Construction cart

A foldable cart is described. The cart may be collapsed for transport in the bed of a pickup truck to a jobsite. Upon reaching the jobsite, the cart is removed from the pickup truck, unfolded and used to transport construction materials.

CROSS-REFERENCED TO RELATED APPLICATIONS

Not applicable.

Not applicable.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention relates to carts and, more particularly, to carts adapted for transporting a variety of elongate materials at a construction site.

II. Related Art

Since the invention of the wheel, various types of carts have been employed to transport construction materials. Examples of such carts presently used include (1) flatbed carts having four wheels, a horizontal deck and an upright handle; (2) carts having a horizontal deck like a flatbed cart and upright sides supported by the horizontal deck; (3) two-wheeled dollies; and (4) wheelbarrows.

Known carts, however, have serious drawbacks when transporting at a job site elongate construction materials which are often ten feet long or longer. Wheelbarrows and two-wheeled dollies are not intended to perform such tasks and do not work well when performing such tasks. Likewise, flatbed carts or flatbed carts with upright sides are typically either too short to be particularly useful when transporting long items. Such carts also typically have wheels too small to transport such materials over the uneven terrain often found at job sites. While larger and taller carts are known, these are not often used because of the difficulty encountered and resources required to transport such carts to a job site.

SUMMARY OF THE INVENTION

In view of the disadvantages of heretofore-known carts, the present invention provides a highly advantageous cart which is big enough to transport virtually any elongate material typically employed at a job site, is narrow enough to fit through gates yet stable, and is foldable or collapsible so that it can easily be transported in the back of a pickup truck. Pickup trucks are typically owned by many residential contractors.

More specifically, a cart for transporting building materials is disclosed. The cart includes a frame comprising a middle frame section, a front frame section, and a rear frame section. The middle frame section comprises a first longitudinal frame member having a front end and a back end, a second longitudinal frame member having a front end and a back end and a support assembly comprising four upright hollow supports, each having an open top, and four cross braces. The first and second supports are fastened to and extend upwardly from the first longitudinal frame member. The third and fourth supports are fastened to and extend upwardly from the second longitudinal frame member. The first cross brace extends between the first and second upright supports. The second cross brace extends between the third and fourth upright supports. The third cross brace extends between the first and third upright supports. The fourth cross brace extends between the second and fourth upright supports.

The front frame section comprises first and second rails and at least one brace. The first rail has a back end pivotally connected to the second support of the support assembly and a front end coupled to the brace. The second rail has a back end pivotally connected to the fourth support of the support assembly and a front end coupled to the brace. As such, the front frame section is pivotal between a folded position in which the front frame overlies the middle frame section and a deployed position in which the front frame extends in a cantilevered fashion from and in front of the middle frame section. When in the deployed position, the first rail is supported by the first cross brace of the support assembly and the second rail is supported by the second cross brace of the support assembly.

The rear frame section comprises first and second spaced apart channel beams. Each channel beam is hollow and has an open back end. Each channel beam also has a front end pivotally connected to the back end of one of the longitudinal frame members of the middle frame section. As such, the rear frame section is pivotal between a folded position in which the rear frame section overlies the middle frame section and a deployed position in which the rear frame section extends from and behind the middle frame section. When the rear frame section is in its deployed position, the first channel beam of the rear frame section extends from the first longitudinal member of the middle frame section at an angle of about 180°. Likewise, the second channel member extends from the second longitudinal member at an angle of about 180°.

When in its deployed configuration, the frame is supported above the ground by a wheel assembly and a leg assembly. More specifically, the wheel assembly includes a transverse axle coupled to the middle frame section near the front end of the first and second longitudinal frame members. A pair of wheels is coupled to the axle for rotation about the axle. The leg assembly is coupled to the rear frame section. The leg assembly comprises a pair of cross braces extending between the channel beams of the rear frame section, each cross brace having a first end secured to one of the channel beams and a second end secured to the other of the channel beams. A first leg is coupled to each of the cross braces near the first end of the cross braces and a second leg is coupled to each of the cross braces near the second end of the cross braces. As noted above, the leg assembly cooperates with the wheels to support the cart when the cart is at rest and the rear frame section is in the deployed position.

