Brake assembly and control mechanism for a cart, and method

A cart having a frame for conveying cargo. The cart includes at least one brake assembly mounted within the frame of the cart. The brake assembly is configured to provide braking by engaging and disengaging a rear wheel axle. The cart further includes a control mechanism configured to selectively engage and disengage the brake assembly by rotation of a cart handle. In addition, the cart includes a brake release device configured to disengage the brake assembly when carts are nested.

TECHNICAL FIELD

This invention generally relates to a braking mechanism for a wheeled cart. More particularly, the invention relates to a brake assembly, control mechanism, and method of braking for use with a wheeled cargo cart.

BACKGROUND

Carts are used to transport items in commercial establishments, such as groceries in supermarkets and luggage in airports. Customers place their items into such carts in order to transport the items to their parked vehicle or other destinations. When customers are done with the carts, the carts are placed in central collection areas or simply left unattended. Often the central collection areas serve as rental and return stations such that the customer is reimbursed for returning a cart.

Unattended carts pose problems. Many existing carts do not have brakes. These unrestrained carts can roll freely and cause damage to both persons and property. This is of particular concern on train platforms, where an unrestrained cart can cause damage to the transportation system. The carts themselves also sustain damage thereby reducing the useful life of the cart. Therefore a brake system is needed that automatically engages when the cart is left unattended in certain installations.

Several attempts have been made to employ brakes in cart. Most existing cart brakes operate against the tire tread of a cart wheel. This has several disadvantages. For example, the tire tread can become abnormally worn down, reducing the traction and ultimate safety of the cart. As the tread wears, brake performance is diminished. In addition, the wheels must be replaced at regular intervals which increases the overall cost of maintaining carts. Also, brake mechanisms acting on the outside of the wheel are more susceptible to damage, e.g., the brakes can be easily struck by a foreign object such as a foot or other carts. In addition, tire treads have a tendency to pick up debris, water and other contaminants which can damage and reduce the overall effectiveness of the braking mechanism. Therefore a need exists for a durable brake which will not degrade the tire nor reduce the operational safety of the cart.

Further, nestable carts place certain demands on the braking system. First, the braking system must be compatible with the typical rental-return station. A common type of rental-return station accepts the rear wheel of a cart through a guided wheel slot. The wheel fits snugly within the slot, and the slot opening is locked to prevent unauthorized access. Brake arrangements that operate by engaging the tire tread are typically positioned on the outside of the wheel, and do not easily fit within the guided wheel slot. Even if the brake fits within the slot, it is highly susceptible to damage by the guided wheel slot.

Another requirement of nestable carts is the release of the braking mechanism. Carts are often nested together and returned to a central collection area in a long train arrangement. When the carts are nested, all brakes must be released in order to transport the train arrangement.

Therefore, a need exists for a durable cart brake mechanism that will automatically engage when left unattended, and be configured for receipt within guided wheel slots of return stations. The brake must also disengage when nested with another cart to facilitate en masse cart movement.

SUMMARY

One aspect of the present invention relates to a cart having a frame with support members that define a cargo carrying region. The cart also includes a moveable handle connected to the frame and a brake assembly mounted to the frame. The brake assembly includes a brake mechanism and an axle. A wheel is mounted to the axle. The brake mechanism of the brake assembly is configured to engage the axle to provide braking operation of the cart, and disengage from the axle to permit free rotation of the axle.

Another aspect of the present invention relates to a brake and control assembly for a cart, the cart having a frame, a handle, and a wheel. The brake and control assembly includes a brake assembly and a brake control arrangement. The brake assembly is configured to mount to the frame of a cart, and includes a brake mechanism and an axle. The brake mechanism is arranged to selectively engage and disengage the axle during braking and non-braking operation of a cart. The brake control arrangement is configured to couple to the handle of a cart and includes a brake rod. The brake rod has an end positioned adjacent to the brake assembly to control the braking and non-braking operation of a cart.

Yet another aspect of the present invention relates to a method of operating a cart, the method including providing a cart having a frame, a moveable handle connected to the frame, a brake assembly having a brake mechanism and an axle, and a wheel mounted to the axle. The method further includes rotating the handle of the cart to disengage the brake assembly to permit free rotation of the axle, and releasing the handle to engage the brake assembly such that the brake mechanism contacts the axle to provide braking operation of the cart.

Still another aspect of the present invention relates to a cart for carrying cargo having a frame a moveable handle and a brake assembly. The brake assembly is configured to engage and disengage by rotation of the moveable handle. The cart also includes a brake release device. The brake release device is configured to pivot from a first position to a second position, wherein the brake assembly disengages to permit transport of the wheel when the brake release device is in the second position.

And another aspect of the present invention relates to a method of transporting carts, including a first cart and a second cart, each of the carts having a brake release pivotably mounted thereto. The method includes pivoting the brake release device of the first cart from a first position to a second position by nesting the second cart within the first cart, and disengaging a brake assembly of the first cart by pivoting the brake release device of the first cart to the second position.

A variety of aspects of the invention are set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practicing various aspects of the disclosure. The aspects of the disclosure may relate to individual features as well as combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the claimed invention.

DETAILED DESCRIPTION

A preferred embodiment of the invention will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to the preferred embodiment does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto.

Referring generally toFIG. 1, the present invention relates to a brake assembly30and a brake control mechanism20for a wheeled cart100. In use, the brake assembly30is normally engaged when a handle16of the cart100is released, that is, the brake assembly prevents the cart from rolling when the handle is not rotated. When the handle16is depressed (i.e. rotated or pushed downward), the brake assembly30is disengaged and the cart100is permitted to roll.

The present invention has many advantages. One advantage is that the brake assembly30is normally engaged when the cart100is left unattended. This enhances the overall safety of the cart100and ensures that the cart is not subjected to damage due to uncontrolled movement.

