Abstract:
A method of making a shopping cart includes forming a frame capable of supporting a plurality of basket assembly types, selecting from the plurality of basket assembly types a first basket assembly defining a first basket assembly type; and connecting the first basket assembly to the frame.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of prior-filed, co-pending U.S. Provisional Patent Application No. 61/532,716, filed Sep. 9, 2011 and U.S. Provisional Patent Application No. 61/660,984, filed Jun. 18, 2012, the entire contents of both of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to shopping carts, and particularly to the manufacture of shopping carts. 
     Conventional shopping cart frames are formed from glass-filled nylon, which is relatively expensive, but has previously been needed in order to meet standards for load and durability for shopping carts. Retail stores often have different needs for their respective shopping carts, requiring manufacturers to provide various cart sizes, shapes, and configurations in order to satisfy various retail stores. The wide variety of carts causes the manufacturer to develop separate tool molds for each of the cart types, resulting in significant costs for the manufacturer. 
     SUMMARY 
     In one embodiment, the invention provides a method of making a shopping cart. The method includes forming a frame capable of supporting a plurality of basket assembly types, selecting from the plurality of basket assembly types a first basket assembly defining a first basket assembly type; and connecting the first basket assembly to the frame. 
     In another embodiment, the invention provides a shopping cart including a frame supported for movement over the ground, a first handle, and a first basket assembly connected to the frame. The frame includes an upright portion and is capable of supporting a plurality of basket assembly types. The first handle is connected to the upright portion. The first basket assembly defines a first basket assembly type. 
     In yet another embodiment, the invention provides a shopping cart including a frame supported for movement over the ground, a first handle, and a first basket assembly. The frame includes an upright portion, and the first handle is connected to the upright portion. The first basket assembly includes a basket frame for supporting a plurality of basket wall types, and one of the plurality of basket wall types attached to the basket frame. 
     In still another embodiment, the invention provides a flat cart including a frame supported for movement over the ground and a deck that is pivotably connected to the frame. The frame includes a base defining a longitudinal axis and an upright portion including a handle. The deck is pivotable about a pivot axis transverse to the longitudinal axis between a lowered position and an upright position. 
     In still another embodiment, the invention provides a shopping cart having a front end and a rear end. The cart includes a first basket supported for movement over a floor or the ground and configured to be loaded from the rear, and a handle for pushing the cart. 
     In still another embodiment, the invention provides a shopping cart having a front end and a rear end and defining a cart axis therebetween. The cart includes a first basket supported for movement over a floor or the ground and a handle for pushing the cart, the handle being pivotable. 
     In yet another embodiment, the invention provides a shopping cart having a front end and a rear end and defining a cart axis therebetween. The cart includes a handle for pushing the cart, a first basket including a moveable first gate, and a second basket including a moveable second gate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a shopping cart. 
         FIG. 2  is an exploded view of the shopping cart of  FIG. 1 . 
         FIG. 3  is a perspective view of a frame. 
         FIG. 4  is a front view of the frame of  FIG. 3 . 
         FIG. 5A  is a perspective view of a cross-section of the frame of  FIG. 4  taken along line  5 A- 5 A. 
         FIG. 5B  is a perspective view of a cross-section of the frame of  FIG. 4  according to another embodiment. 
         FIG. 5C  is a perspective view of a cross-section of the frame of  FIG. 4  according to another embodiment. 
         FIG. 6  is a perspective view of a shopping cart according to another embodiment. 
         FIG. 7A  is a cross-section view of the shopping cart of  FIG. 6  taken along line  7 A- 7 A. 
         FIG. 7B  is a rear perspective view of the shopping cart of  FIG. 6 . 
         FIG. 8  is an exploded view of the shopping cart of  FIG. 6 . 
         FIG. 9  is an exploded view of a shopping cart according to another embodiment. 
         FIG. 10  is a perspective view of a shopping cart according to another embodiment. 
         FIG. 11  is an exploded view of the shopping cart of  FIG. 10 . 
