Abstract:
A plastic shopping cart is disclosed. In accordance with certain aspects of the present invention, all of the components of a shopping cart are formed from a moldable material such as, for example, a thermoplastic resin by means of an injection molding process or the like. The shopping cart is configured so that any metallic parts that are used to connect the various plastic components together are shielded from the ambient environment. This virtually eliminates any rusting and corrosion of any metallic parts that are used to connect the various components of the shopping cart together.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention generally relates to shopping carts and, more particularly, to a shopping cart the components of which are formed from a moldable material such as a thermoplastic resin via an injection molding process.  
         BACKGROUND OF THE INVENTION  
         [0002]    Shopping carts are relatively well known in the art, and are configured in a wide-variety of forms. Typical shopping carts comprise a metal frame, four rolling casters that support the metal frame, and an attached basket that is formed from either metal or plastic.  
           [0003]    As one example, U.S. Pat. No. 4,123,077 to Joesph discloses a goods transport cart with molded plastic panels. The patent states that a basket is made from molded plastic panels, is caster mounted, and comprises a lower horizontal frame supporting an ossature of the basket. The ossature comprises a pair of rear uprights, a bottom panel, a front panel, and a pair of lateral vertical panels. The panels have a perforated or mesh structure, as stated in the patent. The content of this patent is incorporated by reference into this application as if filly set forth herein.  
           [0004]    In yet another example, U.S. Pat. No. 4,537,413 to Rehrig discloses a plastic basket for use with a cart having front and rear baskets. The patent states that the baskets are manufactured from a plastic material. The rear basket is positioned behind the front basket and may be secured to horizontal frame of the cart chassis by bolts or other fastening means such as rivets. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0005]    U.S. Pat. No. 4,632,411 to Badger discloses a shopping cart with a plastic basket. The patent states that a wheeled base assembly is constructed primarily from metal tubing, a separate handle assembly is constructed form metal tubing, and a one-piece plastic basket is rigidly to secured to the base and handle assembly. The basket member is molded in one piece entirely of a plastic material. The one-piece plastic basket is positioned on the base assembly and fixedly attached to both the base and handle assemblies. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0006]    U.S. Pat. No. 4,746,134 to Rehrig discloses a plastic wheeled cart chassis having a reinforced structure. This patent states that a reinforced plastic wheeled cart chassis is used with a bottom-supported plastic basket having a downwardly facing basket mounting portion. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0007]    As another example, U.S. Pat. No. 4,946,059 to Rehrig discloses a reinforced plastic basket. The patent states that a reinforcing ring is disposed around the upper edges of a plastic container to provide additional strength. The content of this patent is incorporated by referenced into this application as if fully set forth herein.  
           [0008]    U.S. Pat. Nos. 5,255,930 and 5,289,936 to Jones et al. both disclose a shopping cart having a plastic basket. These patents state that the basket comprises separate side, front and bottom panel members that are molded from a suitable plastic and that are assembled without need for a basket frame. The patents further state that the wheeled chassis comprises a main frame made from steel tubing that is bent to form two portions extending longitudinally. The wheeled chassis also comprises an intermediate brace made from steel tubing that is bent to form two side portions, each being welded to one of the side portions of the main frame. The content of both of these patents is incorporated by reference into this application as if fully set forth herein.  
           [0009]    As another example, U.S. Pat. No. 5,287,594 discloses a shopping cart swivel yoke assembly with plastic bearing racers. The patent states that the yoke assembly is of the type having a steel yoke with forks which support a wheel. The patent further states that the yoke is permitted to swivel because it is supported between an upper and lower set of ball bearings. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0010]    U.S. Pat. No. 5,791,666 to Mainard discloses a shopping cart having clips that are used to fasten a plastic basket to a wheeled chassis. The patent states that the wheeled chassis comprises a main frame made from steel tubing that is bent to form two side portions. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0011]    U.S. Pat. No. 5,794,952 to Kern et al. discloses a support assembly for a plastic basket of a shopping cart. The shopping cart includes a basket made of plastic, which is attached to a frame by a pair of basket support members, as stated in the patent. The patent states that the basket support member is a rod that includes a first end portion extending within an opening. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0012]    U.S. Pat. No. 5,794,953 to Duchene et al discloses a shopping cart with an advertising card mounted to a plastic basket. The patent states that the shopping cart includes a wheeled chassis, a handle structure, and a basket that is fastened to the wheeled chassis and to the handle structure. The patent states that an advertising card is fastened to a selected panel by certain mechanical fasteners. The content of this patent is incorporated by reference into this patent as if fully set forth herein.  
