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A method of molding a shopping cart component includes providing a first subcomponent and then overmolding the shopping cart component as a second subcomponent about the first subcomponent. The first subcomponent acts as an obstacle to a plastic injection stream and to a gas injection stream during

A method of molding a shopping cart component includes providing a first subcomponent and then overmolding the shopping cart component as a second subcomponent about the first subcomponent. The first subcomponent acts as an obstacle to a plastic injection stream and to a gas injection stream during the overmolding of the second component to assist in defining a first hollow section of the shopping cart component adjacent the first subcomponent.

대표청구항 ▼

What is claimed is: 1. A method of molding a shopping cart component comprising: providing a first subcomponent; and forming the shopping cart component, via overmolding a molten plastic completely around the first subcomponent within a mold, by introducing the first subcomponent as an obstacle wit

What is claimed is: 1. A method of molding a shopping cart component comprising: providing a first subcomponent; and forming the shopping cart component, via overmolding a molten plastic completely around the first subcomponent within a mold, by introducing the first subcomponent as an obstacle within the mold to partially define a first hollow section of the shopping cart component adjacent the first subcomponent. 2. The method of claim 1, wherein the first subcomponent is completely retained within the molten plastic. 3. The method of claim 1 wherein forming the shopping cart component comprises: completely filling the mold via injection of the molten plastic into the mold via at least one plastic injection port with the molten plastic flowing completely around the first subcomponent and engaging a portion of the first subcomponent; injecting a gas into the molten plastic in the mold through at least one gas injection nozzle to forcibly push a portion of the molten plastic out of the mold, via at least one spillover well, to form the first hollow section of the shopping cart component adjacent to the first subcomponent; and removing the molded shopping cart component from the mold. 4. The method of claim 3 wherein injecting the gas further comprises: forming a second hollow section of the shopping cart component with the second hollow section being spaced apart from the first hollow section, the second hollow section comprising a generally uniform wall thickness and a generally uniform cross-sectional area, and wherein the first hollow section of the shopping cart component comprises a generally non-uniform cross-sectional area. 5. The method of claim 4 wherein providing the first subcomponent comprises: arranging the first subcomponent to be sized and shaped to cause the first hollow section of the shopping cart component, during the overmolding of the molten plastic relative to the first subcomponent, to limit a wall thickness of the first hollow section from exceeding a predetermined maximum wall thickness of the shopping cart component. 6. The method of claim 5 wherein the wall thickness of the first hollow section generally corresponds to the wall thickness of the second hollow section of the shopping cart component. 7. The method of claim 5 wherein forming the shopping cart component comprises: molding the shopping cart component as an all-plastic basket of a shopping cart, including: arranging the basket to define a goods-receptacle that includes a front portion and rear portion; positioning the first subcomponent within the mold, during the overmolding of the molten plastic relative to the first subcomponent, for location within a rear upright frame member of the basket adjacent the rear portion of the basket with the rear upright frame member defining the first hollow section. 8. The method of claim 7 wherein positioning the first subcomponent comprises: providing the first subcomponent as an insert member that includes: a first sleeve portion defining an upper slot of the rear upright frame member of the basket; a second sleeve portion defining a lower slot of the rear upright frame member of the basket; and a generally solid midportion extending between the first sleeve portion and the second sleeve portion. 9. The method of claim 8 wherein the insert member has a length substantially the same as a length of the rear upright frame member, and wherein the insert member extends generally vertically alongside a side panel of the basket. 10. The method of claim 3 wherein forming the shopping cart component further comprises: forming the shopping cart component as a generally loop-shaped handle of a shopping cart and providing the first subcomponent as a generally cylindrically shaped plug; arranging the generally loop-shaped handle to include a front portion and a rear portion and locating the at least one plastic injection port and the at least one gas injection nozzle adjacent the rear portion of the generally loop-shaped handle at the mold and locating the plug at the front portion of the generally loop-shaped handle. 