         FIG. 12  is a perspective view of a shopping cart according to another embodiment. 
         FIG. 13  is a perspective view of a shopping cart according to another embodiment. 
         FIG. 14  is a perspective view of a shopping cart according to another embodiment. 
         FIG. 15  is a perspective view of a mold. 
         FIG. 16  is a perspective view of a frame portion and a first mold insert. 
         FIG. 17  is a perspective view of a frame portion and second mold insert. 
         FIG. 18  is a perspective view of a caster lifting mechanism. 
         FIG. 19  is an exploded view of the caster lifting mechanism of  FIG. 18 . 
         FIG. 20  is a partial side view of a shopping cart. 
         FIG. 21  is a partial side view of a pair of shopping carts nested together. 
         FIG. 22  is an exploded view of a shopping cart according to another embodiment. 
         FIG. 23A  is a perspective view of a shopping cart basket including a billboard panel. 
         FIG. 23B  is a perspective view of a shopping cart basket including a billboard panel according to another embodiment. 
         FIG. 23C  is a perspective view of a shopping cart basket including a billboard panel according to another embodiment. 
         FIG. 23D  is a perspective view of a shopping cart basket including a billboard panel according to another embodiment. 
         FIG. 24  is a perspective view of a flat-bed cart. 
         FIG. 25  is a perspective view of a flat-bed cart according to another embodiment. 
         FIG. 26  is a perspective view of a flat-bed cart according to another embodiment in a lowered state. 
         FIG. 27  is a perspective view of the flat-bed cart of  FIG. 26  in an upright state. 
     
    
    
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
       FIG. 1  discloses a shopping cart  10 . The shopping cart  10  includes a frame  14 , a basket assembly  18 , a handle  22 , a rear gate  26 , a lower tray  30 , and multiple wheels  34  supporting the frame  14  for movement over the ground. In the embodiment shown in  FIGS. 1-4 , the frame  14  forms a U-shaped member including a base  38 , uprights or arms  42  extending upwardly from the base  38 , and a cover  46  connected to each arm  42 . As best shown in  FIG. 4 , each arm  42  includes an upper end  50  positioned away from the base  38 . The arms  42  taper inwardly from the upper ends  50 , such that the distance between the arms  42  proximate the base  38  is less than the distance between the upper ends  50  of the arms  42 . The cart  10  defines a front end  52 , a rear end  54  opposite the front end  52 , and a horizontal cart axis  56  extending between the front end  52  and the rear end  54 . As used herein, the term “rearward” refers to a direction that extends toward the rear end  54 , and the term “forward” refers to a direction that extends toward a front end  52 . 
     The frame  14  is formed by a combination of over-molding and gas-assist plastic forming processes. As shown in  FIG. 5A , a substrate  58  such as a piece of metal is over-molded by plastic material  60 . Although the substrate  58  in  FIG. 5A  has a cross-section that is U-shaped, the substrate  58  can be formed into various other shapes, including a round tube ( FIG. 5B ) or an enclosed piece that is partially hexagonal and partially rectangular ( FIG. 5C ). In the illustrated embodiments, the plastic material  60  near the substrate  58  is molded as a lattice structure having ribs  62  for increased rigidity. In one embodiment, the substrate  58  is made from steel, although in other embodiments the substrate could be made from another material. The plastic material  60  may include any type of injection-molded plastic. The gas-assist process creates at least one hollow cavity (not shown) in the plastic material  60 . This combination process yields a frame  14  that is both strong and low weight. The substrate  58  and the geometric relationship between the substrate  58  and the plastic  60  increases rigidity over a simple injection-molded plastic. The combination process satisfies the load and durability standards, is less expensive than conventional glass-filled nylon processes, and provides a frame  14  having a lower density than the glass-filled nylon frames. In one embodiment, a frame  14  made using the combination process costs about $0.60 per pound and has a lower density, whereas a frame made from glass-filled nylon costs about $2 per pound and has a higher density. 
