Stackable refuse cart

A stackable refuse cart includes a container, an axle, a set of wheels. The container includes first and second axle supports. The first axle support supports the axle in an operative position to rotatably support the container. The second axle support supports the axle in a stowage position enabling the container to be stacked with other containers without interference from the axles. In one embodiment, the second axle support includes a recess defined in the floor of the container. In another embodiment, the second axle support includes a pair of supports that hold the axle against a sidewall within the container. In yet another embodiment, the second axle support is a cradle integral with the container handle.

BACKGROUND OF THE INVENTION

The present invention relates to refuse carts, and more particularly to refuse carts that may be stacked together for shipment.

Refuse carts are common in commercial and residential settings for transporting waste. Common refuse carts include a container for holding refuse, and a pair of wheels and an axle for rolling the cart. The container is usually comprised of molded plastic, and includes sidewalls and a floor that define a space for containing refuse. The axle is supported on the container, and the wheels are supported on the axle. A handle may be included for pushing or pulling the cart on the wheels.

In order to take full advantage of shipping space, manufacturers of refuse carts generally stack a number of carts together for shipping. Most commonly this is done by stacking carts together, one container inside another, with only the bottom cart assembled with wheels and an axle. This allows the containers to be stacked tightly together, and reduces the required shipping space per container. The wheels and axles for each remaining stacked cart are often stowed in the empty space between each nested container. More recently, however, manufacturers have increased the draft angle of the sidewalls in order to more densely stack the containers. In these cases, the axles do not fit in the space between stacked containers because they interfere with stacking. Consequently, the axles for all of the containers in a stack are often shipped together as a group. This presents a number of difficulties. First, it is possible to miscount the axles, and thereby ship too few axles for a stack, resulting in one or more useless containers without wheels. Second, some manufacturers provide a separate box or container for stowing the wheels and axles, but these separate containers create an extra cost and they partially defeat the space saving purpose of stacking the carts in the first place. Third, other manufacturers place the wheels and axles for all of the carts inside the top container. This method does not take up additional storage space, but is recognized as being undesirable because the weight in the top container makes the stack top heavy and more difficult to handle.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome by the present invention wherein a refuse cart is provided with an integral axle stowage support. The axle stowage support positions, holds, or retains the axle in a stowage position separate from the assembled position and in a location that does not interfere with stacking. The axle stowage support enables an axle and a set of wheels to be stowed in each container while still allowing the containers to be stacked tightly together.

In one embodiment, the axle stowage support is a recess that is defined in the floor and/or sidewall of the container. The recess is shaped to receive at least a portion of the axle, so the axle can be placed in the container without interfering with another stacked container. The support may additionally include a pair of ribs that extend from the floor of the container and are spaced to fit on opposite sides of the axle.

In another embodiment, the axle stowage support includes one or more ribs on the inner surface of the container. The ribs may extend from one or more sidewalls to support the axle. The ribs may be the front sidewall of the container near the top of the container where the container is wide enough to receive the axle in a horizontal position.

In another embodiment, the axle stowage support is an axle holder on the exterior of the container. The axle holder may include a cradle that is integral with the rim or handle of the cart. In addition, the handle on each cart may include a hold-down, positioned so that when a first container is stacked inside a second container, an axle is held between the cradle in the handle of the second container and the hold-down in the handle of the first container.

The present invention provides a place for stowing axles during transportation of a dense stack of refuse carts. The axle stowage support allows the axle of each cart to be stowed with its respective container, so the manufacturer can take full advantage of shipping space without the cost of an additional container for the axles and wheels and without the concerns of placing all of the wheels and axles in the top container.

These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the detailed description of the current embodiments and the drawings.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

A refuse cart in accordance with the present invention is shown inFIG. 1and generally designated10. In general, the refuse cart10includes a container12, an axle14, and a pair of wheels16. The container12defines a space for containing refuse, and includes first and second axle supports20and22. The first axle support20receives the axle14in a assembled position, wherein the wheels16can be attached to the axle14, forming an assembled refuse cart10that may be transported using the wheels16. The second axle support22receives the axle14in a stowage position, wherein the axle14may be stowed such that a plurality of carts10may be stacked together in an unassembled form (i.e. the wheels and axle are not attached) for shipment. In operation, after a container12is formed, an axle14is disposed in the second axle support22, and a pair of wheels16are disposed inside the refuse containing space of the container12. The container12is then stacked with a plurality of other containers12, also including respective axles14and wheels16, and the stack of unassembled carts10is shipped to a desired location. Upon arrival at the location, the carts10may be unstacked and the axles placed in the first axle support20wherein the wheels can be attached to form assembled carts.