           [0013]    U.S. Pat. No. 5,865,448 to Kern et al discloses an integrally molded gate support for plastic shopping cart baskets. The patent states that the cart is generally formed from a tubular frame, and that the cart includes a plastic basket. The basket is adapted to be support by frame and directly engages rear upstanding supports and intermediate upstanding supports. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0014]    U.S. Pat. No. 5,947,313 discloses a molded plastic basket and rear panel for shopping cart. The patent states that the molded plastic basket includes side and front walls formed of a molded gridwork of ribs extending at an angle. The content of this patent is incorporated by reference into this application as if fully set forth herein.  
           [0015]    The products described above likely are suitable for their intended uses. However, most shopping carts that are in use today are formed from a metal material, or include a significant number of metal components that can rust and become unusable after a period of time of being exposed to inclement weather. In this case, the cart typically is thrown away, and usually placed in a dump. Thus, a need exists for providing a shopping cart that can be easily manufactured from a number of plastic components, all of which can be recycled after the life span of the cart expires.  
         SUMMARY OF THE INVENTION  
         [0016]    It is desirable to provide a shopping cart all of the components of which are formed from a moldable material such as, for example, a thermoplastic resin by means of an injection molding process or the like. The shopping cart is configured so that any metallic parts that are used to connect the various plastic components together are generally shielded from the ambient environment.  
           [0017]    Providing such a plastic shopping cart has a number of distinct advantages. First, the shopping cart is very stable. Second, each component of the shopping cart is readily replaceable. Third, rusting and corrosion of such a shopping cart is virtually eliminated due to the fact that the shopping cart is formed from plastic, and any metallic components are shielded from the ambient environment. Fourth, after the useful life of the cart has expired, the plastic components of the shopping cart can be recycled.  
           [0018]    Other features and advantages of the invention will become apparent from the description that follows. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    The objects and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:  
         [0020]    [0020]FIG. 1 is a perspective view of one embodiment of a plastic shopping cart  10  that is manufactured in accordance a number of aspects of the present invention;  
         [0021]    [0021]FIG. 2 is an exploded view of plastic shopping cart  10  shown in FIG. 1;  
         [0022]    [0022]FIG. 3 is a section view of shopping cart  10  taken along line  3 - 3  in FIG. 1;  
         [0023]    [0023]FIG. 4 is a perspective view of swing gate  42  shown in FIG. 2;  
         [0024]    [0024]FIG. 5A is a side view of a plastic shopping cart  66  in which the gate and seat assembly  36  is disposed in an at-rest position;  
         [0025]    [0025]FIG. 5B is a side view of plastic shopping cart  66 A that is partially nested in the plastic shopping cart  66  shown in FIG. 5A;  
         [0026]    [0026]FIG. 5C is a side view of two shopping carts  66  and  66 A that are fully nested together;  
         [0027]    [0027]FIG. 5D is a side view of a third shopping cart  66 B that is fully nested inside the nested pair of shopping carts  66  and  66 A shown in FIG. 5C that causes the rear caster wheels  18  and  20  of shopping cart  66  to be lifted off the ground;  
         [0028]    [0028]FIG. 6 is a section view of plastic shopping cart  10  taken along line  6 - 6  in FIG. 1;  
         [0029]    [0029]FIGS. 7A and 7B are plan and perspective views of exemplary portions of plastic shopping cart  10  that are provided with an insert molded advertising logo;  
         [0030]    [0030]FIG. 8A is a section view of a prior art support rod that forms a part of a plastic shopping cart basket;  
         [0031]    [0031]FIG. 8B is a section view of a portion of the plastic basket  30  shown in FIG. 2;  
         [0032]    FIGS.  9 A- 9 B are front and rear perspective views of central support member  74  that forms a portion of the swing gate  42  and illustrate a hanging attachment  76 ;  
         [0033]    [0033]FIG. 10A is a plan view of a front portion of the chassis and bottom carrier shown in FIG. 1;  
         [0034]    [0034]FIG. 10B is a section view of the front portion  79  of the chassis  20  and bottom carrier  22  that is taken along lines  10 B- 10 B of FIG. 10A;  
         [0035]    FIGS.  11 A- 11 B are perspective views showing how the seat  52  is rotatably connected to the seat bracket  54 ;  
         [0036]    [0036]FIG. 12 is an enlarged, perspective view of a portion of the shopping cart  10  shown in FIG. 1;  
         [0037]    FIGS.  13 A- 13 B are enlarged, perspective views of the basket  30  and the swing gate  42 ;  
         [0038]    [0038]FIG. 14 is an expanded side view of a portion of swing gate  42  and backrest  48  that are configured in accordance with an aspect of the present invention that allows a baby car seat or the like to be mounted on the plastic shopping cart  10  as schematically shown in FIG. 14.  