     Referring to  FIG. 2 , the basket assembly  18  is removably coupled to the frame  14  and includes a basket frame  74  and a pair of slots  78  on either side of the basket frame  74 . The slots  78  receive the upper ends  50  of the arms  42 . The walls and bottom surface of the basket assembly  18  have been removed for purposes of clarity; the basket assembly  18  also includes basket walls similar to those shown in  FIGS. 12-13  and  FIG. 22 . The basket assembly  18  is moved onto the arms  42  and slides down along the arms  42  until the basket assembly  18  reaches a predetermined position. In the illustrated embodiment, the predetermined position is the point at which the slots  78  engage the arms  42  in an interference fit due to the inward taper of the arms  42 . In other embodiments, the predetermined position may be defined by a detent that locks the basket assembly  18  in place relative to the arms  42 , or the basket assembly  18  may be secured relative to the arms  42  by fasteners. 
     Referring to  FIGS. 1 and 2 , the handle  22  includes a generally U-shaped member having two ends  86  that are adapted to engage the upper ends  50  of the arms  42 . After the basket assembly  18  is secured relative to the frame  14 , the handle  22  is coupled to the upper ends  50  of the arms  42 , further locking the basket assembly  18  in position. The handle  22  also includes a pair of openings  90  ( FIG. 2 ), each of which is positioned proximate one of the handle ends  86 . In the illustrated embodiment, the handle ends  86  are secured to the arms  42  by a snap fit or interference fit. 
     The rear gate  26  includes a wall  94  and a pair of gate arms  98  and is positioned proximate the rearward end of the cart  10 . The gate arms  98  are positioned on opposite edges of the wall  94  and extends away from the wall  94 . In the embodiment shown in  FIGS. 1 and 2 , each gate arm  98  is positioned within one of the openings  90  on the handle  22 . The rear gate  26  is thus pivotably coupled to the handle  22  and pivots about a gate axis  100  transverse to the cart axis  56 . When a second cart (not shown) is pushed into the rear of the shopping cart  10 , the rear gate  26  pivots upwardly, toward the front of the basket assembly  18  in order to enable the basket assembly of the second cart to nest within the basket assembly  18 . In other embodiments, the gate arms  98  may engage openings positioned on the basket assembly  18 . The rear gate  26  engages a stop  102  ( FIG. 7A ) positioned on the basket assembly  18  to prevent the rear gate  26  from pivoting beyond the rearward end of the basket frame  74 , i.e., to limit pivoting of the rear gate  26  in a clockwise direction as shown in  FIG. 7A . 
     The frame  14  is capable of supporting multiple types of basket assemblies  18 . For example, in an alternative embodiment shown in  FIGS. 6-8 , a second basket assembly  218  includes multiple basket frames  274  having different sizes and characteristics from the first basket assembly  18 . The basket assembly of  FIGS. 6-8  includes a first or lower basket  274   a  and a second or upper basket  274   b . In addition, the handle  222  is pivotably coupled to blocks  224  that are coupled to the arms  242 . In the illustrated embodiment, the handle  222  is formed as a U-shaped member that is pivotably coupled to the cart  10  at each end  286 . The handle  222  is pivotable about a handle axis  228  ( FIG. 7B ) transverse to the cart axis  256 . In other embodiments, the handle  222  may be coupled to the basket assembly  218  or the handle axis  228  may be oriented in a different direction. 
     Referring to  FIG. 7B , the upper basket  274   b  is substantially above the lower basket  274   a . The lower basket  274   a  includes a first or lower gate  226   a  proximate the rear end  254  of the cart  210 . The lower gate  226   a  is pivotable about a lower gate axis  300   a  transverse to the cart axis  256  between a raised position and a lowered position. The lower gate  226   a  is similar to the rear gate  26  described above with respect to  FIGS. 1 and 2 . The lower gate  226   a  includes a wall  294   a  and a pair of arms  298   a  for coupling the lower gate  226   a  to the lower basket  274   a . The wall  294   a  extends across the rearward end of the lower basket  274   a  when the lower gate  226   a  is in the lowered position. As shown in  FIG. 7A , the wall  294   a  has an upper end  296  below an upper end  276  of the lower basket  274   a  when the lower gate  226   a  is in the lowered position. 