The cart also includes a handle assembly including a first handle member received in and extending rearwardly from the first channel beam of the rear frame section and a second handle member received in and extending rearwardly from the second channel beam of the rear frame section. The handle members telescope independently of each other with respect to the rear frame section permitting the length of the handles to be adjusted independently. The handle is locked in a desired position with respect to the associated channel beam by aligning a hole in the channel beam with one of a plurality of holes in the handle and then inserting a pin through the aligned holes. This same locking arrangement is used with respect to both handles and both channel beams.

Also disclosed are material support slings which support materials horizontally and support posts which support materials on the cart laterally. Various pockets are incorporated into the frame members which are used to couple the slings and lateral support posts to the frame in a selected fashion.

When the handles are retracted into the channel members and the front and rear frame members are folded to overlie the middle frame section, the overall length width of the cart is such that it will easily fit in the bed of a standard pickup truck with the gate of the pickup truck closed for transport. When the handles, front frame section and rear frame section are in their deployed positions, the cart provides a long enough surface to easily transport elongate items such as lumber, pipe, rolls of carpet, rolls of house wrap and other building materials about the job site.

DETAILED DESCRIPTION

In one embodiment the foldable cart10comprises three frame sections—a middle frame section12, a front frame section14and a rear frame section16. InFIG. 1, the three frame sections are shown in their folded configuration. As shown inFIG. 2, when the frame sections are in their folded configuration, the cart10can easily be transported in the bed of a pickup truck2even with the tailgate4of the pickup truck2closed.FIG. 3shows the three frame sections of cart10in their unfolded configuration, resting on the ground and ready for use to haul lumber of other construction materials from one location to another at a job site.

As illustrated, the middle frame section12of the cart10comprises a base20and a support assembly38. The base20has a front22where the support assembly38is joined to base20. The base also has a back24where the rear frame section16is joined to the middle frame section12.

The base20of the middle frame section12comprises a first longitudinal frame member26and a second longitudinal frame member28. As shown, longitudinal frame members26and28are spaced from each other and extend parallel to each other from the front22to the back24of the base20. The base20also includes a traverse brace30extending between and attached to the longitudinal frame members26and28proximate the front22of base20.

The support assembly38includes four upright hollow supports40,42,44and46, each having an open top41,43,45and47respectively. The first upright hollow support40is attached to and extends upwardly from first longitudinal frame member26proximate the front of the first longitudinal frame member26. The second upright hollow support42is also attached to, and also extends upwardly from, the first longitudinal frame member26, but about a foot back along the first longitudinal frame member26from the first upright hollow support40. The third upright hollow support44is attached to and extends upwardly from the second longitudinal frame member28proximate the front of frame member28. The fourth upright hollow support46is also attached to, and also extends upwardly from, the second longitudinal frame member28, but about a foot back along the second longitudinal frame member28from the third upright hollow support44.

The support assembly38of the middle frame section12also includes four cross braces48,50,52and54. The first cross brace48extends between and is joined at its opposite ends to the first and second upright hollow supports40and42. The second cross brace50extends between and is joined at its opposite ends to the third and fourth upright hollow supports44and46. The third cross brace52extends between and has opposite ends joined to the first and third upright hollow supports40and44. The fourth cross brace54extends between and has opposite ends joined to the second and fourth upright hollow supports42and46. As so configured, the support assembly38is capable of supporting the front frame section14.