Another advantage is that the brake assembly30does not interact with the wheel18when braking. As a result, braking action is not affected by wheel wear nor does the brake assembly inflict undue damage on the tire tread. Further brake performance is not affected by sand, moisture, or other damaging contaminants that are airborne or would be picked up by the tire tread. This lengthens the useful life of the brake assembly and the wheel.

Still another advantage is that the brake assembly30does not interfere with existing guided wheel slots of rental-return stations200(FIG. 3), which capture and release the rear wheel18of the cart100. In addition, the present brake assembly provides braking action in both the forward and reverse directions. Finally, the brake assembly30is configured and arranged for easy replacement and maintenance.

The cart100illustrated inFIG. 1is configured for transporting materials, such as packages or luggage, for example. The cart includes a frame10generally having a front end34and a rear end36. The frame10includes first and second rearward upright support members12extending upward from a sleeve joint82. The first and second rearward upright support members12have a hollow tubular construction (shown inFIG. 12). A lower platform24extends forward from the sleeve joint82. A pair of rear wheels18are oppositely positioned toward the rear end36of the cart100. A front rotatable caster22that permits the cart to turn is mounted to the lower platform24toward the front end34of the cart100.

The handle16is operably coupled to each of the rearward upright support members12to manually control operation of the brake assembly30and transport of the cart100. In particular, the handle16is interconnected to first and second brake control mechanisms20by first and second lever arms44. The first and second brake control mechanisms20are positioned adjacent to an upper portion52of the rearward upright support members12.

The brake control mechanisms20operate to engage and disengage the brake assemblies30. When the handle16is released, represented by position (A) inFIG. 1, the brake assemblies30are normally engaged and prevent rotation of the rear wheels18. When the handle16is depressed, as represented by dashed lines and position (B) inFIG. 6, the brake assemblies30become disengaged and permit rotation of the rear wheels18.

Still referring toFIG. 1, the frame10further includes forward upright support members14and cross support members26. The forward upright support members14are connected to the upper portion52of the rearward upright support members12and to the cross support members26. The cross support members26are connected to a lower portion54of the rearward upright support members12and to the lower platform24. In the illustrated embodiment the cross support members26have an arcuate shape.

The lower platform24of the frame10extends forwardly from the rearward upright support members12. In the illustrated embodiment, the lower platform24includes an outer lower support member56and an inner lower support member58.

In the illustrated embodiment, the outer lower support member56has a U-shape configuration. The outer lower support member56is arranged to extend from the sleeve joint82and an angle C relative to the ground. The angle C is constructed so that cargo placed on the lower platform24is oriented or angled upward from horizontal to prevent the cargo from falling forward off the cart100. In a preferred embodiment the angle C is greater than 6 degrees, more preferably, the angle C is between 7 degrees and 20 degrees. Most preferably, the angle C is about 14 degrees.

To further improve cargo stability, the cross support members26of the frame10are configured so that larger suitcases can be rearwardly tipped or oriented on the lower platform24of the cart100. For example, larger suitcases can be placed on the lower platform24of the cart100and pushed rearwardly towards the cross support members26so that the bottom of the suitcase contacts the most forward end of the cross support member26. The top end of the suitcase can then be tipped backwards toward the upright support members12,14to lessen the tendency for the suitcase to fall forward.

As can be seen inFIG. 1, a bumper assembly68including cushioned side rollers70is secured to the outer lower support member56at the front end34of the cart100. The bumper assembly68and side rollers70protects the cart and other objects from damage caused by impact that may occur during use.

The inner lower support member58is connected to, and positioned centrally inward from, the outer lower support member56. In the illustrated embodiment, the inner lower support member58also has a U-shape configuration. As shown inFIG. 10, a mounting bracket60is coupled to the inner lower support member58toward the front end34of the cart100. The front caster22(FIG. 1) is mounted to the cart100at the mounting bracket60.

Still referring toFIG. 1, the frame10further includes transverse supports. First and second transverse bars64,66are positioned to structurally support the rearward upright support members12. The first transverse bar64is positioned and coupled to the lower portions54of the rearward upright support members12. The second transverse bar66is positioned and coupled to the upper portions52of the rearward upright support members12. A transverse lower support member62is interconnected to the outer lower support member56, extending transversely across the U-shaped configuration. The transverse lower support member62structurally supports the lower platform24.

Referring toFIG. 10, the lower platform24is configured such that during nesting operation, the forward end of a trailing cart (e.g.100bshown inFIG. 10) that is nested within a leading cart100arides up on the inner lower support member58. The forward end of the trailing cart100bis thereby lifted upward so that the front caster22of the trailing cart no longer contacts the ground. This design saves on wear and tear of the front caster22during transport of a nested group of carts.

Still referring toFIGS. 1 and 10, a pair of stopping elements72is positioned on the inner lower support member58of the cart frame10to stop forward motion of a trailing cart100b. In particular, the stopping elements72of a leading cart100aengage the outer lower support member56of a trailing cart100bso that neither of the carts interfere with the other cart's rear wheels18. The stopping elements72also provide a space between successive carts. The space provides “spatial play” between successive carts of a long nested group so that each cart can turn relative to another. The spatial play permits a long nested group to curve or bend during transportation of the nested carts.

During a nested group transport (i.e. transport of a number of nested carts), a rope or cable (not shown) can be hooked and entrained to a loop member74(FIG. 1) of each cart. The rope or cable can be used to interconnect each of the nested carts of the group to hold the carts together during movement or transport.

In the illustrated embodiment ofFIG. 1, a cargo basket76is mounted to the rearward and forward upright support members12,14. It is contemplated that the cargo basket76can be mounted to other frame components; or that other types and configurations of baskets or cargo carrying structures can be used. The illustrated embodiment further shows side panels78located between the rearward and forward upright support members12,14; and a rear panel80located between each of the rearward upright support members12. The panels assist to contain luggage or cargo carried on the cart and can further be used as a surface upon which logos, information, or advertisements may be placed.