     As shown in  FIG. 7B , the upper basket  274   b  includes a second or upper gate  226   b  proximate the rear end  254  of the cart  210 . The upper gate  226   b  is pivotable about an upper gate axis  300   b  transverse to the cart axis  256  between a raised position and a lowered position. The upper gate  226   b  includes a wall  294   b  ( FIG. 7B ) and a pair of arms  298   b  for coupling the upper gate  226   b  to the upper basket  274   b . The wall  294   b  extends across a rearward end of the upper basket  274   b  when the upper gate  226   b  is in a lowered position. Both the lower gate  226   a  and the upper gate  226   b  pivot upwardly toward the front of each basket  274   a ,  274   b  to allow the lower basket  274   a  and the upper basket  274   b  to receive a lower basket and upper basket, respectively, of another cart (not shown). The stops  102  ( FIG. 7A ) prevent the gates  226   a ,  226   b  from pivoting backward beyond the rearward end of each basket  274   a ,  274   b.    
     The lower basket  274   a  is configured to be loaded from the rear. As best illustrated in  FIGS. 7A and 7B , the lower basket  274   a  is positioned partially behind the upper basket  274   b , enabling a user to load and unload the lower basket  274   a  from behind the cart  210  and beneath the handle  222 . Stated another way, a rearward end of the upper basket  274   b  is positioned forward of a rearward end of the lower basket  274   a  to provide easy access to the contents of the lower basket  274   a  from the rear of the cart  210 . In addition, because the upper end  296  of the wall  294   a  is below the upper end  276  of the lower basket  274   a  when the lower gate  226   a  is in the lowered position, it is easier for a user to load and unload the lower basket  274   a.    
     The handle  222  is moveable about the handle axis  228  between at least a first or rear position ( FIG. 6 ) and a second or forward position ( FIG. 7A ). As shown in  FIG. 6 , in the rear position the handle  222  extends toward the rear end  254  of the cart  210 . This configuration allows the user to push the cart  210  with the handle  222 . Referring to  FIG. 7B , in the forward position the handle  222  extends toward the front end  252  of the cart  210 . In the forward position, the handle  222  is substantially aligned with the upper gate  226   b  (see  FIG. 7B ) and forward of the rearward end of the lower basket  274   a . This position of the handle  222  improves access to the lower basket  274   a , allowing the user to more easily load or unload the lower basket  274   a  from the rear. The frame  14  is configured to support many types of basket assemblies  18 , so the manufacturer can select a basket assembly  18  from multiple types of basket assemblies  18  in order to customize the cart  10  as necessary. This reduces the need to manufacture many types of carts  10  individually, instead providing a modular approach for manufacturing the carts  10  from similar parts. 
     In other embodiments, shown in  FIG. 9 , multiple basket assemblies  418  may be positioned on the arms  442 , including one or more rear-facing baskets  474   c . In this embodiment, the handle  422  includes ends  486  that are coupled to the arms  442  by fasteners such as bolts. Alternatively, as shown in  FIGS. 10-11 , the arms  642  can be removably received on the frame  614 , and the basket assemblies  618  include brackets  620  for coupling each basket assembly  618  to the arms  642 . The bracket  620  can be secured to the arms  642  by a snap fit or by fasteners. The alternative embodiments of  FIGS. 12-14  also illustrate that the basket assembly  818  can be directly fastened to the frame  814 , and the handle  822  may be formed integrally with the basket assembly  818  or the frame  814 . In addition,  FIG. 13  shows a cart  810  in which the lower tray  830  includes an open-ended basket. 