The container12is generally formed from plastic, such as by injection molding, but may be comprised of a variety of desired materials. The container12generally includes a floor24and a plurality of sidewalls26. As shown inFIG. 2, the container12includes a front sidewall28, a rear sidewall30, and left and right sidewalls32and34. The sidewalls28,30,32and34each include lower edges36,38,40and42that attach to the floor24, and upper edges44,46,48and50that define an opening of the container12. The sidewalls26and floor24combine to form a space52for containing refuse. As shown inFIG. 3, the sidewalls26may further include a lower portion54and an upper portion56that are joined by a transitional portion58. The lower portion54extends upwardly from the floor24, the transitional portion58flares outwardly from the lower portion54, and the upper portion56extends upwardly from the transitional portion58. The floor24includes an upper surface60attached to the sidewalls26, and a lower surface62. As shown inFIG. 3, the floor24may include a lower portion64, and a raised portion66. The raised portion66is raised from the lower portion64to accommodate the first axle support20which is disposed on the lower surface62of the raised portion66. The first axle support20includes a plurality of ribs68that extend downwardly from the lower surface62of the raised portion66of the floor24. Each rib68defines at least one axle14receiving hole70. The holes70of each rib68are aligned so that they may slidably receive an axle14. The left and right sidewalls32and34may each include a deformation72proximate the first axle support20that defines a space for the wheels16when they are assembled.

As shown inFIGS. 1-8, a rim74may extend from the upper edges44,46,48and50of the sidewalls26. The rim74extends outwardly from the upper edges44,46,48,50and then curves downward. The rim74may be formed integrally with the container12, and may be supported by a plurality of stacking ribs76that extend from the sidewalls26and attach to an inside surface78of the rim74. The stacking ribs76include a lower surface77for supporting the weight of the container12when it is stacked. One or more handles80may also extend from one or more of the sidewalls26, for instance, the handles80may extend outwardly from the upper edge46of the rear sidewall30. As illustrated, the container12includes a pair of handles80that each include a pair of handle supports82, and a cross piece84. The handle supports82are generally narrow ribs that extend outwardly from the rear sidewall30at spaced apart locations. Each pair of handle supports82is generally joined by a cross piece84by a conventional method, such as by extending the cross piece through holes86in the handle supports82. The container12may additionally include a conventional cover90that hingedly attaches to the handles80. The cover may be moveable from a closed position wherein it rests on the rim74, to an open position where it is folded back against the rear sidewall30.

The axle14is generally an elongated cylindrical rod. The axle14may be comprised of a variety of materials, such as steel or plastic. As illustrated, the axle includes a body92and first and second ends94and96. In addition, the axle14may include grooves98near each of the ends94and96that extend around the circumference of the axle14. The wheels16are generally conventional, and with therefore not be described in great detail. Suffice it to say that the wheels may be comprised of any desired material, and are designed to attach to the ends94and96of the axle14.

The second axle support22is shaped to hold the axle14in a stowage position, and it may be attached to or integrally formed with the container12. In the embodiment shown inFIGS. 2-8, the second axle support22includes a recess100defined in the floor24of the container12. As illustrated, the recess100is located in the raised portion66of the floor24and is shaped to receive one of the ends94or96of the axle14and a portion of the axle body92so that one of the ends94or96of the axle may be disposed in the recess100, and the other end94or96may extend across the floor24and rest on the lower portion64of the floor24near the front sidewall28. The second axle support22may also include a pair of upstanding ribs102for holding the end94or96of the axle14opposite the end94or96disposed in the recess100. As shown inFIGS. 2 and 3, the ribs may extend upwardly from the floor24and may be attached to the front sidewall28. Alternatively, a second recess (not shown) may be defined in the floor24at the location of the ribs102to hold the end of the axle14. Although not shown, the floor24on each side of the recess100may be angled slightly downward towards the recess100to direct an axle14into the recess100.FIGS. 3,5and7illustrate one particular embodiment of the recess100, wherein the recess defines a depth104that is less than the diameter of the axle14. In this embodiment, when the axle14is disposed in the recess100, a portion106of the axle14extends above the upper surface60of the floor24. To accommodate for this portion106when the containers12are stacked together, the floor24may include an angled section108between the raised and lower portions64and66of the floor24. As shown inFIG. 7, when the containers12and axles14of this embodiment are stacked together, the angled portion108provides space for the portion106so that the lower surface110of the first axle support ribs68may seat properly on the lower portion66of the floor24. Another embodiment of the recess100′ is shown inFIGS. 4,6and8. In this embodiment, the depth104′ of the recess100′ is greater than the diameter of the axle14. Because of this added depth, the angled portion108is not necessary, because (as shown inFIG. 8) the containers can seat properly without it.