     
    
     DETAILED DESCRIPTION  
       [0039]    While the present invention is susceptible of embodiment in various forms, there is shown in the drawings a number of presently preferred embodiments that are discussed in greater detail hereafter. It should be understood that the present disclosure is to be considered as an exemplification of the present invention, and is not intended to limit the invention to the specific embodiments illustrated. It should be further understood that the title of this section of this application (“Detailed Description Of The Invention”) relates to a requirement of the United States Patent Office, and should not be found to be limiting to the subject matter disclosed and claimed herein.  
         [0040]    Referring now to the drawings, FIG. 1 is a perspective view of one embodiment of a plastic shopping cart  10  that is manufactured in accordance a number of aspects of the present invention. The plastic shopping cart  10  comprises a number of distinct components each of which is formed from a moldable material such as, for example, a thermoplastic resin via an injection molding process. Forming the shopping cart  10  in this manner provides a sturdy, stable structure for transporting heavy goods or products. The plastic shopping cart  10  is comprised of easily replaceable components, which reduces the cost of maintenance. In addition, because the components are plastic, the plastic shopping cart will not rust, and may be recycled after the useful life of the cart has expired.  
         [0041]    [0041]FIG. 2 is an exploded view of plastic shopping cart  10  shown in FIG. 1. The plastic shopping cart  10  includes a base assembly  12  that includes two swivel caster wheels  14  and  16 , two fixed caster wheels  18  and  19 , and a chassis  20 . The caster wheels are affixed to the chassis  20  by means of suitable fasteners, enable the plastic shopping cart  10  to be easily maneuvered, and are designed to support loads of up to several hundred pounds. In one embodiment, four screws are utilized to secure each caster wheel to the chassis  20 . The base assembly  12  also includes a bottom carrier  22 , two close-out panels  24  and  26 , and a cross-member  28 , all of which are secured to the chassis  20 . The bottom carrier  22  provides the shopping cart  10  with additional space for the undercarriage storage of goods.  
         [0042]    A plastic basket  30  is mounted on the base assembly  12  as shown. In the illustrated embodiment of the present invention, eight fasteners such as, for example, screws are utilized to secure the plastic basket  30  onto an upper surface  32  of the chassis  20 . A handle  34  is attached to an upper, rear portion of the plastic basket  30  to allow a user to move the plastic shopping cart over the ground.  
         [0043]    Plastic shopping cart  10  also includes a gate and seat assembly  36  that is pivotably attached to the plastic basket at apertures  38  and  40 . In the illustrated embodiment of the invention, gate and seat assembly  36  includes a swing gate  42 , two aluminum rods  44  and  46 , a back rest  48 , seat bracket  50 , a seat  52 , and a flip top  54 . The back rest  48  is pivotable with respect to the swing gate  42  about the axis of aluminum rod  46 . The seat  52  and the flip top  54  are pivotable about the axis of aluminum rod  44 .  
         [0044]    A section view of a portion of the plastic shopping cart  10  taken along line  3 - 3  in FIG. 1 is shown in FIG. 3. In accordance with one aspect of the present invention disclosed herein, the gate and seat assembly  36  are pivotable about an axis defined between apertures  38  and  40  as, for example, shown in FIGS.  5 A- 5 D to allow multiple carts to be nested together and easily maneuvered as discussed in greater detail hereafter.  