     As shown in  FIGS. 15-17 , the frame  14  is formed in a mold  106 . The mold includes a removable first module or insert  110 . In the illustrated embodiment, the first insert  110  forms a portion of the frame base  38 . The first insert  110  may be removed from the mold  106  and replaced with a second insert  114  that forms the same portion of the base  38 , but the portion of the base  38  has a shorter dimension than the portion that is formed by the first insert  110 . In other embodiments, the second insert  114  could provide a different shape for the portion of the base  38 . In still other embodiments, the inserts  110 ,  114  could form a different portion of the frame  14  or another component of the cart  10 . The removable inserts  110 ,  114  enable the operator to readily customize the size and shape of the manufactured frame  14  by changing the configuration of the mold  106 . Because the mold  106  is capable of producing various frame configurations, the forming process requires only a single large mold  106  with several smaller inserts like the first insert  110  and second insert  114 , rather than multiple large molds for each desired configuration. In this way, tooling costs are reduced. 
     As shown in  FIGS. 18-21 , the frame  14  also includes a caster lift mechanism  122  to raise the wheels  34  when the cart  10  is nested or stacked with another cart. The caster lift mechanism  122  includes a ridge  126  formed on an upper surface  130  of the base  38 , a housing  134  formed on an inside surface  138  of at least one of the arms  42 , and an insert  142  ( FIG. 19 ) positioned within the housing  134  and behind the cover  46 . In one embodiment, the insert  142  is made of a wear-resistant plastic material. In the illustrated embodiment the housing  134  extends inwardly or toward the center of the base  38  and forms a cylindrical recess  146 . The recess  146  is open at the inner end of the housing  134  and the housing  134  has a longitudinal slot  150  communicating with the bottom of the recess  146 . The insert  142  is cylindrical and is inserted into the inner end of the recess  146  such that the lower portion of the insert  142  extends through the slot  150 . Referring to  FIG. 21 , when a second cart is nested into the rear of a first cart  10 , the insert  142  from the first cart  10  engages the ridge  126  and causes the rear of the first cart  10  to lift away from the ground. Lifting the rear end of the cart  10  insures that the rear wheels  34  do not contact the ground, thereby reducing the friction between the nested carts  10  and the ground. This reduced contact makes it easier for the nested carts  10  to be pushed and maneuvered together. Over time, the repeated engagement between the ridge  126  and the insert  142  will cause the insert  142  to wear down. The insert  142  provides a replaceable wear surface such that once the insert  142  wears down to a predetermined point, the user can replace the insert  142  to extend the working life of the caster lift mechanism  122 . 
     In an alternative embodiment, shown in  FIG. 22 , the cart  1210  includes a basket frame  1274 , a bottom surface  1276 , and multiple walls  1280 . The basket frame  1274  is configured to support multiple types of basket walls  1280  that can be removably coupled to the basket frame  1274 . In one embodiment, the basket frame  1274  is molded separately from the walls  1280 , and the walls  1280  are coupled to the basket frame  1274  by a snap fit. In other embodiments the walls  1280  are coupled by fasteners. The basket frame  1274  is configured to support many types of basket walls  1280 , so the manufacturer can select a basket wall  1280  from many basket wall types in order to customize the cart as necessary. For instance, various walls  1280  may define different mesh patterns or wall cross-sections. This reduces the need to manufacture many types of baskets individually. Instead, the manufacturer can create the same basic frame  1274  and then select a particular wall  1280 , thereby implementing a modular approach to manufacturing the basket frames  1274  from similar parts. 
     The wall  1280  of the basket frame  1274  may also include one or more billboard panels  1284  for displaying graphics or other information. The panels  1284  can be molded with an in-mold graphic foil  1288  ( FIG. 23 ) and changed as desired (for example, seasonally).  FIGS. 23A-23D  provide various examples of billboard panels  1284 . As shown in  FIG. 23A , the graphic foil  1288  may be slidably received through the basket frame  1274  and positioned within the billboard panel  1284 . Alternatively,  FIGS. 23B and 23C  show that the panel  1284  may include a transparent window  1292  that is pivotable relative to the basket frame  1274  to allow the graphic foil  1288  to be positioned behind the window  1292 . The panel  1284  may also be removably fitted within the basket frame  1274 , as shown in  FIG. 23D . 