Front frame section14comprises a first longitudinal rail70, a second longitudinal rail72, a first brace73, and a second brace74. Longitudinal rails70and72each have a front end (75and77, respectively) and a back end (76and78, respectively). Longitudinal rails70and72are also spaced apart and extend from their fronts to their backs in a substantially parallel manner. The first brace73extends between and is joined to the top of the first and second rails70and72proximate the fronts75and77of the rails. The second brace74extends between and is joined to the bottom of the first and second rails70and72also proximate the fronts75and77of the rails.

The front frame section14is joined to the middle frame section12using first and second hinges56and57. As shown, hinge56is essentially a bolt which connects the second upright hollow support42of the support assembly38of the middle frame section12to the first rail70of the front frame section14. More specifically, the bolt passes through aligned holes near the top of the second hollow support42and the back end76of the first rail70. Any suitable means may be employed to secure the bolt in place, e.g., a nut, cotter pin or the like. A second hinge57is likewise employed to connect the back end78of the second rail72of the front frame section to the fourth upright hollow support46of the support assembly38of the middle frame section12. Hinges56and57permit the front frame section14to be pivoted between the folded position illustrated onFIGS. 1 and 2and the deployed position illustrated inFIG. 3. The reader should note that when the front frame section14is in its deployed position, the bottom of first rail70engages the top of first cross brace48and the bottom of the second rail72engages the top of the second cross brace50such that the support assembly38supports the front frame section14in a cantilevered fashion as shown inFIGS. 3 and 4.

Hinges56and57, as illustrated, certainly meet the requirements of the present invention. However, alternative hinge arrangements may also be employed without deviating from the invention. For example, a single axle passing through the second and fourth upright hollow supports42and46of the support assembly38and the first and second rails70and72could be employed. Virtually any hinge arrangement enabling the front frame section14to pivot from its folded position to its deployed position could suitably be employed. Likewise, stops other than the tops of the first and second cross braces48and50could be employed to hold the front frame14in a deployed cantilevered fashion without deviating from the invention.

As noted above, the frame of cart10also has a rear frame section16. Rear frame section16comprises first and second hollow channel beams80and84. The back ends82and85of the hollow channel beams80and84are open for reasons discussed below. Hinges35and36couple the front ends83and86of channel beams80and84to the rear ends of the first and second longitudinal frame members26and28of the middle frame section12. These hinges35and36permit the rear frame section to be pivoted between the folded position illustrated inFIGS. 1 and 2in which the rear frame section16overlies the middle frame section12and the deployed position illustrated inFIG. 3. When the rear frame section is in the deployed position, the first channel beam80extends from the first longitudinal frame member26at substantially a 180° angle. Likewise, the second channel beam84extends from the second longitudinal frame member28at substantially a 180° angle. A locking mechanism, which may be part of the hinges35and36such as110and112, is employed to secure the channel beams and longitudinal frame members at this angle. The locking means may also be selectively employed to fix the channel beams to the longitudinal frame members at any other desired angle. Combination hinges and locks like those used commercially on Little Giant Ladder Systems work well for this purpose. Alternatively, the lock can be in the form of plates extending from the first and second longitudinal frame members26and28upon which the first and second channel beams80and84rest when in the extended position and pins or clamps which couple the plates to the channel beams.

When the rear frame assembly is in its deployed position and the cart10is at rest as illustrated inFIGS. 3 and 5, the frame of cart10is supported above the ground by a wheel assembly31and a leg assembly90. The wheel assembly31is coupled to the front22of base20of the middle frame section12. The leg assembly90is coupled to the front ends83and86of the channel beams80and84of the rear frame section16.

More specifically, the wheel assembly31includes an axle32coupled to the first and second longitudinal frame members26and28proximate their front ends. A first wheel33is mounted for rotation about the axle32outside of the first longitudinal frame member26. A second wheel34is mounted for rotation about the axle32outside the second longitudinal frame member28. This arrangement provides the cart10with improved stability. To reduce the width of cart10, the wheels33and34could be mounted between the longitudinal frame members26and28. Also, one wheel mounted at the center of the axle, rather than the two wheels shown, could be employed.