Referring now toFIG. 2, one embodiment of the rear wheel18and brake assembly30is illustrated. The brake assembly30is fixedly positioned and mounted within the sleeve joint82of the frame10. As can be understood, maintenance and replacement of the brake assembly is easily performed, as the brake assembly30is readily accessible at the sleeve joint82. The brake assembly30of the illustrated embodiment is a pre-assembled component to also simplify maintenance and replacement. Because of the placement and the pre-assembled configuration of the brake assembly, any necessary replacements can be accomplished less than 2 minutes. In the preferred embodiment, the brake assembly has no expendable parts; thus the entire brake assembly is replaced whenever replacement is necessary. The illustrated brake assembly30is a sealed assembly to reduce the frequency of cleaning maintenance and any affect caused by moisture or other contaminates.

The brake assembly30includes a housing83having an input location84, and a shoulder88. The illustrated housing83is approximately 1.5 inches in diameter. The shoulder88of the housing83is configured to position the brake assembly30within the sleeve joint82such that the input location84is aligned with the rearward upright support member12.

In a preferred embodiment, the brake assembly30is a wrap-spring type brake assembly. A typical wrap-spring brake assembly includes a stationery member (not shown), an output member86, and a torsion spring (not shown) arranged to contact both the stationery member and the output member86. Wrap-spring brake assemblies require no operating pressure to engage or disengage the brake, such as found in compression-spring type brakes. Rather, the torsion spring, in this embodiment, wraps down upon the output member86when engaged. The wrap-spring configuration requires less user effort to engage or disengage the brake, as compared to traditional compression-spring type brakes.

In the illustrated embodiment, the output member86of the brake assembly30is arranged to operate as a wheel axle; the brake assembly30functions to engage and disengage the wheel axle86to provide braking action. The rear wheel18includes a wheel hub90configured to couple with the axle86. Bearings (not shown) are located within the brake assembly30. Thus, rotation of the rear wheel18occurs only in concert with the axle86. Because the brake assembly30operates to brake the axle86rather than contact the wheel18, the brake assembly30can be used with a variety of different sized wheels configured to fit the axle86.

In the illustrated embodiment, a fastener92is used to securely couple the rear wheel18to the axle86. When the wheel18is worn, the fastener92is simply removed and the wheel replaced, without having to remove or replace the brake assembly30. Other configurations, such as a cotter pin connection, for example, can be used to couple the rear wheels18to the output member86in accord with the principles disclosed.

In one embodiment, the brake assemblies30are adjustable so that the slip torque of the brake assembly can be modified to fit a customer's particular application. That is, various airports and customers have different needs and standards with regards to preventing carts from rolling. In some situations the brake assembly must be configured to prevent a cart from rolling down a gentle incline; while in other situations the brake assembly must be configured to prevent a cart from rolling down a much steeper incline. Thus, in the preferred embodiment, the brake assembly30is adjustable to accommodate a variety of customer applications, while configured and constructed to provide consistent braking power at the selected torque output. One brake assembly that can be used in accord with the principles disclosed is manufactured by Reell Precision Manufacturers, and generally described in U.S. Pat. No. 6,561,333, which U.S. Patent is herein incorporated, in its entirety, by reference. Other types of brakes that operate to engage and disengage an axle to prevent and permit rotation, in accord with the present disclosure, are contemplated.

Referring now toFIG. 3, the presently disclosed cart embodiment is configured for use with standard vending systems or return stations200. One example of a return station is described in U.S. Pat. No. 3,978,959, and herein incorporated by reference. A return station typically includes a channel202into which at least one of the rear wheels18of the cart100is retainably placed.

Older conventional carts did not include brakes. Newer conventional carts incorporating brakes are often, incompatible with, or difficult to position within the channel202of a return station200because of obstruction or interference between the brakes and the channels202. The present disclosure discloses a cart100having a brake assembly30that is compatible with existing return stations. In particular, the braking assembly30is positioned, and operates, so as to not obstruct the area surrounding the rear wheels18; so that placement of the rear wheel within the channel202of a return station200is not hindered.

The brake assembly30is engaged and disengaged by operation of an actuation assembly. Referring now toFIG. 4, one embodiment of the actuation assembly94, in accord with the present disclosure, is illustrated. As can be understood, the illustrated cart100includes first and second actuation assemblies94corresponding to the first and second brake assemblies30. Each of the actuation assemblies94is positioned within the hollow construction of the rearward upright support members12.

The actuation assembly94includes an actuation or brake rod92, a spring106, and a brake rod center piece110. The brake rod center piece110is secured to the brake rod92by a retaining ring or clip114and positioned so that an end portion116of the brake rod92extends beyond the brake rod center piece110(FIG. 5). The brake rod center piece has a main portion104and a shoulder112. As shown inFIG. 5, the spring106is positioned on the outer diameter of the main portion104. Fasteners108(e.g. rivets) are mounted within corresponding holes102formed in the rearward upright support members12. The fasteners108are positioned to preload the spring against the shoulder112of the brake rod center piece110. When the actuation assembly94is assembled within the rearward upright support members12, the brake rod center piece110centers the end portion116of the brake rod92with the input location84(FIG. 2) of the brake assembly30.

FIG. 5illustrates the actuation assembly94in relation to the brake assembly30. A target or brake actuation button118is located adjacent to the input location84of the brake assembly30. When the target118is depressed by contact with the end portion116of the brake rod92, the brake assembly30engages the axle86to provide braking action. When the target118is released, the end portion116of the brake rod92is moved upward off the target118and the brake assembly disengages the axle86to permit free rotation.

Still referring toFIG. 5, the actuation assembly94is shown in relation to the brake control mechanism20. The brake rod92, residing within the rearward upright support members12, interconnects the actuation assembly94and the brake control mechanism20. As can be seen inFIG. 1, the rearward upright support members12can be slightly curved. The brake rod92can also be slightly curved or angled to correspond to the rearward upright support members12(FIG. 13).

The brake control mechanism20of the present disclosure generally includes a first compression spring122, a first catch126, and a lift wire130. The first catch126includes an aperture192through which the brake rod92is positioned. The first catch126is located adjacent to the lift wire130. The first compression spring122biases the first catch126downward on the lift wire130.