In operation, a container12, an axle14, and a pair of wheels16are gathered for a plurality of respective carts10. For each cart10, a pair of wheels16are placed in the bottom of the refuse containing space52, such that they lie approximately flat on the floor24. The axle14is then placed into the second axle support22, such that a first end94or96is located in the recess100, and a second end94or96is located between the ribs102. A plurality of containers12are then stacked together for shipment. As mentioned previously, the containers generally stack inside of each other, such that the bottom surface77of the stacking ribs76of one container12rests on the rim74of the container12below it in the stack. The bottom surface110of the first axle support ribs68of one container12are therefore held just above the raised portion66of the floor24of another container12. Because the axle14is placed in the second axle support22, it does not interfere with the containers as they are stacked together. In one embodiment, the axle14of the bottom container12is inserted into the first axle support20, and the wheels16attached to the axle14so that the bottom cart and all carts stacked above it may be rolled on the wheels16and easily transported, for instance, to a waiting truck. After the unassembled stacked carts10arrive at a desired location, they are unstacked and the wheels16and axles14removed from each respective container12. The axles14may then be inserted into corresponding first axle supports20, and the wheels16attached to the axles14, forming a plurality of assembled carts10.

First Alternative Embodiment

A first alternative embodiment is shown inFIGS. 9-12. In this embodiment, the second axle support222is a pocket200attached to one or more of the sidewalls26. As illustrated, the pocket200includes a pair of ribs202extending upwardly from an inner surface204of the transitional portion58of the front sidewall28. The ribs202act to hold the axle14in a stowage position wherein the ends94and96of the axle14are trapped between the ribs202and the transitional portion58of the front sidewall28. The ribs202may also attach to the inner surfaces208and210of the left32and right34sidewalls for added strength. Alternatively, the pocket200may be a recess disposed in one of the sidewalls26, such as in the transitional portion58of the front sidewall28. As shown inFIGS. 10 and 12, the pocket200may be located in various positions on the transitional portion58of the front sidewall28, and may be located on a different sidewall26, such as on the transitional portion58of the rear sidewall30. Operation of this embodiment is similar to that of the previously disclosed embodiment, except for the differences in the axle stowage positions. As shown inFIG. 12, when the containers of this embodiment are stacked together, the axles14are held in the pocket200so that they fit in a gap220between sequentially stacked containers12.

A second alternative embodiment is shown inFIGS. 13-15. In this embodiment, the second axle support322is an axle holder300formed in the handles80. Shown inFIG. 14, the axle holder300may be a cradle or a set of cradles302defined in each of the handle supports82. The cradle302is shaped to correspond to the circumference of the axle14, so that an axle14can rest on top of each of the handle supports82and be held in the cradles302of each of the supports82. In one embodiment, one or more of the cradles302may be shaped to correspond to the circumference of one of the grooves98on one of the axle ends94or96so that the cradle302, or a portion thereof, prevents side-to-side movement of the axle when it is disposed in the axle holder300. As shown inFIG. 14, the axle holder300also includes one or more notches304that are defined in a lower surface306of the support ribs76located on the rear sidewall30. Similar to the cradles302in the handles80, the shape of the notches304in the support ribs76may correspond to a portion of the circumference of the axle14. Referring now toFIG. 15, when the containers12are stacked, each axle14is held in the axle holder300between the cradles302in the handle82and the notches304in the support ribs76. Alternatively, the notches304may be defined in a lower surface308of each of the handle supports82. In operation, this embodiment is similar to that of the previously disclosed embodiments in that the unassembled carts10including an axle14, a container12, and a pair of wheels16are gathered by a manufacturer and the wheels16are placed inside the refuse containing space52. The axle14is disposed in an axle stowage position in the axle holder300. As the containers12are stacked together, the wheels16of a first container12are placed within a refuse defining space52of that first container12and the axle14corresponding to the first container12is placed in the cradles302on the handle supports82of the first container12. The axle14may be disposed in the axle holder300so that one of the grooves98fits into the particular cradle302shaped to fit within the groove98. The axle14is further held in place by the notches304in the support ribs76of a second container that is stacked within the first container12. Each sequential container is stacked in a similar way so that each of the axles14is trapped between the cradles302and the handle supports82of a first container and the notches304on the support ribs76of a second container. In this embodiment, before transporting the stack of unassembled carts10to a truck or other vehicle for shipment, the placement of each of the axles14into the stowage position can be visually verified.

The above descriptions are those of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention, which are to be interpreted in accordance with the principles of patent law including the Doctrine of Equivalents.