FIELD OF THE INVENTION AND BACKGROUND
The present invention relates to wagons and, more particularly, to the construction of a plastic wagon.
Wagons are popular with both children and parents. While children enjoy playing with wagons as toys, parents appreciate the utility offered by wagons and often use them to transport children and cargo.
A difficulty facing manufacturers and shippers of wagons is that the products are bulky and sometimes heavy. This causes packaging difficulties and increases the shipping costs for manufacturers. In addition, the products consume valuable inventory space for distributors and retailers. A need exists for a wagon that provides a compact profile when packaged, shipped and stored in inventory. A need also exists for such a wagon to be economical to construct, durable and lightweight.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top front perspective view of an embodiment of the wagon of the present invention;
FIG. 2 is a bottom front perspective view of the wagon of FIG. 1;
FIG. 3 is top plan view of the wagon of FIGS. 1 and 2;
FIG. 4 is a sectional view of the wagon of FIGS. 1-3 taken along line 4-4 of FIG. 3;
FIG. 5 is a top front partial perspective view showing the rear portion of the interior of the wagon of FIGS. 1-4;
FIG. 6 is an exploded perspective view of the body of the wagon of FIGS. 1-5;
FIGS. 7A and 7B are enlarged bottom perspective views showing insertion of a nut into one of the nut recesses formed in the rim of the footwell of the body of the wagon of FIGS. 1-6;
FIG. 8 is a bottom front perspective view of the wagon body of FIG. 6 in an assembled condition showing insertion of screws to further secure the wagon pan to the footwell;
FIG. 9 is a top front perspective view of the assembled wagon body of FIG. 8;
FIG. 10 is a side elevational view showing the wagon of FIGS. 1-5 with the handle in a storage position;
FIG. 11 is an enlarged perspective view of a rear portion of the wagon illustrating use of the seat belts of FIGS. 6 and 9;
FIG. 12 is a bottom rear partial perspective view of the rear portion of the wagon body of FIGS. 6, 8 and 9 illustrating the molded rear axle mount prior to installation of the rear axle;
FIG. 13 is a bottom partial perspective exploded view illustrating assembly of the rear axle and wheels to the molded rear axle mount of FIG. 12;
FIG. 14 is a bottom rear partial perspective view of the rear portion of the wagon body and axle mount of FIGS. 12 and 13 after installation of the rear axle and wheels;
FIG. 15 is a top front perspective view of the wagon of FIGS. 1-14 in a disassembled and packaged configuration.
DETAILED DESCRIPTION OF EMBODIMENTS
An embodiment of the wagon of the present invention is indicated in general at 20 in FIGS. 1-5. The wagon features a two-piece body, indicated in general at 21, which consists of an upper portion wagon pan 22 and a lower portion footwell 24 which are molded separately and then secured together with screws after shipping and unpacking. The wagon pan 22 is preferably rotationally molded from plastic, while the footwell 24 is preferably injection molded from plastic. Alternative materials, including, but not limited to, metal, may be used for either or both the wagon pan and footwell.
A handle 26 is pivotally attached to the front wall of the wagon pan by a pin 27 and handle mounting brackets 25a and 25b. Handle mounting brackets 25a and 25b are preferably molded into the front wall of the wagon pan, but may be separately produced and then attached. The handle pivots between an upright position, illustrated in FIGS. 1-5, and a storage position underneath the footwell 24, illustrated in FIG. 10.
The wagon pan 22 features integrally molded front and rear walls and sidewalls as well as front and rear seat surfaces 32a and 32b. The top of the wagon pan is open as is the area between the front and rear seat surfaces. The wagon footwell features an integrally molded bottom 33 and front and rear walls and sidewalls. As illustrated in FIGS. 4 and 5, the assembled wagon provides a storage space 34 under the rear seat surface 32b. Furthermore, children riding in the wagon and seated on seat surfaces 32a and 32b may comfortably position their feet within the interior of foot well 24, indicated at 36 in FIG. 4.
It should be noted that in an alternative embodiment, the seating surfaces 32a and 32b could be omitted to provide the wagon with greater cargo hauling capacity.
