Patent Application
20240285069
The invention relates to the field of mobile delivery carts and methods for constructing the same, specifically a mobile delivery cart which allows for variations present during the fabrication process.
The food service industry, hospitals, and schools have long used mobile carts for accommodating cafeteria-style trays and other items used to serve food or other comestible goods. Typically, many of these carts comprise an interior cabinet which comprises a frame or a plurality of shelves for accommodating a number of trays thereon. Many carts further comprise a heating and/or cooling element such as a refrigerator or the like for maintaining the food stuffs at a desired temperature. Additionally, many carts traditionally comprise a plurality of casters or wheels which allow the cart to be moved or rolled to and from multiple locations.
Most carts used in schools or hospitals are made from plastic or plastic composites and are made using a technique known as rotational molding which is a well-known fabrication method. Typically, a shot of material is inserted into a mold which is then heated as it is rotated about at least one axis. As the mold is heated and rotated, the material spreads and fills every aspect and contour within the mold, producing a finished product dictated by the mold itself. Using rotational molding, everything from cooking utensils to storage containers can be quickly and cheaply made on an industrial scale.
However, a drawback commonly associated with rotational molding production is that due to small differences in pressure, temperature, and material purity, it is often difficult to maintain universal or consistent production between each piece that is made. This is particularly true when small or intricate detail is required within the product. The problem of inconsistent production can often be frustrating to manufacturers, however this problem is made noticeably worse when rotationally molded products require several different parts as non-uniform components may render the product more difficult to use or even worthless.
For example, as applied to rotationally molded mobile serving carts, many current designs require a rotationally molded door to be coupled to its frontal façade. However due to production inconsistencies, a rotationally molded door may be too large or misshapen and not always fit within the frame of the serving cart it was designed for in the exact manner as was intended. Production inconsistencies not only make assembly of the final product more difficult to assemble, but they may even make components of the mobile serving cart inappropriate for its intended purpose, thereby rendering the component worthless. This common problem decreases efficiency and increases the cost of production which in turn increases the costs for consumers interested in purchasing the serving cart.
What is needed is a mobile delivery cart which is not only easy to use, convenient, and efficient in a variety of different settings, but which is also capable of being manufactured while avoiding the known drawbacks associated with rotational molding techniques.
The current invention provides a food service cart which includes at least one side panel, at least one door removably coupled to the at least one side panel, and a removable hinge disposed between the at least one side panel and the at least one door. The hinge itself preferably includes a longitudinal length that is defined by a plurality of facets and a bore that is defined through the longitudinal length of the hinge which is off-center relative to a longitudinal axis of the hinge.
In one embodiment, the hinge is rotatable relative to the at least one door and the at least one side panel.
In a further embodiment, the hinge comprises a top surface and a bottom surface joined to the top surface by a body, wherein the body comprises a plurality of facets that are defined around an outer circumference of the body.
In one embodiment, the bore defined through the longitudinal length of the hinge is specifically defined through a longitudinal length of the body.
In a separate embodiment, a plurality of bevels are disposed around the outer circumference of the body, wherein at least one of the plurality of bevels is disposed between at least two of the plurality of facets.
In yet another embodiment, the plurality of facets are specifically disposed along the entire longitudinal length of the body.
In some embodiments, the bore is configured to accommodate a hinge pin therein.
In a related embodiment, the food service cart also includes an expandable end table that is coupled to the at least one side panel, wherein the end table further forms a flush surface with the at least one side panel when the end table is in a contracted position. Here, the end table may also include a first bracket and an adjustable prop rod coupled to the first bracket. The prop rod may be further configured to removably couple to a second bracket disposed on the at least one side panel. Additionally, the end table may also include a rod indentation that is defined in a bottom surface of the end table and a bracket cutout that is defined in the bottom surface of the end table. Preferably, the rod indentation is configured to accommodate the longitudinal length of the prop rod, while the bracket cutout is configured to accommodate the second bracket disposed on the at least one side panel. In a related embodiment, the at least one side panel of the food service cart comprises a recess that is configured to accommodate a thickness of the end table in order to form the flush surface. In yet another related embodiment, the at least one door is configured to open to a maximum of 270 degrees relative to a closed configuration when the end table is in the contracted position, and to a maximum of 190 degrees relative to the closed configuration when the end table is in an expanded configuration.
In another embodiment, the food service cart also includes a first magnet that is disposed on the at least one door and a second that is disposed on the at least one side panel. The first magnet engages with the second magnet when the at least one door is disposed adjacent to the at least one side panel.
In a further embodiment, the food service cart has an internal volume that is subdivided into a plurality of parts by a dividing wall disposed therein. Here, a plurality of tray supports may also be disposed on the dividing wall and on an inside surface of the at least one side panel. Additionally, each of the plurality of parts of the internal volume includes a flume defined therein.