The illustrated leg assembly90includes a first cross brace91having a first end92and a second end93. End92of cross brace91is secured to the first channel beam80near its front end83. End93of the cross brace91is secured to the second channel beam84near its front end86. The leg assembly also includes a second cross brace94having ends95and96similarly secured to the channel beams80and84. These cross braces serve to retain in a spaced generally parallel relation not only the channel beams80and84, but also the longitudinal frame members26and28. The leg assembly also includes a first leg97and a second leg102. Leg97has a generally V-shape and includes a first straight leg portion98, a second straight leg portion99and a curved section100joining the bottoms of the straight leg portions98and99. The top of straight leg portion98is fastened to the first cross brace91and the top of straight leg portion99is fastened to the second cross brace94. Leg102likewise has a first straight leg portion103, the top of which is fastened to the first cross brace91, a second straight leg portion104, the top of which is fastened to the second cross brace94, and a curved section105joining the bottom of the straight leg portions103and104. As illustrated, the legs97and102are spaced from each other such that leg97is mounted at or near the first ends92and95of cross braces91and94and the second leg102is mounted near the second ends93and96of the cross braces91and94. This helps stabilize the cart10and its load of lumber, sheet rock, carpet, pipe, or other construction materials when the wheels33and34and legs97and102engage the ground. To strengthen the leg assembly90, braces such as106and108can be employed such that the opposite ends of the braces are connected to the legs97and102.

Cart10, as illustrated, has a handle assembly comprising first and second elongate handles130and140. The handles130and140are shown in their retracted position inFIGS. 1 and 3and in an extended position inFIG. 5. Handle130has a first end located within hollow channel beam80and a second end extending rearwardly of channel beam80. Handle140has a first end located within the hollow channel beam84and a second end extending rearwardly of channel beam84. The cross sections of the channel beams80and84and the handles130and140are such that the handles can be independently moved (or telescoped) between an extended position (seeFIG. 5) wherein much of the handle is exposed and a retracted position (seeFIGS. 1 and 3) in which most of the elongated handle is within the associated channel member.

Separate locking arrangements are employed to secure the handles with a desired portion exposed. Specifically, the first channel beam80has one or more transverse apertures114extending through the channel beam80. Handle130also has one or more transverse holes132extending through handle130. When the desired portion of the handle130is exposed and a transverse aperture114of the first channel beam80is aligned with a transverse hole132of the handle130, a first locking pin120is inserted through the aligned transverse aperture and transverse hole to secure the handle130in the desired position relative to the first channel beam80. A cotter pin123or the like may be employed to ensure the pin does not fall out of the aligned hole132and aperture114. Similarly and independently, the second channel beam84is provided with one or more transverse apertures116and the second handle140is provided with one or more transverse holes142. The handle is retracted or extended to a desired length such that an aperture116and a hole142are aligned and a second locking pin122is inserted through the aligned hole and aperture. If the pin is threaded, a nut can be used to ensure the pin does not fall out. Otherwise, a cotter pin123or any other suitable securement mechanism may be employed. The independent nature of the handles130and140and locking arrangements permits the exposed length of the handles to be adjusted independently. When the rear frame section16is in its folded position, the handles130and140are retracted into the channel beams80and84. When the rear frame section16is in its deployed position, the handles130and140are extended from the channel beams80and84.

Supports of various configuration can be coupled to the frame of cart10to vertically and laterally support loads of differing construction materials. To provide greater flexibility, various pockets or receivers are provided on different parts of the frame. For example, and to provide vertical support for the load, the tops41,43,45and47of the upright hollow supports40,42,44and46of the support assembly are open and act as receivers for first and second removable support slings60and64. As illustrated inFIG. 3, sling60has a transverse member61extending between and fixed to a first attachment member62and a second attachment member63. Attachment member63is inserted into the top41of the first upright hollow support40and attachment member62is inserted into the top of the third upright support44to couple the sling60to the frame. Sling64likewise has a transverse member67coupled to and extending between a first attachment member65(which mates with the open top47of the fourth upright hollow support46) and a second attachment member66(which mates with the open top43of the second upright hollow support42).