When the handle16is released, the catch126is oriented generally perpendicular to the brake rod92. The first compression spring122assists to bias and maintain the first catch126in this release position (represented as126(A)).

The lift wire130of the brake control mechanism20is arranged and configured to move in concert with the handle16. As the handle16is depressed, the lever arm44causes the lift wire130to pivot. Specifically, as the handle16is depressed, the lever arm44rotates around the pivot joint134, which pivots the lift wire130from a position shown as130(A) inFIG. 6, to a position shown as130(B).

When the handle16is depressed, the force from the pivoting action overcomes the bias of the first spring122, and the lift wire130pivots causing the first catch126to pivot. In particular, as the lift wire130pivots from a release position130(A) to a depressed position130(B), the catch126likewise pivots from the release position126(A) to a depressed position126(B). During rotation of the handle16, the plane of the catch126moves from a position that is generally perpendicular to the axis of the rod92to a position that is cocked or non-perpendicular to the axis of the rod92. When the catch126cocks in this matter, edges124of the aperture192bind or catch on the outer diameter of the brake rod92. This causes the first catch126to bind or catch in a fixed relation or interference with the brake rod92. Continued rotation of the handle16further pivots the lift wire130, thereby lifting both the first catch126and the bound brake rod92. In one embodiment, the catch126causes the brake rod92to move upward a distance d1of between 0.25 inches and 0.5 inches; preferably the catch126moves the brake rod92upward a distance d1of approximately 0.325 inches. As the brake rod92moves upward, the end portion116(FIG. 5) of the brake rod92lifts off the target118, represented by arrow (B), thereby disengaging the brake assembly30.

Referring now toFIGS. 7-9, the brake control mechanism20includes a control mechanism housing132to which the lever arm44of the handle16is pivotally connected. A cover170is provided to cover and protect the internal components of the brake control mechanism20. The cover170includes a first portion171and a second portion173. A guide pin154is formed on the control mechanism housing132. The guide pin154corresponds to guide structure (not shown) formed on each of the first and second portions171,173of the cover, and assists in aligning and joining the portions of the cover170. When the portions171and173are joined, a slot175is formed through which the lever arm44extends. The slot175is configured to accommodate the pivoting motion of the lever arm44.

The lever arm44connects to control mechanism housing132at a pivot joint134. The pivot joint134includes two flanges136extending outward from the control mechanism housing132. The flanges136have apertures138sized and configured for receipt of bearings140. A pin142extends through each of the bearings140and flanges136, and an opening144in the lever arm44, to pivotally connect the lever arm44to the control mechanism housing132.

As show inFIGS. 8 and 9, the lever arm44includes holding structure146located on either sides of the lever arm. The holding structure146is configured for receipt of each of the free ends160of the lift wire130. In the illustrated embodiment the holding structure146includes a pair of grooves148within which the free ends160of the lift wire130are positioned and securely held. Other types of structure that fixedly retain the lift wire130in relation to the lever arm44can be used.

Still referring toFIG. 8, the lever arm44also includes a contact surface152. The contact surface152of the lever arm44is configured to contact a surface156(FIG. 9) of the control mechanism housing132. The contact surface152of the lever arm44and the stop surface156of the control mechanism housing132are configured to limit rotation of the handle16. Referring back toFIGS. 5 and 6, the handle16and lever arm44are configured to rotate downward to the depressed position (B) oriented at an angle D from the released position (A). Preferably the handle16(and the lever arm44) has a limited angle of rotation D between 8 degrees and 15 degrees; more preferably the angle of rotation is limited to approximately 12 degrees.

Still referring toFIG. 8, the illustrated brake control mechanism20also includes a second catch128, a second compression spring162, and a third extension spring164. The third extension spring164is coupled between a closed end158of the lift wire130and a connection166located on the control mechanism housing152. The third expression spring164acts to bias the closed end158of the lift wire130downward, thereby biasing the free ends160of the lift wire130upward. Because the free ends160of the lift wire130are secured within the grooves148of the holding structures146on the lever arm44, the extension spring164also acts to bias lever arm44and handle16toward the upward release position (A).FIGS. 7 and 9illustrate the lever arm in release position (A).

As best shown inFIG. 9, while the third extension spring164is biasing the first end158of the lift wire130downward, the first compression spring122also acts to bias first catch126and the lift wire130downward. The second catch128and the second compression spring162operate to release the brake assembly30, as will be discussed in greater detail hereinafter.

The control mechanism housing132defines a number of chambers or regions sized, arranged, and configured to operably connect the brake control mechanism's components. In particular, the housing132includes: a first region194(FIGS. 7 and 8) at which the first catch126and the first compression spring122are positioned; a second region196(FIG. 9) within which the second compression spring162is positioned; and a third region198(FIGS. 7 and 8) within which the second catch128is positioned. The second region196extend into the third region198to provide interaction between the second compression spring162and the second catch128, as will be described in greater detail hereinafter. A cap163(FIG. 8) is secured to an opening197of the second region196to contain and preload the second compression spring162. The housing132further defines a first opening184positioned adjacent to the first region194through which an end of the first catch126extends, and a slotted opening186positioned adjacent to the second region196through which the second catch128extends.

Referring back toFIG. 10, it is desirable to transport multiple carts in a nested group, and/or to nest a plurality of carts within a vending system or island200. As previously discussed, when the handles16of the carts100are not depressed, the brake assemblies30prevent rotation of the rear wheels18. In the present disclosure, the carts are not configured such that the handles16are depressed when engaged in a nested group. In accordance with the present disclosure, a brake release device96is provided to disengage the brake assemblies30when the cart is nested.

FIGS. 10-14illustrate one embodiment of the brake release device96. As the carts are nested, the trailing cart100bengages the brake release device96of a leading cart100a. The brake release device96causes the actuation assembly94(FIG. 5) to disengage from the brake assembly30, thereby permitting rotation of the rear wheels18for transport. As described in greater detail hereinafter, the brake assembly30remains disengaged until the brake control mechanism20is reset by depressing and releasing the handle16.