The current invention further provides a method for constructing a food service cart. The method includes providing at least one side panel and at least one door, disposing an adjustable hinge between the at least one side panel and the at least one door, and then adjusting a relative position of the hinge between the at least one side panel and the at least one door. The at least one door is then coupled to the at least one side panel. Preferably, adjusting the relative position of the hinge between the at least one side panel and the least one door includes adjusting a relative position of a bore that is defined through a longitudinal length of the hinge until a vertical alignment between the at least one side panel and the at least one door is obtained.
In one embodiment, adjusting the relative position of the hinge between the at least one side panel and the least one door specifically includes rotating the hinge relative to the at least one side panel and the at least one door.
In another embodiment, the method also includes preventing further movement between the hinge and either the at least one side panel or the at least one door after the at least one door has been coupled to the at least one side panel. Specifically, preventing further movement between the hinge and either the at least one side panel or the at least one door after the at least one door has been coupled to the at least one side panel includes applying a plurality of facets disposed on the hinge to an internal surface of the at least one side panel.
In yet another embodiment, disposing the adjustable hinge between the at least one side panel and the at least one door specifically includes inserting the hinge into a cavity that is defined within the at least one side panel. Here, adjusting the relative position of the bore defined through a longitudinal length of the hinge preferably includes changing the position of the bore relative to an internal surface of the cavity.
In a further embodiment, providing at least one side panel and at least one door specifically includes rotationally molding both the at least one side panel and the at least one door.
In one embodiment, coupling the at least one door to the at least one side panel specifically includes inserting the at least one door into the bore defined in the hinge.
In another embodiment, the method also includes providing at least one expandable end table that is coupled to the at least one side panel, a plurality of tray supports that are within an internal volume of the food service cart, and a flume that is defined within the internal volume of the food service cart.
While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The disclosure can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
The disclosure and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the embodiments defined in the claims. It is expressly understood that the embodiments as defined by the claims may be broader than the illustrated embodiments described below.
Greater understanding of the mobile delivery cart may be had by turning to
In a preferred embodiment, the first and second doors 22, 24 rotate or pivot about at least one removable hinge 26 disposed between each of the respective doors 22, 24 and corresponding side panels 18, 20. More specifically, the first side panel 18 and the second side panel 20 each comprise a hinge column 94 disposed or integrally coupled to a forward or front facing edge, while each door 22, 24 comprises an upper hinge housing 96. Each hinge column 94 and upper hinge housing 96 comprises a bore or cavity defined through at least a portion of their respective longitudinal lengths for accommodating a hinge 26 therein.
The first and second doors 22, 24 as well as the main structural components of the cart 10 including but not limited to the top surface 12, bottom surface 14, rear surface 16, and the side panels 18, 20 are each comprised of plastic or plastic composites and are preferably manufactured using a rotational molding process. Each structural component comprises a thickness with a relatively hollow internal volume which allows the cart 10 to be relatively lightweight while still being thermal insulating for any food items that are stored within the cart 10.
Greater detail of the hinges 26 disposed in the cart 10 may be had by turning to
Because the hinge 26 comprises a plurality of facets 86, the hinge 26 may be used to compensate or correct errors or deficiencies that are inherent with the rotational molding process. More specifically, when the doors 22, 24 and the hinge column 94 portions of the side panels 18, 20 of the cart 10 are manufactured via a rotational molding method, there are often slight inconsistencies which render proper vertical alignment between the upper and hinge housings 96, 98 with a corresponding hinge column 94 difficult. In other words, if a traditional hinge pin as is known in the art is inserted between the hinge column 94 a corresponding upper hinge housing 96, any manufacturing defects could mean that the doors 22, 24 do not rotate properly or do not shut completely when closed.
The current hinge 26 solves this issue by providing an adjustable means for coupling each of the doors 22, 24 to their respective hinge columns 94. In one embodiment, as the hinge column 94 of each respective side panel 18, 20 is being rotationally molded, an aperture or socket 102 is defined within a top facing surface 104 of the hinge column 94. The socket 102 in certain embodiments comprises an internal volume which matches or corresponds to the overall shape of the hinge 26. For example, the socket 102 defined in the hinge column 94 comprises a substantial decagonal shape so as to fit or accommodate each of the plurality of facets 86 of the hinge 26 in a substantially nested or fitted configuration. Once formed, the hinge 26 is inserted into the socket 102 by first placing the bottom surface of the hinge 26 into the socket 102 and then dropping or sliding the hinge 26 into the socket 102 at an initial position or orientation with the top surface 84 of the hinge 26 flush or exposed relative to the top facing surface 104 of the hinge column 94 as seen in the cross sectional view of
Next, in one particular embodiment, a first lateral end of a hinge pin 106 seen in
Once the door 22, 24 has been hung or coupled to the cart 10, the user may check the vertical position of the door 22, 24 and the ability of the door 22, 24 to rotate about the hinge column 94. If the door 22, 24 does not properly operate or is otherwise misaligned with the cart 10, the door 22, 24 is removed from the hinge 26 and the hinge 26 is then rotated relative to the socket 102 defined in the hinge column 94 in which it is disposed. Because the bore 90 defined in the hinge 26 is substantially off-center relative to the longitudinal axis 92 of the hinge 26, the position of the bore 90 is also rotated a corresponding amount. The user may then reinsert the hinge pin 106 and/or recouple the door 22, 24 to the hinge 26 with the bore 90 at a second or adjusted position, thereby disposing the door 22, 24 at a slightly different position and orientation relative the hinge column 94. If the door 22, 24 is still misaligned, the hinge 26 may again be repeatedly rotated within the socket 102 until a position for the bore 90 is found which in turn places the door 22, 24 in a proper vertical alignment with the hinge column 94 and the rest of the cart 10. Because the hinge 26 comprises a plurality of facets 86 which matches the cross sectional shape of the socket 102, relative rotational movement between the hinge 26 and the hinge column 94 and/or the hinge housing 96 is prevented. In other words, the facets 86 ensure that the hinge 26 remains stationary even when the door 22, 24 is actively being rotated open or closed.