         [0045]    Referring to FIG. 4, a perspective view of swing gate  42  shown in FIG. 2 is illustrated. In the illustrated embodiment of the present invention, swing gate  42  includes fifteen support members  56  that are generally perpendicular to the axis of the aluminum rods  44  and  46  as well as the axis defined by the handle  34 . Four cam members  58  are disposed in between adjacent pairs of the support members  56  as shown. Each one of the cam members  58  include an inclined portion  60 , an intermediate portion  62 , and a curved end portion  64 . A notch portion  66  is defined in each one of the support members  56 . The curved end portion  64  of each cam member  58  is configured for engagement with a handle portion of an additional shopping cart so that when at least three shopping carts are nested together, the rear caster wheels of all of the nested carts other than the rear two carts are lifted off there ground, thereby allowing the nested shopping cart assembly to be easily maneuvered as discussed in greater detail hereafter.  
         [0046]    Referring to FIG. 5A, a side view of a plastic shopping cart  66  in which the gate and seat assembly  36  is disposed in an at-rest position is shown. FIG. 5B is a side view of a plastic shopping cart  66 A that is partially nested inside the plastic shopping cart  66  shown in FIG. 5A. In this position, the front portion of the plastic basket  30 A of plastic shopping cart  66 A causes the gate and seat assembly  36  of shopping cart  66  to be rotated about the axis defined by member  68 . Referring to FIG. 5C, plastic shopping carts  66  and  66 A are fully nested together. In this case, the front portion of the plastic basket  30 A of plastic shopping cart  66 A supports the gate and seat assembly  36  in the fully raised position shown.  
         [0047]    [0047]FIG. 5D is a side view in which a third shopping cart  66 B is fully nested inside the nested pair of shopping carts  66  and  66 A shown in FIG. 5C. The action of inserting plastic shopping cart  66 B into a fully nested configuration with shopping cart  66 A proceeds in accordance with that discussed above with regard to FIG. 5A- 5 C. In particular, while shopping cart  66 B is being inserted inside shopping cart  66 A, the front portion of basket  30 B causes the gate and seat assembly  36 A to be disposed in a fully raised position (shown in FIG. 5B). This causes the handle  34  of the shopping cart  66  to travel up the inclined portions  60  of the cam members  58  of the gate and seat assembly  36 A and, therefore, lift the rear caster wheels of the shopping cart  66  off of the ground.  
         [0048]    As shown in FIG. 5D, the handle  34  is locked in a close position in engagement with the notch portions  66  of the gate  42  of cart  66 . This allows, for example, the swivel caster wheels of the shopping cart  66  to control the path of movement of the entire nested assembly of shopping carts over the ground. The feature of the present invention is applicable to any number of shopping carts that are nested together so long as at least three carts are nested together.  
         [0049]    Referring to FIG. 6, a section view of plastic shopping cart  10  taken along line  6 - 6  in FIG. 1 is shown. A storage compartment  68  is integrally formed as a portion of the handle  34  as handle  34  is formed. Various small items such as, for example, keys, a wallet or change can be stored in the storage compartment  68 . This aspect of the present invention provides a number of distinct advantages such as, for example, providing significant additional structure integrity to the storage compartment over that which would be the case if a separate storage compartment were bolted onto a shopping cart handle.  
         [0050]    [0050]FIGS. 7A and 7B illustrate an additional aspect of the present invention disclosed in this application. In particular, FIGS. 7A and 7B are plan and perspective views of exemplary portions of the plastic shopping cart  10  shown in FIG. 1 in which a decorative badge  66  or  68  can be provided. In the illustrated embodiment of the invention, the decorative badge  66  (FIG. 7A) is formed in the close-out panel  24 , and the decorative bade  68  (FIG. 7B) is formed in a front portion of bottom carrier  22 . In both examples discussed above, decorative badges  66  and  68  are formed their substrate carriers by means of an insert molding technique.  
         [0051]    Referring to FIG. 8A, a sectional view of what is understood to be one of the support members that form a portion of a prior art plastic basket is shown. Prior art support member  70  includes four sharp corner portions as shown. This is undesirable because, for example, of the risk of injury to a user or to a small child that is carried inside a prior art plastic basket. In particular, the sharpness of the corner portions may cause significant cuts and abrasions. In order to reduce the risk that this may happen, the support members that form the plastic basket  30  shown in FIG. 2 are formed with rounded corner portions. One such support member  72  is shown in FIG. 8B.  