Referring toFIG. 11, the brake release device96is positioned adjacent to the lower portion54of at least one of the rearward upright support member12. The brake release device96generally includes an engagement lever172connected to a housing174. The housing174includes an inclined plane or cam surface176.

The position of the brake release device96at the rear end36of the cart100provides several advantages. One advantage relates to the timing of brake release in nesting operations. Conventional cart designs incorporating braking devices often require a trailing cart to depress the handle of a leading cart to disengage the braking device. In this design, the trailing cart needs to be almost completely placed or nested within the leading cart before the braking device is disengaged. Another design uses a cable interconnected to and activated by a device located near the caster wheel. In this design, again, the trailing cart needs to be almost completely nested within the leading cart before the braking device is disengaged.

In the present brake release device arrangement, the brake assembly30is disengaged when the trailing cart100bcontacts the engagement lever172of the leading cart's brake release device96. The cart need only be partially nested to disengage the brake assembly30. In addition, the brake release device96is designed so that the trailing cart can initially engage the leading cart at an angle and still contact the engagement lever172to disengage the brake assembly30. Thereby precise placement of the cart100is not necessary to disengage the brake assembly30, permitting a user some variance in nested placement. Because the brake assemblies30of the leading carts are more quickly disengaged than in conventional designs, a user can more quickly move the carts together in a tight nested group, and more quickly transport the nested group.

Further, some conventional designs requiring almost complete nesting to disengage the braking devices can cause transport problems if one or more of the carts being transported become partially separated and lock up when the brakes engage. In the present disclosure, spatial separation between nested carts during transport does not cause the brake assembly30to lock up.

Referring back toFIG. 4, a lift pin or dowel178is secured to the brake rod92at a positioned in relation to the brake release device96(see alsoFIG. 12). When a trailing cart100b(FIG. 10) is not nested or engaged with a leading cart100a, the engagement lever172of the brake release device96extends inward towards the center of the cart frame10(see alsoFIG. 1). Referring still toFIG. 10, when a trailing cart100bengages the leading cart100a, the engagement lever172rotates forward, as shown by the arrow inFIGS. 10 and 11. Rotation of the engagement lever172is caused by contact from the cross support member26of the trailing cart100b.

Referring toFIG. 11, when the housing174rotates, the lift pin178rides upward along the cam surface176to lift the brake rod92upward. The pin178extends out through slots98formed in the hollow construction of the rearward upright support members12. The slots98are configured and oriented to accommodate the upward movement of the lift pin178. In the illustrated embodiment, the housing174includes two cam surfaces176upon which the opposite ends of the lift pin178engage.

As shown inFIG. 12, the lift pin178and brake rod92are lifted upward a distance d2. In one embodiment, the lift pin178and brake rod92are lifted upward a distance d2of between 0.350 inches and 0.500 inches; preferably the lift pin178and brake rod92are lifted upward a distance d2of approximately 0.400 inches. As the brake rod92moves upward, the end portion116(FIG. 5) of the brake rod92lifts off the target118, thereby disengaging the brake assembly30.

Referring now toFIGS. 13-14, operation of the second catch128with respect to operation of the brake release device96is illustrated. The second catch128includes an aperture190through which the brake rod92is positioned. When the handle16is released, position (A), the second catch128of the brake control mechanism20is biased downward on one end182. As shown best inFIG. 13A, the second compression spring162causes edges168of the aperture190of the catch128to bind or catch on the brake rod92. Thus, when the handle16in is a release position, the second catch128binds on the brake rod92preventing downward movement of the brake rod92.

Referring now toFIG. 14, when the handle is depressed, a portion188of the lever arm contacts the one end182of the second catch128. The upward force caused by the portion188of the lever arm is sufficient to overcome the biasing force of the second compression spring162. As shown inFIGS. 14 and 14Athe upward force from the portion188of the lever arm shifts the second catch128upward to a position (B) generally perpendicular with the brake rod92. In position (B), the brake rod92is free to move up or down within the aperture190of the second catch128. As previously described, when the handle is further rotated, the lift wire130(FIG. 6) pivots to engage the first catch126. By this arrangement, the lever arm44acts to both un-bind the second catch128and bind the first catch126when the handle16is depressed. This action occurs in a substantially simultaneous period of time.

When the brake rod92is lifted upward by the cam surfaces176of the brake release device96, and the handle16is in the released position, the second catch128is oriented to bind with the brake rod92, as shown inFIG. 13A. The force of the cam surface acting on the lift pin178(FIG. 12), however, is sufficient enough to overcome the frictional force caused by the binding engagement of second catch128and the brake rod92. Thus, the brake rod92slides through the aperture190in the second catch128when the brake release device96is rotated, even though the second catch128is bound.

It is to be understood that the frictional forces caused by the second catch128can be modified by incorporating a compression spring having of a different strength, thereby providing a greater or lesser spring force and modifying the frictional force between the second catch128and the brake rod92. The extension spring164can likewise be modified to change the frictional force between the first catch126and the brake rod92.

When a cart is removed from a nested group of carts and the handle has not yet been moved, a return spring (not shown) contained within the housing174of the brake release device96returns the engagement lever172and the housing174of the brake release device96to their original positions. When this occurs, the second catch128is still engaged and binding on the brake rod92to hold the brake rod92up from the brake assembly target118. The brake assembly30is thereby still disengaged and the cart is free to roll.

To re-engage the brake assembly30, the handle16is depressed to reset the brake control device20. In particular, depressing the handle16causes the portion188of the lever arm44to shift the second catch128to the position (B) generally perpendicular to the brake rod92(FIG. 14). At substantially the same time, the first catch126binds on the brake rod92, as previously described. When the handle16is subsequently released, the brake control mechanism20and the brake rod92are “re-set” to the release position (A). When the brake rod92moves downward, i.e. the handle is released, the end portion116(FIG. 5) of the brake rod92contacts the target118, thereby engaging the brake assembly30. The first compression spring122and the compression spring106of the actuation assembly96assist in biasing the brake rod92downward.

