assembled wagon body of  FIG. 8 ; 
           [0014]      FIG. 10  is a side elevational view showing the wagon of  FIGS. 1-5  with the handle in a storage position; 
           [0015]      FIG. 11  is an enlarged perspective view of a rear portion of the wagon illustrating use of the seat belts of  FIGS. 6 and 9 ; 
           [0016]      FIG. 12  is a bottom rear partial perspective view of the rear portion of the wagon body of  FIGS. 6 ,  8  and  9  illustrating the molded rear axle mount prior to installation of the rear axle; 
           [0017]      FIG. 13  is a bottom partial perspective exploded view illustrating assembly of the rear axle and wheels to the molded rear axle mount of  FIG. 12 ; 
           [0018]      FIG. 14  is a bottom rear partial perspective view of the rear portion of the wagon body and axle mount of  FIGS. 12 and 13  after installation of the rear axle and wheels; 
           [0019]      FIG. 15  is a top front perspective view of the wagon of  FIGS. 1-14  in a disassembled and packaged configuration. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0020]    An embodiment of the wagon of the present invention is indicated in general at  20  in  FIGS. 1-5 . The wagon features a two-piece body, indicated in general at  21 , which consists of an upper portion wagon pan  22  and a lower portion footwell  24  which are molded separately and then secured together with screws after shipping and unpacking. The wagon pan  22  is preferably rotationally molded from plastic, while the footwell  24  is preferably injection molded from plastic. Alternative materials, including, but not limited to, metal, may be used for either or both the wagon pan and footwell. 
         [0021]    A handle  26  is pivotally attached to the front wall of the wagon pan by a pin  27  and handle mounting brackets  25   a  and  25   b.  Handle mounting brackets  25   a  and  25   b  are preferably molded into the front wall of the wagon pan, but may be separately produced and then attached. The handle pivots between an upright position, illustrated in  FIGS. 1-5 , and a storage position underneath the footwell  24 , illustrated in  FIG. 10 . 
         [0022]    The wagon pan  22  features integrally molded front and rear walls and sidewalls as well as front and rear seat surfaces  32   a  and  32   b.  The top of the wagon pan is open as is the area between the front and rear seat surfaces. The wagon footwell features an integrally molded bottom  33  and front and rear walls and sidewalls. As illustrated in  FIGS. 4 and 5 , the assembled wagon provides a storage space  34  under the rear seat surface  32   b.  Furthermore, children riding in the wagon and seated on seat surfaces  32   a  and  32   b  may comfortably position their feet within the interior of foot well  24 , indicated at  36  in  FIG. 4 . 
         [0023]    It should be noted that in an alternative embodiment, the seating surfaces  32   a  and  32   b  could be omitted to provide the wagon with greater cargo hauling capacity. 
         [0024]    The wagon features four wheels  28 . A pair of caster mounts  38   a  and  38   b  ( FIGS. 1-3 ) are preferably molded into the wagon pan  22  and support the front wheels via caster rods  42   a  and  42   b  so that the front wheels are free to pivot as the wagon is pulled by the handle  26 . The caster mounts may alternatively be separately produced and then attached to the wagon pan. 
         [0025]    As illustrated in  FIGS. 2-5 , a pair of cup holders  44   a  and  44   b  are preferably molded into the bottom  33  of the footwell  24 . In addition, a barrier wall, illustrated at  45  in  FIGS. 4 and 5  is preferably molded into the floor of the footwell to assist in securing items in storage space  34  under rear seat surface  32   b.    
         [0026]    Assembly of the wagon pan  22  and footwell  24  to form the wagon body is illustrated in  FIGS. 6-9 . As illustrated in  FIG. 6 , the footwell  24  features a circumferential rim portion  46  which features molded nut recesses  48 . As illustrated in  FIGS. 6 ,  7 A and  7 B, each nut recess  48  receives a nut  52 . While four nut recesses are illustrated, an alternative number of nut recesses, nuts and corresponding screws may be used. 
         [0027]    As shown in  FIG. 6 , fasteners in the form of primary screws  54  are positioned through corresponding openings in the seat surfaces  32   a  and  32   b  of the wagon pan and engage the nuts  52  of the footwell. As a result, the footwell  24  is secured to the wagon pan  22 , as illustrated in  FIG. 8 . Other fasteners known in the art may be used as alternatives to the primary screws. 
         [0028]    As illustrated in  FIGS. 6 and 9 , seatbelts  56   a  and  56   b  are preferably secured by their proximal ends to the tops of seat surfaces  32   a  and  32   b  using the primary screws  54  (i.e. the same screws that secure the wagon pan and footwell together). Of course alternative fastener arrangements known in the art may be used to secure the seat belts to the wagon seat surfaces. As illustrated in  FIG. 11 , rear seatbelt  56   b  is provided with a quick release buckle  62  so that a child  64  riding, in the wagon may easily fasten and unfasten the seatbelt. Seatbelt  56   a  is also provided with such a buckle. 
         [0029]    Threaded inserts, illustrated in phantom at  72  in  FIG. 8 , are positioned and secured within the sidewalls of the wagon pan. The threaded inserts may be molded in place or inserted and secured in place, such as with threads, adhesive or another securing arrangement, after the wagon pan is constructed. Secondary screws, illustrated at  74  in  FIG. 8 , are inserted through corresponding openings  76  formed in the circumferential rim  46  of the footwell and engage the threaded inserts  72 . As a result, the wagon pan and footwell are securely fastened together, as illustrated in  FIG. 9 . 
         [0030]    As illustrated in  FIG. 12 , a rear axle mount, indicated in general at  80 , is molded with the rear edge of the footwell  24 . In alternative embodiments, the axle mount could take the form of openings formed through the footwell or an axle mount that is made separately from the footwell, out of plastic, metal or another material, and attached to the footwell. The axle mount features a number arcuate members  81   a - 81   d  that receive the rear axle  82  of the wagon, as illustrated in  FIGS. 13 and 14 . During assembly, the rear axle  82  is preferably moved through the arcuate members of the axle mount  80 , as illustrated in  FIG. 13 . As shown in  FIGS. 13 and 14 , a pair of spacers  84  are preferably positioned on each end of the axle after installation to the rear axle mount  80 . After the rear wheels  28  are mounted on the axles, a pair of end caps  86  are attached by interference fit with the ends of the rear axle. 
         [0031]    As illustrated in  FIG. 15 , the two-piece body and other construction details of the wagon of  FIGS. 1-14  permits compact packaging and shipping in a nested configuration where the footwell  24  is positioned within the wagon pan  22 , and then the handle  16 , wagon wheels  28  and associated components are positioned within the footwell. A cardboard insert  100  preferably holds the wheels and other components in place within the footwell. The compact nested assembly of  FIG. 15  may then be packaged within a box, indicated in  FIG. 15  by dashed lines  102 . 
         [0032]    The wagon of  FIGS. 1-15  provides a compact packaging and shipping profile and is inexpensive to produce. Furthermore, the wagon is lightweight and durable when assembled. 
         [0033]    While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by the appended claims.