         [0052]    Referring now to FIGS.  9 A- 9 B, front and rear perspective views of central support member  74  that forms a portion of the swing gate  42  and illustrate a hanging attachment  76 . In the illustrated embodiment of the invention, an L-shaped member  76  and an aperture  78  are integrally formed as portions of the central support member aperture  74  as it is formed. The L-shaped member  76  and the aperture  78  allow items such as, for example, a purse, coat or the like to be hung from the L-shaped member  76 . It should be understood that, for example, the L-shaped member  76  can be formed in any manner or shape desired, so long as it is formed during the formation process of the central support member  74 .  
         [0053]    FIGS.  10 A- 10 B illustrate a further aspect of the present invention. Referring to FIG. 10A, a plan view of a front portion of the chassis  20  and the bottom carrier  22  is shown. FIG. 10B is a section view of the front portion of the chassis and bottom carrier section that is taken along lines  10 B- 10 B of FIG. 10A. The front portion  79  of the bottom carrier  22  forms a living hinge, and includes a plurality of mountings  80 ,  82 , and  84 . In the illustrated embodiment of the invention, the mountings  80 ,  82 , and  84  are threaded and adapted to receive a corresponding screw (not shown) that attach the chassis  20  to the bottom carrier  22 . One innovative feature of this aspect of the present invention is that the means by which the chassis  20  and the bottom carrier are connected together (screws, rivets, or the like) are disposed on the underside thereof. This provides a number of distinct advantages such as, for example, significantly reducing the corrosion and rusting of the typically metal fasteners that are used to attach the chassis  20  and the bottom carrier  22  together.  
         [0054]    FIGS.  11 - 11 B are perspective views showing how the seat  52  is rotatably connected to the seat bracket  54 . As illustrated in FIG. 11A, post members  86  and  88  of the seat bracket  50  are inserted through openings in the backrest  48 . The seat bracket  50  includes two knurled connecting members  90  and  92  that are adapted to be engaged with corresponding C-clamp members  94  and  96  that are disposed on the underside of seat  54  as shown in FIG. 11B. In a locked condition, the C-clamp members  94  and  96  allow the knurled connecting members  90  and  92  to rotate about the axis defined between the C-clamp members. The C-clamp members  94  and  96  are integrally formed as a portion of the seat  54  as the seat is formed. The knurled connecting members  90  and  92  also are integrally formed as a portion of the seat bracket  50  as it is formed.  
         [0055]    [0055]FIG. 12 is an enlarged, perspective view of a portion of the shopping cart  10  shown in FIG. 1. In particular, and in the illustrated embodiment of the invention, backrest  48  includes a contoured tab portion  98  that is integrally formed as a portion of the backrest  48 . The contoured tab portion  98  engages the top edge  100  of the plastic basket  30 , and slidably moves along its top edge  100 . This facilitates movement of the gate and seat assembly  36  from an initial, at-rest position (FIG. 3 or FIG. 5A) to an extended position (FIG. 5D).  
         [0056]    FIGS.  13 A- 13 B are enlarged, perspective views of the basket  30  and the swing gate  42  that show how the swing gate  42  engages with basket  32 . In the illustrated embodiment of the invention, a plurality of tabs  102  extend away from a distal end of the swing gate  42  that cooperate with apertures  104  formed in the basket  30  as shown. The apertures  104  are sized so that the swing gate  42  may rotate about the axis  68  (FIG. 5B) until the tabs  102  engage the plastic basket  30  as shown in FIG. 13B. It should be noted that the swing gate  42  is oriented with respect to the plastic basket  30  so that it is disposed in the position shown in FIG. 13B, unless it is moved.  
         [0057]    [0057]FIG. 14 is an expanded side view of a portion of swing gate  42  and backrest  48  that are configured in accordance with an aspect of the present invention that allows a baby car seat  106  or the like to be mounted on the plastic shopping cart  10  as schematically shown in FIG. 14. Baby car seats typically include first and second notches  108  and  110  located on the bottom portion thereof. In accordance with this aspect of the present invention, upper portion  112  of back rest  42  is adapted to be received in first notch portion  108 , and an upper portion  114  of swing gate  48  is adapted to be locked into second notch  110 . In this regard, second notch  110  includes a latch member  116  that may be forced into engagement with portion  114  of swing gate  48 .  
         [0058]    From the foregoing, it will also be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims when the claims are properly interpreted.