An conceptual illustration of a specific embodiment of how the hinge 26 may be adjusted to compensate for variations in the manufacturing process may be seen in
Returning to
In a related embodiment, the cart 10 further comprises one or more pockets 56 disposed thereon. The pockets 56 are preferably comprised of plastic or other substantially transparent material and are preferably disposed on each of the first door 22 and the second door 24 or any other highly visible surface of the cart 10. The pockets 56 are sized to hold and display any object placed therein including but not limited to menus, business cards, advertising, and the like.
In one embodiment seen in
In a further embodiment, a prop rod 34 is adjustably disposed between the side panel 20 and the end table 28 so as to maintain the end table 28 in a substantially horizontal or extended position that is perpendicular relative to the side panel 20 as best seen in
To expand or use the end table 28, a reverse method from the process described above is performed, namely with the user rotating the end table 28 about the rail 30 until the end table 28 is substantially perpendicular relative to the vertical surface of the second panel 20. As the end table 28 is rotated away from the recess 36, the bracket cutout 44 is moved away from the panel bracket 38 thereby exposing it to the user while the prop rod 34 falls away from the rod indentation 42 under gravity or, alternatively, the user may remove the prop rod 34 from the rod indentation 42. The user may then rotate the prop rod 34 about the end table bracket 40 and then insert the distal end of the prop rod 34 into the panel bracket 38, thereby propping up or maintaining the end table 28 in the expanded configuration seen in
In a related embodiment seen in the top down view of
Greater understanding of the interior of the cart 10 and how the first and second doors 22, 24 operate may be seen in
In one embodiment, the interior surfaces of each half or part 66, 68 of the internal volume of the cart 10 comprises an indentation or flue 70. In one particular embodiment, the flue 70 comprises an upper portion 70a and a lower portion 70b defined in an inner rear wall surface 74 and an inner bottom surface 72, respectively. Because the flue 70 is recessed or defined within the inner surfaces 72, 74, a trough or negative volume is created which allows heat to more easily travel or move from a lower portion of the cart 10 to an upper portion of the cart 10. For example, heat radiating from any food items disposed on any of the trays disposed on a corresponding pair of tray supports 64, or any other means for providing or generating heat, will draw cooler air from outside the cart 10 into the interior volume where it begins to warm. The warmed air then travels vertically upward through the interior volume of the cart 10 via the lower portion 70b and/or the upper portion 70a of the flume 70 where it then begins to cool. In this fashion, the flume 70 helps establish a convection current through the interior of the cart 10.
Greater detail of the paddle latches 48, 50 may be seen by turning to
In one embodiment, once the first and second door 22, 24 have been opened, the user may continue to swing or rotate the doors 22, 24 open about their respective hinges 26 up to 270 degrees to their maximum open position or configuration as seen in
To close the doors 22, 24, the user rotates the doors 22, 24 about their hinges 26 in an opposing direction toward the front of the cart 10. As each door 22, 24 is rotated inward, the bolt 74 disposed thereon is brought into contact with a corresponding strike plate 78, 80. Continued rotation of the doors 22, 24 pushes the bolt 74 across the strike plate 78, 80, which in turn compresses a spring or other biasing means disposed within the housing 76. The bolt 74 continues to traverse or slide across the surface of the strike plate 78, 80 until the bolt 74 then slides or moves beyond the lateral edge of the strike plate 78, 80, thereby allowing the spring to once again expand and push the bolt 74 beyond the edge of the strike plate 78, 80 and lock the door 22, 24 into place.
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the embodiments. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the embodiments as defined by the following embodiments and its various embodiments.
Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the embodiments as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the embodiments includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the embodiments is explicitly contemplated as within the scope of the embodiments.
The words used in this specification to describe the various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the embodiments.