       FIG. 24  shows a nesting flat-bed cart  1610 . The flat-bed cart  1610  includes a frame  1614 , a pivoting load bed or deck  1616 , at least one spring-loaded slow-close hinge  1620 , and a latch mechanism  1624 . In one embodiment, the deck  1616  is made from a non-slip plastic material. The frame  1614  includes a base  1628  having a handle  1622 , multiple wheels or casters  1634  coupled to the base for supporting movement of the frame over the ground, and a cross piece  1636 . In the illustrated embodiment, the rear wheels  1634  can swivel, while the front wheels  1634  are fixed. The frame  1614  defines a longitudinal axis  1640 . The deck  1616  includes a hand grip  1644  and a ribbed underside  1648  ( FIG. 27 ) to provide increased rigidity. 
     The deck  1616  is pivotably attached to the base  1638  by the spring-loaded slow-close hinge  1620 . The deck is pivotable about a pivot axis  1652  transverse to the longitudinal axis  1640 . The slow-close hinge  1620  is similar to those used for toilet seats. The spring action of the hinge  1620  biases the deck  1616  toward an upright position as shown in  FIG. 24 . The latch mechanism  1624  is located on the cross piece  1636  extending between the front wheels  1634 . When the deck  1616  is moved to a lowered or use position, the latch mechanism  1624  locks the deck  1616 . In one embodiment, the latch mechanism  1624  includes a rotating hook (not shown). The hook may be spring-biased to automatically engage and lock the deck  1616  in place when the deck  1616  is moved to the lowered position. When the latch mechanism  1624  is unlocked, the slow-close hinge  1620  moves the deck  1616  to the upright position. The hand grip  1644  enables the user to assist in lifting the deck  1616  to the upright position. In other embodiments, a heavy spring or gas strut may be used in addition to or in place of the slow-close hinge  1620 . 
     With the decks  1616  in the upright position, multiple flat-bed carts  1610  can be stacked or nested together in a manner similar to the cart  10  of  FIG. 1 . That is, the frame of a second flat-bed cart  1610  can be pushed into the first flat-bed cart  1610  from the rear, such that the frames  1614  of the two carts  1610  nest together The flat-bed cart  1610  of  FIG. 24  can be made with a frame  1614  that is similar to the frame  14  of  FIG. 1  except with a different handle. In addition, the flat-bed cart  1610  of  FIG. 24  can include the caster lift mechanism  122  described above with respect to  FIGS. 18-21 . In the embodiment shown in  FIG. 25 , the flat-bed cart  1610  further includes a small basket  1618  that can be removably attached to the handle  1622 , such as by a snap fit or by fasteners. The basket  1618  may also be integrally formed with the handle  1622  or frame  1614 . 
       FIGS. 26-27  disclose a nesting flat-bed cart  1810  with a folding deck  1816 . The flat-bed cart  1810  of  FIGS. 26-27  is similar to the flat-bed cart  1610  of  FIG. 24 , except that it is designed to support greater weights or loads. The deck  1816  includes a first or rear section  1844  pivotably coupled to the frame  1814 , and a second or front section  1848  pivotably connected to the rear section  1844  by a hinge  1852 . The deck  1816  folds along a lateral break line that is transverse to the longitudinal axis  1840  of the frame  1814 , in a manner similar to a folding banquet table. The deck  1816  can pivot about the hinge  1852  when in a lowered position, which allows the flat-bed cart  1810  to accommodate bumps or rough surfaces over which the cart  1810  travels. In the illustrated embodiment, the front section  1848  and rear section  1844  include at least one hand grip  1856  for moving the deck  1816  between the upright and lowered positions, and the front section  1848  includes one or more casters  1860 . In one embodiment, a single caster  1856  is used for supporting up to 2000 pounds and two casters  1856  are used for supporting up to 3000 pounds. 
     Various features of the invention are set forth in the following claims.