Material handling cart

The present invention provides a new material handling cart adapted for easy travel over uneven surfaces including a pair of independently extendable handles, and optionally having a convertible secondary deck assembly.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates material handling carts and more particularly to a new material handling cart adapted for use on and off of flat surfaces.

2. Description of the Prior Art

Material handling carts are well known in the prior art. Hardware and large home-improvement department stores often supply carts for use by their customers for carrying construction or home-improvement supplies, such as lumber. These carts generally consist of a pair of upright side rails supported on a horizontal deck, which in turn is carried by a plurality of wheels or casters.

While these known carts provide a means for transporting supplies, the known carts have several drawbacks. The known carts are provided with small diameter wheels or casters that, while providing relatively easy movement over hard, flat surfaces such as concrete floors and asphalt parking lots, are difficult or impossible to use in “off-road” conditions such as at construction sites or through loose gravel. The known carts are also equipped with stationary handles, which become difficult to reach when trying to move large and/or long materials and make maneuvering of the cart difficult around corners, such as at fence gates and doorways.

The known carts are also limited in the variety of materials that may be handled at one time. If a product to be moved is odd-shaped, then it becomes difficult to stack additional supplies on the cart for simultaneous transport. Thus, the customer or handler must make multiple trips to securely transport the different materials.

In these respects, there is a need for a material handling cart that is well adapted for travel over uneven ground and irregular surfaces, such as grass, dirt and gravel; which includes easily reachable handles; and further including a means for safely carrying multiple, different-shaped materials.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the known material handling carts, the present invention provides a new material handling cart adapted for easy travel over uneven surfaces including a pair of independently extendable handles, and optionally having a convertible secondary deck assembly.

The material handling cart of the present invention generally comprises a primary deck supported on at least two, spaced apart, rotatable wheel assemblies. The cart further includes a first side-rail assembly connected to the primary deck at a first side and a second side-rail assembly connected to the primary deck at an opposing second side, each of which are adapted and positioned to prevent the lateral movement of objects transported by the material handling cart. Each of said first and second side-rail assemblies include an independently extendable handle assembly comprising a handle tube connected to the respective side-rail. The handle tube preferably has a longitudinal axis substantially perpendicular to the axis of rotation of the rotatable wheel assemblies. The handle tube includes an inner passage and an inner handle member adapted to be received and seated concentrically within the inner passage and further adapted to be selectively positioned therein. The inner handle member is preferably longer than the handle tube and adapted to be slidably seated within the inner passage of the handle tube. The inner handle member is further adapted to be adjustably positioned such that the inner handle member may extend outwardly from the handle tube. Preferably, each independently extendable handle assembly further includes a means for securing the inner handle member at a desired outwardly extending position.

Optionally, the cart may include a convertible secondary deck assembly. Preferably, the secondary deck assembly comprises a first convertible deck arm and second convertible deck arm. The first convertible deck arm includes a first end and a second end, the first end being pivotably connected to one of the first and second side-rails at a position vertically spaced from the primary deck and more preferably pivotably connected to a handle tube at a position vertically spaced from a first end of the primary deck. The first convertible deck arm is adapted to pivot about an axis substantially parallel to the longitudinal axis of the respective side-rail to which it is pivotably connected. The second end is adapted to make rotation-limiting engagement with the opposite side-rail at a position vertically spaced from the primary deck and preferably at a position vertically spaced from a first end of the primary deck.

The second convertible deck arm includes a third end and a fourth end, the third end being pivotably connected to one of the first and second side-rails at a position vertically spaced from the primary deck, more preferably pivotably connected to a handle tube at a position vertically spaced from the second end of the primary deck, and horizontally spaced from the first convertible deck arm. The second convertible deck arm is adapted to pivot about an axis substantially parallel to the longitudinal axis of the side-rails. The fourth end is adapted to make rotation-limiting engagement with the opposite side-rail to the side-rail which the third end is pivotably connected, preferably at a position vertically spaced from the second end of the primary deck and horizontally spaced from the first convertible deck arm. The first and second convertible deck arms may be pivotably connected to the same or different side-rails.