As shown, the transverse members of the slings60and64are flat and straight. This arrangement is very suitable, for example, when transporting lumber used to construct decks, gazebos or the framing for a building. Without deviating from the invention, the transverse members61and67of the slings60and64may be concave when the cart10is being used to transport pipes, rolls of house wrap, carpet or other elongate construction items having a round or curved cross-section. Also, the sling can be stiff or somewhat flexible. While slings60and64are shown coupled to the upright supports of the support assembly38, pockets for receiving the sling attachment members62/63can be formed in or secured to other portions of the frame to secure additional slings to other portions of the frame.

The drawings also illustrate how lateral support may be provided for a load of material place on and to be transported using cart10. As shown, a plurality of pockets150having open tops are coupled to or formed in the frame at various locations. Lateral support posts160are inserted into and extend upwardly from selected pockets to laterally support the load. Both the support posts160and the slings60and64are removable and repositionable. Other support devices can be inserted into the pockets150to support windows, drywall or wallboard, plywood or the like on edge on the cart which may be necessary to transport such items on the cart through gates, doorways or the like since the width of the drywall or wallboard, plywood, windows or panels may be wider than the opening of the gate or doorway such that they should not be laid flat on the cart.

As shown, the lateral supports can be as simple as a member inserted into the pocket. Alternatively, the lateral supports can be designed to slide back and forth within the pocket between an extended and retracted position. The lateral supports can also be designed to have sections which telescope with respect to each other much like the legs of a camera tripod. The lateral supports may also be hinged and locked in extended and retracted positions like the legs of a card table. What is important is that adequate lateral support be provided for safe transport of the load, not how the supports are coupled to the frame.

Use of the cart10will now be described. With the cart10in its folded configuration, it is loaded into the bed of a standard pickup truck2and the tailgate4is then closed. This task can be easily performed by a single person given the weight of the cart10. The cart10is then transported to the job site in the pickup truck2.

Upon arrival at the job site, the cart10is removed from the pickup truck2and placed so the wheels33and34are on the ground. Again, the weight of the cart is such that one person can easily do so. The cart10is then unfolded. More specifically, the front section frame section14is rotated about hinges56and57from its folded position to its deployed position. When fully deployed, the bottoms of the first rail70and the second rail72engage the tops of cross braces48and50which act as a stop and retain the front frame section14in a cantilevered manner with respect to the support assembly38of the middle frame section12.

Next, the rear frame section16is unfolded. More specifically, the rear frame section16is rotated about hinges35and36from its folded position to its deployed position and the channel beams80and84of the rear frame section16are locked in place at about a 180° angle (or any other desired angle) with respect to the first and second longitudinal frame members26and28of the middle frame section12. The handles130and140are then telescopically extended from the channel beams80and84and locked in place using locking pins120and122which are inserted through aligned apertures in the channel beams and holes in the handles. Selective insertion of slings and/or lateral support pipes into the pockets completes the preparation of the cart for use.

With the cart supported by the wheels33and34and legs97and102, construction materials are then placed on the cart for transport from one location at the job site to another. When the cart is loaded, a user lifts on the handles130and140until the bottom of legs97and102come off the ground. The user then pulls or pushes on the handles causing the cart and its load to move. When the desired location is reached, the user sets the cart10down on legs97and102and the cart is either unloaded or used to store the materials off the ground until they are ready for use.

Various features of the invention have been shown and described to meet the disclosure requirements of the patent laws. The foregoing description and the accompanying drawings are intended to be illustrative and not limiting. The invention is confirmed only to the broadest scope consistent with the following claims and the full range of equivalents.