Referring now toFIGS. 15-30, a second embodiment of a wheeled cart300is illustrated. As shown inFIG. 15, the second embodiment of the wheeled cart300also includes a brake assembly230and a brake control mechanism220. In use, the brake assembly230is normally engaged when a handle216of the cart300is released, that is, the brake assembly prevents or inhibits the cart from rolling when the handle is not rotated. When the handle216is rotated (i.e. depressed or pushed downward, or raised or lifted upward), the brake assembly230is disengaged and the cart300is permitted to roll.

The second embodiment of the present invention includes the advantages as discussed with regards to the previous embodiment. For example, the brake assembly230is normally engaged when the cart300is left unattended; the brake assembly230does not interact with the surface of the wheel218when braking; and brake performance is not affected by sand, moisture, or other damaging contaminants that are airborne or would be picked up by the tire tread. Also, the brake assembly230does not interfere with existing guided wheel slots of rental-return stations200(FIGS. 3 and 17), provides braking action in both the forward and reverse directions; and is configured and arranged for easy replacement and maintenance.

The basic frame construction of the cart300is similar in configuration to that of cart100described with respect to the first embodiment of the invention. The cart300illustrated inFIG. 15includes a frame210generally having a front end234and a rear end236. The frame210includes first and second rearward upright support members212extending upward from a sleeve joint282(FIG. 16). The first and second rearward upright support members212have a hollow tubular construction (shown inFIG. 18). A lower platform224extends forward from the sleeve joints282. Rear wheels218are oppositely positioned toward the rear end236of the cart300. A front rotatable caster222that permits the cart to turn is mounted to the lower platform224toward the front end234of the cart300.

Still referring toFIG. 15, the handle216is operably coupled to each of the rearward upright support members212to manually control operation of the brake assembly230and transport of the cart300. In particular, the handle216is interconnected to first and second brake control mechanisms220by first and second lever arms244. The first and second brake control mechanisms220are positioned adjacent to an upper portion252of the rearward upright support members212.

The brake control mechanisms220operate to engage and disengage the brake assemblies230. When the handle216is released, represented by the handle position shown inFIGS. 15 and 21, the brake assemblies230are normally engaged and prevent rotation of the rear wheels218. When the handle216is rotated, as shown inFIGS. 22 and 23, the brake assemblies230become disengaged and permit free rotation of the rear wheels218.

Still referring toFIG. 15, the frame210further includes forward upright support members214and cross support members226. The forward upright support members214are connected to the upper portion252of the rearward upright support members212and the cross support members226. The cross support members226are connected to a lower portion254of the rearward upright support members212and the lower platform224. In the illustrated embodiment the cross support members226have an arcuate shape.

The lower platform224of the frame210extends forwardly from the rearward upright support members212. In the illustrated embodiment, the lower platform224includes an outer lower support member256and an inner lower support member258.

In the illustrated embodiment, the outer lower support member256has a U-shape configuration. The outer lower support member256is arranged to extend from the sleeve joint282. Similar to the previous embodiment, the outer lower support member256is oriented so that cargo placed on the lower platform224is oriented or angled upward from horizontal to prevent the cargo from falling forward off the cart300. Cushioned side rollers270are secured to the outer lower support member256at the front end234of the cart300. The side rollers270protect the cart and other objects from damage caused by any impact that may occur during use.

The inner lower support member258is connected to, and positioned centrally inward from, the outer lower support member256. In the illustrated embodiment, the inner lower support member258also has a U-shape configuration. A mounting bracket260(also partially shown inFIG. 24) is coupled to the inner lower support member258toward the front end234of the cart300. The front caster222(FIG. 15) is mounted to the cart300at the mounting bracket260.

Still referring toFIG. 15, the frame210further includes transverse supports. In particular, first and second transverse bars264,266are positioned to structurally support the rearward upright support members212. A transverse lower support member262, located near the front end234of the cart300, is interconnected to the outer lower support member256. The transverse lower support member262structurally supports the lower platform224. In addition, the traverse lower member262is configured such that during nesting operation, the traverse lower support member262of a trailing cart (e.g.300bshown inFIGS. 24 and 25) rides upon on the inner lower support member258of a leading cart300a. The trailing cart300bis thereby lifted upward so that the front caster222of the trailing cart330bno longer contacts the ground.

Still referring toFIGS. 15 and 24, pair of stopping elements272is positioned on the outer lower support member256of the cart frame210to stop forward motion of the trailing cart300b. In particular, the stopping elements272of the trailing cart300bengage corresponding stop structures383of the leading cart300aso that neither of the carts interferes with the other cart's rear wheels.

During a nested group transport (i.e. transport of a number of nested carts), a rope or cable (not shown) can be hooked and entrained to a loop member274(FIGS. 15 and 16) of each cart. The rope or cable can be used to interconnect each of the nested carts of the group to hold the carts together during movement or transport. Similar to the previous embodiment, the wheeled cart300also includes a cargo basket276mounted to the rearward and forward upright support members212,214.

Referring now toFIG. 16, the brake assembly230of the second embodiment is fixedly positioned and mounted within the sleeve joint282of the frame210. The brake assembly230includes a housing283having an input location284, and a shoulder288. The shoulder288of the housing283is configured to position the brake assembly230within the sleeve joint282such that the input location284is aligned with the rearward upright support member212. A snap ring213is used to secure the brake assembly230within the sleeve.

The brake assembly230is similar in construction and operation to the brake assembly30previously described with respect to the first embodiment of the invention. The brake assembly230is a wrap-spring type brake assembly including an output member286arranged to operate as a wheel axle. The brake assembly230functions to engage and disengage the output member or axle286to provide braking action. The rear wheel218includes a wheel hub290configured to couple with the axle286. A fastener292couples the rear wheel218to the axle286.