DETAILED DESCRIPTION OF THE INVENTION

A presently preferred embodiment of the invention is described below with reference to the drawings, in which like reference numerals refer to like elements in the various views. Referring to the drawings and particularly toFIGS. 1 and 4, there is illustrated a material handling cart, generally designated10having a first side11, a front end13, a rear end15and a second side17. Generally, the material handling cart10includes a primary deck12including a floor panel14of a suitable material such as aluminum, plastic or other sheet material. Preferably, and as shown, the primary deck12and floor panel14are substantially rectangular. The dimensions may be any that are desired, but preferably, the width (distance between the first and second sides11and17) is selected such that the material handling cart may be navigated through standard doorways and gate openings. Preferably, the primary deck includes support beams16a–f(shown in phantom inFIG. 3) about the perimeter and across its lower width by support beams16gand16hto support the floor panel14and thereby reinforce the load carrying capacity of the deck12.

The material handling cart10further includes at least two spaced apart wheel assemblies20. The wheel assemblies20each include wheel support brackets18that are positioned at opposing sides of the primary deck12and are adapted to receive and support a wheel21. Preferably, the wheel assemblies are positioned centrally to the length of the primary deck12such that loads are easily centered and balanced for transport. The wheel assemblies20preferably include a rubber tire21ahaving a sufficient diameter to allow the material handling cart10to be navigated over rough terrain, such as gravel, and that easily passes over uneven surfaces.

The material handling cart10further includes a first side-rail assembly22and a second side-rail24. The first and second side-rails22and24are connected to the primary deck12at opposing sides and preferably have longitudinal axis parallel to the rotation axis of the wheels21. The first and second side-rails22and24are preferably made of a suitable material such as aluminum pipe, although other materials such as wood and plastic may be used. Any configuration of the side-rails is suitable so long as the side-rails provide for the lateral containment of objects being transported by the material handling cart10. The first and second side-rails22and24are shown in a substantially inverted U-shape configuration; however, such a shape is merely a preference and other shapes are readily envisioned. Preferably, as shown inFIGS. 1–2, the first and second side-rails22and24each comprise a substantially continuous metal pipe having a front leg28, a front corner29, a top rail30, a rear corner31and a rear leg32. Optionally, the side-rails may be fitted with a mesh, screen or sheet wall (none shown) so that small items that otherwise might pass laterally through the space between the front leg28, rear leg32, primary deck12and top rail30are contained. Likewise, a suitable mesh, screen or wall may be fitted between the front leg28of the first side-rail22and the front leg28of the second side-rail, or between the rear legs32for similar function.

The first and second side-rails22and24are preferably removably connected to the primary deck12. This is accomplished by providing a plurality of support sleeves26that are rigidly connected to the primary deck12. Each of the plurality of support sleeves26include a cavity26a(seen inFIG. 3) having an inner diameter greater than the outer diameter of the pipe or other material from which the side-rails22and24are fashioned. The plurality of support sleeves26are appropriately spaced and each are adapted to receive a leg of the side-rails22and24. As best illustrated inFIG. 2, the support sleeves26each preferably include a shoe member27that closes the bottom of the support sleeve26. When the legs28and32of the side-rails22and24are inserted into the support sleeves, the bottoms of the front and rear legs28and32rest in the support sleeves26on the shoe members27. A retaining pin33may be provided that can be inserted through complimentary apertures in the support sleeves26and respective legs28and32to prevent the unwanted removal of the side-rails22and24. The shoe members27are preferably inclined such that when the material handling cart is allowed to rest upon a surface, the underside of the shoe member27engages the surface over substantially its entire lower surface area. In other words, the inclination of the shoe members27provide for increased contact with the surface and thereby reduces the risk of slipping or rolling, especially when the cart is brought to rest on an incline, since the underside of the shoe members27rest flat on the surface. Optionally, each of the shoe members27may be fitted with a rubber sole to increase the friction with the support surface and/or to prevent scratching of flooring surfaces.