11. A method of molding a handle of a shopping cart, the method comprising: providing a mold shaped to produce a generally loop-shaped handle, the handle including at least one rear corner portion and a front portion, the front portion located at a generally opposite end of the handle relative to the at least one rear corner portion; injecting a molten plastic via a plastic injection port, adjacent the at least one rear corner portion of the handle, to flow along a first plastic flow path and a second plastic flow path within the mold until the mold is completely filled with the molten plastic, wherein the first plastic flow path extends in a generally opposite direction from the second plastic flow path; injecting a gas via a gas injection nozzle, adjacent the at least one rear corner portion of the handle, to flow along a first gas flow path and a second gas flow path into the molten plastic within the completely filled mold to forcibly push a portion of the molten plastic out of the mold, into at least one spillover well located adjacent the front portion of the handle, to form a hollow structure of the handle, wherein the first gas flow path extends in a generally opposite direction from the second plastic flow path; and removing the generally loop-shaped handle from the mold, wherein injecting the molten plastic comprises: placing, prior to injecting the molten plastic, a plug entirely within the mold at the front portion of the handle to cause overmolding of the plug such that the plug is entirely embedded within the front portion of the handle, wherein the plug defines an end portion of each respective first plastic flow path, second plastic flow path, first gas flow path, and second gas flow path of the mold. 12. The method of claim 11 wherein injecting the molten plastic further comprises: arranging the plug with a size and a shape to substantially block flow of the molten plastic between the first plastic flow path and the second plastic flow path at the front portion of the handle. 13. The method of claim 12 wherein arranging the plug comprises: providing at least one ribbed portion on the plug to induce flow of the molten plastic into the at least one ribbed portion of the plug to cause mechanically locking the plug relative to the molten plastic. 14. The method of claim 12 wherein providing the mold comprises: arranging the at least rear corner portion of the handle to define a prong of the handle, wherein the prong comprises at least one of the plastic injection port and the gas injection port; and concealing both of the plastic injection port and the gas injection port on the prong via slidably insertion and securing the prong into a slot of a basket of the shopping cart. 15. The method of claim 12 wherein injecting the gas comprises: providing the at least one spillover well as a first spillover well and a second spillover well; positioning the first spillover well adjacent the end portion of the first gas flow path and the second spillover well adjacent the end portion of the second gas flow path, with the second spillover well being substantially larger than the first spillover well. 16. The method of claim 15 wherein the second plastic flow path is substantially longer than the first plastic flow path and the second gas flow path is substantially longer than the first gas flow path. 17. A method of molding an all-plastic shopping cart comprising: forming a generally hollow handle of the shopping cart within a first mold via a full shot, gas-assisted plastic injection molding process; forming a basket of the shopping cart within a second mold via a full shot, gas-assisted plastic injection molding process, the basket including at least one hollow section; forming a generally hollow base of the shopping cart within a third mold via a full shot, gas-assisted plastic injection molding process; and assembling the shopping cart via removably attaching the handle to the basket and via removably attaching the base to the basket; wherein forming the handle comprises: arranging the first mold to include a pair of generally oppositely oriented plastic flow paths and a pair of generally oppositely oriented gas flow paths, arranging the first mold to produce the handle as a generally loop-shaped member and introducing a plug completely within the first mold between the generally oppositely oriented plastic flow paths to terminate flow of the molten plastic from the respective plastic flow paths and between the generally oppositely oriented gas flow paths to terminate flow of the gas from the respective gas flow paths, and locating a spillover well adjacent each respective plastic flow path. 18. The method of claim 17 wherein forming the basket comprises: arranging the second mold to produce the at least one hollow section of the basket, including introducing an insert member as an obstacle within a plastic flow path and a gas flow path of the second mold to cause molten plastic within the mold to form the at least one hollow section as a first hollow section adjacent to and extending from the plug. 19. A method of molding a product comprising: providing a first subcomponent; and forming the product, via gas-assisted, plastic injection overmolding of a molten plastic about the first subcomponent within a mold, including positioning the first subcomponent within the mold to direct a gas flow path within the mold to partially define a first, gas-filled hollow section of the product defining an open space directly abutting the first subcomponent; and removing the product from the mold. 20. The method of claim 19 wherein forming the product comprises: providing the mold with a first shape configured to produce a generally loop-shaped product, the product including a first portion and a second portion, the second portion located at a generally opposite end of the product relative to the first portion; providing the first subcomponent as a solid insert member and positioning the solid insert member within the mold adjacent the second portion of the product; and the gas-assisted plastic injection molding process includes: injecting the molten plastic, adjacent the first portion of the mold, within the mold to completely fill the mold with the molten plastic with the solid insert member defining an end point of a plastic flow path within the mold; and injecting the gas, adjacent the first portion of the product, to forcibly expel a portion of the molten plastic out of the mold into at least one spillover well with the solid insert member positioned adjacent the at least one spillover well to cause the expelled portion to exit the mold into the at least one spillover well. 21. The method of claim 19, further comprising: inserting the first subcomponent within the mold prior to forming the product such that the molten plastic completely surrounds the first subcomponent during plastic injection overmolding.