Referring now toFIG. 17, the second wheeled cart embodiment300is also configured for use with standard vending systems or return stations200. That is, the brake assembly230is compatible with existing return stations. In particular, the braking assembly230is positioned, and operates, so as to not obstruct the area surrounding the rear wheels218; so that placement of the rear wheel within a channel202of a return station200is not hindered.

The brake assembly230is engaged and disengaged by operation of an actuation assembly294. Referring now to FIGS.18and21-23, another embodiment of the actuation assembly294, in accord with the present disclosure, is illustrated. As can be understood, the illustrated cart300includes first and second actuation assemblies294corresponding to the first and second brake assemblies230. Each of the actuation assemblies294is positioned within the hollow construction of the rearward upright support members212.

The actuation assembly294includes an brake rod292, a spring306, and a brake rod center piece310. The brake rod center piece310is positioned about the brake rod292. When assembled, the brake rod center piece310rests upon the sleeve282. That is, the hole (not shown) formed in the sleeve282through which the brake rod292extends is typically less than the inside diameter of the upright support member212; thereby providing a shoulder upon which the brake rod center piece310may rest. In the alternative, the brake rod center piece310can be configured with an interference fit so that the center piece310is frictionally secured at a position within the support member212. When the actuation assembly294is assembled within the upright support members212, the brake rod center piece310axially centers an end portion316of the brake rod292in alignment with the input location284(FIG. 18) of the brake assembly230.

Referring now toFIGS. 21-23, the spring306of the actuation assembly294is positioned about the outer diameter of the brake rod292. Tabs308are formed on the brake rod292. The tabs308are positioned in relation to the spring306so that the spring306biases the brake rod292toward the brake assembly230. As shown inFIG. 18, a target or brake actuation button318is located adjacent to the input location284of the brake assembly230. When the target318is depressed by the end portion316of the brake rod292(e.g. when the handle216is released as shown inFIG. 21), the brake assembly230engages the axle286to provide braking action. When the target318is released (e.g. when the handle216is rotated as shown inFIGS. 22 and 23), the end portion316of the brake rod292moves upward off the target318and the brake assembly disengages the axle286to permit free rotation.

Still referring toFIGS. 21-23, the actuation assembly294is shown in relation to the brake control mechanism220. The brake rod292of the actuation assembly294is generally the interconnecting member between and the brake control mechanism220and the brake assembly230.

As shown, the brake control mechanism220of the second embodiment includes a control mechanism housing332. A first compression spring322, a positioning structure326and a lift piece330are arranged within the housing332. The brake rod extends through a spacer385also positioned with the housing332. The spacer385operably compresses the spring306of the actuation assembly294to provide the downward bias upon the brake rod292.

The positioning structure326and the lift piece330each includes an aperture through which the brake rod292is positioned (only aperture392of the lift piece330is shown, seeFIG. 20). The first compression spring322is placed between the positioning structure326and fasteners327attached to the end of the brake rod292. In overall operation, the positioning structure326in combination with the first compression spring322function to return the handle216of the cart300from a rotated position to a non-rotated position when the handle216is released; and the lift piece330in combination with the spring306function to raise and lower the brake rod292to disengage and engage the brake assembly230.

To disengage and engage the brake assembly, the brake rod292is raised and lowered by rotating and releasing the handle216. When the handle216is depressed, for example, the force from the pivoting action of the handle216overcomes the bias of the first spring322, and first and second ends335,337of the lift piece330pivot as shown inFIG. 22. As the first end335of the lift piece330pivots upward, edges324(FIG. 20) of the aperture392bind or catch the outer diameter of the brake rod292. That is, the lift piece330binds or catches in a fixed relation or interference with the brake rod292. Continued downward rotation of the handle216further pivots the lift piece330, thereby lifting both the lift piece330and the bound brake rod292. As the brake rod292is lifted upward, the end portion316(FIG. 22) of the brake rod292lifts off the target318, thereby disengaging the brake assembly230.

Likewise, when the handle216is raised or pivoted upward, the force from the pivoting action of the handle216overcomes the bias of the first spring322, and the first and second ends335,337of the lift piece330pivot as shown inFIG. 23. As the second end337of the lift piece330pivots upward, the edges324(FIG. 20) of the aperture392bind or catch the outer diameter of the brake rod292. Continued upward rotation of the handle216further pivots the lift piece330, thereby lifting both the lift piece330and the bound brake rod292to disengage the brake assembly230.

In general, the lift piece330is arranged and configured to move in concert with the handle216(as shown inFIGS. 21-23). That is, when the handle216is rotated, the lift piece330rotates or pivots accordingly. The first compression spring322and the positioning structure326bias the lift piece330to return the handle216of the cart300from either of the rotated positions to the non-rotated position when the handle216is released.

Referring now toFIG. 20, the first end335of the lift piece330includes a hooked structure339configured to couple to a connection piece341. The connection piece341couples to flanges of the lever arm244. The positioning structure326is located adjacent to the lift piece330. The first compression spring322provides a force that biases the positioning structure326to the position shown inFIG. 21. When the handle216or lever arm244is rotated downward, the first end335of the lift piece330contacts a first end331(FIG. 22) of the positioning structure326. The spring322and positioning structure326act to push downward on the first end335of the lift piece330to return the lever arm244back to the released position shown inFIG. 21. Likewise, when the lever arm244is rotated upward, the compression spring322and an intermediate region343(FIG. 23) of the positioning structure326act to push downward on the second end337of the lift piece330. This force also biases the lever arm244back to the released position shown inFIG. 21.

Referring toFIGS. 19 and 20, the lever arm244of the handle216is pivotally connected to the housing332of the brake control mechanism220at a pivot joint334. The pivot joint334includes a pin342extend through at least one bearing340contained by the housing332. The pin342is secured to the lever arm244by snap rings387.

The housing332couples to the support member212of the frame210by a clamp structure313. The clamp structure313includes first and second flanges315(only one shown inFIG. 20) that are clamped together by a fastener317to secure the housing332to the support member212. In addition, the housing332includes a slot319to further secure the housing332to the support member212. As shown inFIG. 19, a set screw321is positioned to extend through the slot319and into a threaded hole323formed in the support member212. As can be understood, the slot319permits for ease of assembly by providing allowable play in the angular orientation of the housing332relative to the support member212.

Still referring toFIG. 19, a cover370is provided to cover and protect the internal components of the brake control mechanism220. The cover370includes a first portion371and a second portion373secured together by fasteners. When the portions371and373are joined, a slot375is formed through which the lever arm244extends. The slot375is configured to accommodate the pivoting motion of the lever arm244.

As shown best inFIGS. 21-23, the lever arm244includes a contact surface352arranged to contact a stop surface356of the control mechanism housing332. The contact surface352of the lever arm244and the stop surface356of the control mechanism housing332are configured to limit downward rotation of the handle216. Likewise, the brake control mechanism220includes an arrangement configured to limit the upward rotation of the handle216and lever arm244. In particular, the hooked construction339of the lift piece330is configured to contact a stop structure325(see alsoFIG. 20) formed on the housing332.

In accordance with the present disclosure, the second embodiment of the wheeled cart300also includes a brake release device296(FIG. 15) configured to disengage the brake assemblies230independent of the brake control mechanism220when the cart is nested. That is, the brake release device296disengages the brake assembly without input from the brake control mechanism220and whether or not the handle216is rotated.

FIGS. 24-29illustrate an alternative embodiment of the brake release device296. As previously described with regard to the first embodiment, when the carts are nested (FIGS. 24 and 25), the trailing cart300bengages the brake release device296of a leading cart300a. The brake release device296causes the actuation assembly294(FIG. 21) to disengage the brake assembly230, thereby permitting rotation of the rear wheels218for nested transport.

Referring toFIGS. 26-29, the second embodiment of the brake release device296is positioned adjacent to the lower portion254of at least one of the rearward upright support member212. The brake release device296generally includes an engagement lever372connected to a housing374. In the illustrated embodiment ofFIG. 27, the housing374includes a first housing compartment353and a second housing compartment355. The first and second compartments353,355are separated by a divider structure357.

Referring toFIGS. 26 and 27, the brake release device296includes collar359fastened or secured to the upright support member212. The collar359is positioned within the first housing compartment353when the brake release device296is fully assembled (FIGS. 28 and 29). An extension spring361is coupled to the collar359and the housing374. In particular, one end of the extension spring361is connected to bosses363formed on the collar359by a first pin connection365. The opposite end of the extension spring361is connected to the housing374by a second pin connection367. The extension spring361biases the housing to a non-pivoted position as shown inFIGS. 15 and 24.

The housing374preferably includes at least one inclined plane or cam surface376. In the illustrated embodiment, the housing374has two cam surfaces376located in opposite halves of the housing (FIGS. 27 and 30). The cam surfaces376are located within the second housing compartment355of the housing376.

When a trailing cart300b(FIG. 24) is not nested or engaged with a leading cart300a, the engagement lever372of the brake release deice296extends inward towards the center of the cart frame210(see alsoFIG. 15). When a trailing cart300bengages the leading cart300a, the engagement lever372rotates or pivots forward, as shown by the arrows inFIG. 25. Rotation of the engagement lever372is caused by contact of the lever372with the outer lower support member256of the trailing cart300b.

Referring toFIG. 26, a dowel or lift pin378is fixed in relation to the brake rod292. In particular, the pin378extends through slots298formed in the upright member212and is positioned through an aperture345(FIG. 28) formed in a flat347of the brake rod292. Rollers349are positioned on ends of the pin378. As can be understood, the arrangement of the pin378rotationally fixes the brake rod292relative to the support member212.

Referring toFIGS. 28 and 29, when the housing374pivots, the rollers349(rotationally fixed) roll along the cam surfaces376. The force of the cam surfaces376acting upon the lift pin378and brake rod292is sufficient enough to overcome the force from the spring306of the activation assembly294, which acts downward upon the brake rod292. The cam surfaces376thereby push the pin378, and the brake rod292, upward as the housing pivots374. The slots298formed in the support member212are configured and oriented to accommodate the upward movement of the pin378. As the pin378and brake rod292move upward, the end portion316(FIG. 21) of the brake rod292lifts off the target318, thereby disengaging the brake assembly230.

Referring back toFIG. 27, the housing374pivots relative to the collar359. The collar359is configured to function as a bearing surface upon which the housing374pivots. When the housing pivots, the extension spring361extends. The collar359further includes a groove structure377that functions to contain and guide the extension spring361as the housing374pivots.

When a cart300is removed from a nested group of carts, the extension spring361biases the brake release device296back to the original non-pivoted position shown inFIG. 24. As the brake release device296returns to the non-pivoted position, force from the spring306of the actuation assembly294also causes the brake rod292, pin378and rollers249to follow the cam surface376back to the original position. As the brake rod292returns to the original position, the end316of the rod292engages and activates the brake assembly230.

In an alternative embodiment, the cam surface376may include a detent389(shown in phantom inFIG. 30) to maintain the brake rod292in the lifted position even when the cart300is removed from a nested group. This arrangement would permit movement of the un-nest cart300until the handle216is rotated. That is, by rotating the handle216, the brake rod292is further lifted thereby raising the rollers249out from the detent389and permitting the extension spring361to return the brake release device296back to the original non-pivoted position.

The housing374of the brake release device296shown inFIGS. 27-29is a right-handed housing configured to attach to the right upright support member212. Referring now toFIG. 30, half of a left-handed housing374is illustrated. The left-handed housing is a mirror image of the right-handed housing. The left-handed housing view illustrates stops or ribs379that are also incorporated into the right-handed housing. Referring toFIG. 30, rotation of the housing374is limited by the ribs379formed in the first housing compartment353of the housing374. In particular, the ribs379contact the bosses363of the collar359when the housing374has rotated a predetermined distance.

The above specification provides a complete description of two embodiments of the Brake Assembly and Control Mechanism for a Cart, and Method. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.