The wagon features four wheels 28. A pair of caster mounts 38a and 38b (FIGS. 1-3) are preferably molded into the wagon pan 22 and support the front wheels via caster rods 42a and 42b so that the front wheels are free to pivot as the wagon is pulled by the handle 26. The caster mounts may alternatively be separately produced and then attached to the wagon pan.
As illustrated in FIGS. 2-5, a pair of cup holders 44a and 44b are preferably molded into the bottom 33 of the footwell 24. In addition, a barrier wall, illustrated at 45 in FIGS. 4 and 5 is preferably molded into the floor of the footwell to assist in securing items in storage space 34 under rear seat surface 32b.
Assembly of the wagon pan 22 and footwell 24 to form the wagon body is illustrated in FIGS. 6-9. As illustrated in FIG. 6, the footwell 24 features a circumferential rim portion 46 which features molded nut recesses 48. As illustrated in FIGS. 6, 7A and 7B, each nut recess 48 receives a nut 52. While four nut recesses are illustrated, an alternative number of nut recesses, nuts and corresponding screws may be used.
As shown in FIG. 6, fasteners in the form of primary screws 54 are positioned through corresponding openings in the seat surfaces 32a and 32b of the wagon pan and engage the nuts 52 of the footwell. As a result, the footwell 24 is secured to the wagon pan 22, as illustrated in FIG. 8. Other fasteners known in the art may be used as alternatives to the primary screws.
As illustrated in FIGS. 6 and 9, seatbelts 56a and 56b are preferably secured by their proximal ends to the tops of seat surfaces 32a and 32b using the primary screws 54 (i.e. the same screws that secure the wagon pan and footwell together). Of course alternative fastener arrangements known in the art may be used to secure the seat belts to the wagon seat surfaces. As illustrated in FIG. 11, rear seatbelt 56b is provided with a quick release buckle 62 so that a child 64 riding, in the wagon may easily fasten and unfasten the seatbelt. Seatbelt 56a is also provided with such a buckle.
Threaded inserts, illustrated in phantom at 72 in FIG. 8, are positioned and secured within the sidewalls of the wagon pan. The threaded inserts may be molded in place or inserted and secured in place, such as with threads, adhesive or another securing arrangement, after the wagon pan is constructed. Secondary screws, illustrated at 74 in FIG. 8, are inserted through corresponding openings 76 formed in the circumferential rim 46 of the footwell and engage the threaded inserts 72. As a result, the wagon pan and footwell are securely fastened together, as illustrated in FIG. 9.
As illustrated in FIG. 12, a rear axle mount, indicated in general at 80, is molded with the rear edge of the footwell 24. In alternative embodiments, the axle mount could take the form of openings formed through the footwell or an axle mount that is made separately from the footwell, out of plastic, metal or another material, and attached to the footwell. The axle mount features a number arcuate members 81a-81d that receive the rear axle 82 of the wagon, as illustrated in FIGS. 13 and 14. During assembly, the rear axle 82 is preferably moved through the arcuate members of the axle mount 80, as illustrated in FIG. 13. As shown in FIGS. 13 and 14, a pair of spacers 84 are preferably positioned on each end of the axle after installation to the rear axle mount 80. After the rear wheels 28 are mounted on the axles, a pair of end caps 86 are attached by interference fit with the ends of the rear axle.
As illustrated in FIG. 15, the two-piece body and other construction details of the wagon of FIGS. 1-14 permits compact packaging and shipping in a nested configuration where the footwell 24 is positioned within the wagon pan 22, and then the handle 16, wagon wheels 28 and associated components are positioned within the footwell. A cardboard insert 100 preferably holds the wheels and other components in place within the footwell. The compact nested assembly of FIG. 15 may then be packaged within a box, indicated in FIG. 15 by dashed lines 102.
The wagon of FIGS. 1-15 provides a compact packaging and shipping profile and is inexpensive to produce. Furthermore, the wagon is lightweight and durable when assembled.
While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by the appended claims.
Patent Application
20120248722