Each of the first and second side-rail assemblies22and24include an independently extendable handle assembly40, which is best illustrated inFIG. 2. For ease of illustration, the description of the independently extendable handle assembly40will be made with respect to the first side-rail assembly22; however, such description is equally applicable to the independently extendable handle assembly40of the second side-rail assembly24. The independently extendable handle assembly40comprises a handle tube41connected to the first side-rail22and preferably includes a longitudinal axis substantially perpendicular to the axis of rotation of the rotatable wheel assemblies20. Preferably, the handle tube41extends parallel to the primary deck12and the full length of the first side-rail22. Preferably, the handle tube41includes a first portion41aand second portion41bthat extend outwardly beyond the front leg28and rear leg32respectively for reasons that will become more apparent below. The handle tube41includes an inner passage42(shown in phantom lines inFIG. 2) extending substantially the length thereof and adapted to receive a inner handle member43. The inner handle member43comprises a rod or tube having an outer diameter less than the inner diameter of the handle tube41such that the inner handle member43may be slidably received by the handle tube41. The inner handle member43is preferably longer than the handle tube41and is further adapted to be adjustably positioned such that the inner handle member43may extend outwardly form the handle tube41a desirable amount. A rear stop45amay be provided on the handle tube41to prevent the inner handle member43from extending beyond the rear end of the handle assembly40. Preferably, the independently extendable handle assembly40further includes a means for adjustably securing the inner handle member43at desired outwardly extending positions, such as a hand-turnable setscrew44extending through a front stop collar45b. Alternatively, the inner handle member43could be provided with a plurality of longitudinally spaced apertures that could be independently aligned with a complimentary aperture provided through the stop collar45. In such a case, a pin could then be placed through the aligned apertures to secure the inner handle member43in a selected position.

In another embodiment of the invention (not illustrated), the handle tube41is open at both ends and both the front and rear ends include a means for securing the inner handle member43. The inner handle member43may then be selectively extended from either end of the cart10. Thus, one inner handle member43could be extended and secured outwardly from the front end13, while the other inner handle member43is extended outwardly and secured at the rear end15. This feature doubles the usable length of the cart10by allowing one operator to push on an inner handle member while a second operator pulls on the opposite inner handle member.

Optionally, the material handling cart10further includes a convertible secondary deck assembly, shown generally at60. The secondary deck assembly60comprises a first convertible deck arm61and second convertible deck arm62. The first convertible deck arm61preferably is comprised of similar material to the side-rails and includes a first end63and a second end64. As best shown inFIG. 1, the first end63is pivotably connected to the first side-rail assembly22at a position vertically spaced from the primary deck12, and more preferably pivotably connected to the first portion41aof the handle tube41at a position vertically spaced from the front end13of the primary deck12. However, the first convertible deck arm61may also be connected to the top rail30or any other position on a side-rail. InFIGS. 1 and 2, the first end63includes a deck arm sleeve66that is adapted to fit over and around the handle tube41at the first projection41a. In other words, the deck arm sleeve66includes a passage having an inner diameter greater than the outer diameter of the handle tube41. The first convertible deck arm61is retained on the handle tube41by stop collar45a. Thus, the deck arm61can rotate freely about the handle tube41. As the skilled artisan will appreciate, the first convertible deck arm61may be pivotably attached to either the first side-rail22or the second side-rail24. The second end64is adapted to make rotation-limiting engagement with the second side-rail24. Preferably, the second end64includes an engagement bracket65that enables the first convertible deck arm61to rest on the opposing side-rail in a substantially horizontal position. The engagement bracket65may take any form, such as an L-bracket as shown inFIG. 4or a semi-circular bracket having a central axis parallel to the handle tube, as shown inFIG. 1. The engagement bracket65ensures that the first convertible deck arm61has a length greater than the distance between the first and second side rails22and24. Thus, the deck arm61may pivot about the first end63until the second end64engages the opposing side rail and may rest thereupon.

The second convertible deck arm62is preferably comprised of similar material as the side-rails and includes a first end63and a second end64identical to that described for the first convertible deck arm61. As best shown inFIGS. 1 and 2, the first end63is pivotably connected to the first side-rail assembly22at a position vertically spaced from the primary deck12, and more preferably pivotably connected to the second portion41bof the handle tube41at a position vertically spaced from the rear end17of the primary deck12. However, the first convertible deck arm61may also be connected to the top rail30or any other position on a side-rail. InFIGS. 1 and 2, the first end63includes a deck arm sleeve66that is adapted to fit over and around the handle tube41at the second portion41band is retained on the handle tube by the rear stop45a.

The first and second deck arms61and62may also be connected together by a cross arm (not illustrated) that would provide for the simultaneous pivoting of both arms. Thus, an operator may engage the convertible secondary deck assembly by manipulating only the closest deck arm. A plurality of such cross arms or mech screen may be provided to create a basket-like secondary deck. When not engaged by and resting upon the opposing side rail, the first and second convertible deck arms61and62hang parallel to the front and rear legs28and32. Optionally, the front and rear legs28and32may include a retaining element (not shown) to prevent the arms61and62from swinging freely when not in use.

While various features of the invention have been particularly shown and described in connection with the illustrated embodiments of the invention, it must be understood that these particular arrangements merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims.