AU2019100052A4 - Flat-packable storage unit - Google Patents

Abstract

Interlockable panels for a flat-packable container includes a first panel (14) and a second panel (12). The first panel (14) is provided with a tenon projection (181) extending from the panel (14). The tenon projection (181) has a hook-profile (1813, 5 1814) defined by a distal portion (1811) of the tenon projection (181) returning towards the panel (12) compared to an adjacent less-distal portion (1812). The second panel (12) is provided with a mortise hole (1821) adapted to receive the tenon projection (181). The mortise hole (1821) is defined by a mortise surround (1820) which cooperates with the hook profile (1813, 1814) of the tenon projection (181). lo

Description

Flat-packable Storage Unit

Field of the invention

The present invention relates to flat-packable containers. In particular, the invention relates to flat-packable panels able to be assembled to provide an ancillary storage unit for a vehicle.

Background of the invention

An overwhelming majority of commercially available vehicle-mounted storage boxes are one-piece structures mounted in the car trunk. Due to their great volume and weight, it is very inconvenient to dismantle and clean them.

For this reason, some companies have produced vehicle-mounted storage boxes capable of being assembled and disassembled. They break down a vehicle-mounted storage box into several detachable plates. However, this structure has a huge flaw as described below. Vibration in the car trunk is inevitable during driving. After the plates are assembled together, they may become loosened or even come apart under the effect of car vibration during driving and thus impact driving safety.

Another disadvantage of existing vehicle-mounted storage boxes is that they do not take full advantage of the space in a storage compartment of the vehicle. For example, the width and the internal shape of a storage compartment may vary between different types of vehicles. Therefore, storage boxes comes in standard sizes to fit most makes 20 and models, thus leaving valuable remaining space in the storage compartment.

Therefore it is an object of the present invention to provide interlocking panels for a flatpackable container which ameliorates or overcomes the abovementioned disadvantage of panels loosened by vibration. Another object of the present invention is to provide an ancillary storage unit for a vehicle which at least ameliorates the wastage of valuable 25 space in the storage compartment of a vehicle.

Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be combined with other pieces of prior art by a skilled person in the art.

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Summary of the invention

In accordance with a first aspect of the present invention, there is provided, an ancillary storage unit for a vehicle including: a plurality of interlockable panels adapted for assembly into one or more drawer storage compartments forming part of the unit, the 5 panels including: a plurality first panels, each provided with a tenon projection extending from the panel, the tenon projection having a hook-profile defined by a distal portion of the tenon projection returning towards the panel compared to an adjacent less-distal portion; and a second top panel provided with a mortise hole adapted to receive the tenon projection, the mortise hole defined by a mortise surround which cooperates with 0 the hook profile of the tenon projection, wherein the tenon projection of the first panel is receivable in the mortice hole of the second top panel to provide a flat extent of the top surface of the second top panel.

A tenon projection is preferably provided along an edge of the first panel. There may be a plurality of tenon projections at spaced locations along the edge of the first panel.

Moreover, there may be a plurality of tenon projections along a plurality of edges of the first panel.

The first panel may be substantially planar and the or each tenon projection may extend in the plane of the first panel.

The tenon projection may be integrally moulded with the first panel. For example, the 0 first panel may be moulded from plastic, more preferably, blow-moulded. Preferably, the tenon projection is of uniform thickness throughout.

The tenon projection may include a main portion which is attached to the first panel and a cantilevered portion which incorporates the distal portion and the adjacent less-distal portion. The cantilevered portion preferably defines the hook profile facing the first 25 panel. The hook profile may include a return provided on the distal portion facing the first panel and an undercut provided on the less-distal portion.

The profile of the return may be in the form of a bump or a ridge which cooperates with a complementary form on the mortise surround.

The tenon projection is suitably flexible to enable the hook profile to move into 30 engagement with the complementary profile on the mortise surround. For example, the plastic material of the first and second panels may be polypropylene.

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Preferably, the mortise surround defines the mortise hole and also defines a barrier portion which partially blocks the mortise hole. The barrier portion may have a profiled face which is complementary to the hook profile of the tenon projection. The profiled face may define a ledge or a bump, and an indent. The return on the distal portion of 5 the tenon projection is suitably received in the indent in the home position of the mortise-tenon joint. Thus, preferably the opening in the mortise hole which is not blocked by the barrier portion is sufficient to receive the tenon projection.

Preferably, the cantilevered portion resiliently deflects or deforms to clear the ledge or bump when the panels are relatively slid to engage the distal portion with the indent.

Receipt of the distal portion may comprise a snap engagement that can be released only by use of a suitable tool.

A waterproof gasket may also be provided to seal the tenon-mortise joint.

In the second panel, a plurality of mortise holes may be arranged linearly to accommodate respective tenon projections of the first panel. Suitably, there will be a 5 series of tenon projections on the first panel which match a series of mortise holes on the second panel. There may be a set of panels to define the flat-packable container including base, sides, rear and top.

The ancillary storage unit may include at least one support beam which is extendible and retractable, the at least one beam being supportable by the plurality of first panels 0 compartment(s).

In accordance with another aspect of the invention (not claimed herein), there is provided an ancillary storage unit for a vehicle including:

a body portion including one or more storage compartments defined by at least a top panel and a bottom panel with the or each storage compartment defined between 25 two spaced upright panels, the top panel being supported on the upright panels with at least one support beam supported by the top panel and/or at least one of the upright panels, wherein the at least one beam is extendible and retractable, the beam being extendable beyond the body portion, an extension panel at the side of the body portion supported by the beam.

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The panels may be separable panels. Alternatively, some of the panels may be joined or articulated. Preferably, the panels are substantially planar and flat-packable.

In a preferred form of the invention, the beam(s) bridge between at least two adjacent upright panels and in extension, creates support for one or more extension panels at the 5 side of the body portion. The beam(s) may be extendible on both sides of the body portion to support an extension panel on each side. The extension panel(s) may be flush with the top panel. Preferably, the extension panel will fill in between the top panel and the vehicle body to create a sundries compartment. Accordingly, the extendibility of the beams allows the beam length to be adjusted to suit the vehicle. Additionally, the 0 retractability of the beam(s) allows for easy removal of the storage unit from the vehicle, since the internal width of the storage compartment in a vehicle is commonly wider than the opening of the storage compartment.

The extension panel(s) may have an access panel to provide entry into the sundries compartment.

Preferably, the beam(s) is telescopic.

In accordance with yet another aspect of the present invention (not claimed herein), there is provided an ancillary storage unit for a vehicle including:

a plurality of panels for assembly into a main body portion having one or more storage compartments;

one or more extendible and retractable components which are extendible beyond the extent of the main body portion; and extension panels supportable by the one or more extendible and retractable components for extending the storage capacity of the unit beyond the main storage compartment(s).

Any of the features described above in connection with the foregoing aspects for an ancillary storage unit may be applied to the above aspect.

In accordance with yet another aspect of the present invention (not claimed herein), there is provided a method of installing a storage unit within the storage compartment of a vehicle, the method including:

installing a body portion of the storage unit within the storage compartment of a vehicle, the body portion assembled from components which include flat-packable

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2019100052 17 Jan 2019 panels, wherein the assembled body portion includes one or more extendible/retractable components; and extending the one or more extendable/retractable components to the vicinity of a boundary of the storage compartment to extend the usable space within the storage 5 unit.

The body portion may be in the form of a carcass and the one or more extendable/retractable components are supportable by the carcass. Preferably the one or more extendable/retractable components are in the form of telescopic beams. Tthe carcass may include a top panel and the method preferably further includes supporting 0 one or more removable extension panels on the one or more extendable/retractable components to lay flush with the top panel. The method may further include retracting the one or more extendable/retractable components and removing the body portion from the vehicle.

Any of the features described above in connection with the foregoing aspects for an 5 ancillary storage unit may be applied to the above aspect.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Brief description of the drawings

In order that the invention may be more fully understood, one embodiment will now be described by way of example, with reference to the figures in which:

Figure 1 is a front perspective view of an ancillary storage unit for a vehicle according to a preferred embodiment of the present invention;

Figure 2 is a perspective view of the storage unit of Figure 1 with the drawers open;

Figure 3 is a perspective view of the storage unit shown in Figure 2 with a refrigerator housed in the large drawer;

Figure 4 is a perspective view of the carcass of the storage unit of Figure 1, without the drawers;

Figure 5 is a rear perspective view of the carcass of Figure 4;

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Figure 5A is a fragmentary cross-section depicting how the storage unit is located in position in a rear compartment of a vehicle;

Figure 6 is an exploded perspective view of the carcass of Figure 4;

Figure 7 is an exploded perspective view of the top panel and support beams of the 5 carcass of Figure 4;

Figure 8 is an exploded perspective view of the telescopic support beams of Figure 7;

Figure 9 is an exploded perspective view of the fastener assembly to assemble the top panel and support beams together;

Figure 10 is an exploded perspective view of the extension panel of the carcass shown 0 in Figure 4;

Figure 11 is a detailed view of the tenon projection provided on the upright divider panels of the carcass of Figure 4;

Figure 12 is a perspective view of the mortise hole provided in the top panel, bottom panel and rear panel of the carcass shown in Figure 4;

Figure 13 is a front perspective view of the rear panel of the carcass shown in Figure 4;

Figure 14 is a rear profile view of the rear panel shown in Figure 13;

Figure 15 is a cross sectional view along A-A of the rear panel shown in Figure 14;

Figure 15A is a detailed cross-sectional view of Figure 15;

Figure 15B is a cross-sectional detail of the divider panel of the carcass of Figure 4;

Figure 16 is a front perspective view of the large drawer of the storage unit shown in Figure 1;

Figure 17 is a rear perspective view of the large drawer shown in Figure 16;

Figure 18 is an exploded view showing the panels of the large drawer of Figure 16;

Figure 19 is an exploded view of the large drawer of Figure 16, including the drawer 25 mounts for sliding movement of the drawers;

Figure 20 is a rear profile view of the rear panel of the drawer of Figure 16;

Figure 21 is a profile view of the right hand side panel of the large drawer of Figure 16;

Figure 22 is a profile view of the left hand side panel of the large drawer;

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Figure 23 is a cross sectional view through the left hand side panel of Figure 22;

Figure 23A is a detailed cross sectional view of Figure 23;

Figure 23B is a detailed cross sectional view of the right hand side panel of Figure 21;

Figure 24 is a rear perspective view of the rear panel of the large drawer;

Figure 25 is a front perspective view of the rear panel of the large drawer;

Figure 26 is a cross sectional view through the rear panel of the large drawer;

Figure 26A is a detailed cross sectional view of Figure 26.

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Detailed description of the embodiments

The figures show a multipurpose vehicle-mounted storage unit 10 which is made up of flat-packable panels which are substantially planar or plate-like. The panels may be shipped to the end user in a flat-pack for do-it-yourself assembly by the end user. The 5 panels and the assembly features provided thereon, also lend themselves to being deconstructed as desired by the end-user for lower volume storage. The panels make up a carcass 101 to accommodate a number of drawers. The drawers are also constructed from flat-packable panels.

As shown in Figs. 4 to 6, the storage unit 10 has a carcass 101 comprising a rear panel 0 11, a horizontally arranged top panel 12 and bottom panel 13, and several upright divider panels 14 uprightly placed between the top panel 12 and bottom panel 13. The panels 11, 12, 13 and 14 are all fabricated using the construction technique of blowmoulding of plastics material e.g. polypropylene to produce hollow panels as will be described further below.

The bottom panel 13, top panel 12, and rear panel 11 are connected to the divider panels 14 with mortise-tenon joints, thus forming two side-by-side storage compartments used for placing drawers 200 as shown in Figs. 1 to 3. When the unit 10 is installed, these compartments open towards the same direction as the opening of the vehicle (not shown).

Support beams

As shown in Figs. 6 to 8, three support beams 17 are placed upon the upper edges of the divider panels 14 and received in complementary recesses provided on the underside of the top panel 12. The top panel 12 is fixed to the beams 17 with fastenings 171. The beams 17 increase the rigidity of the top panel 12.

As shown in Fig. 9, each fastening 171 passes through the top panel 12. As shown in Fig. 6, there are 3 rows of fasteners 171 spaced across the top panel 12. The central row of fasteners 171 are fixed in the fastening screw holes 1711 which are threaded holes provided in the beams as shown in Fig. 8. At the outer edges of the top panels, the fasteners 171 seat into the extension pieces 1713 to provide adjustment of the extension pieces 1713 as will be explained below.

As shown in Fig. 9, a dust cap 1715 is placed on the top of the fastener 171. A fastening ring 1716 that is convenient for manual handling is provided on the fastener 171, and

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2019100052 17 Jan 2019 the dust cap 1715 is provided with a cavity (not shown) on its underside for containing the fastening ring. The ring 1716 enables users to manually adjust the tightness of the fastener 171 without the help of any tools, and the dust cap 1715 prevents dust and dirt from entering into the fastener 171 and the fastening screw hole 1711 and thus protects 5 them from rust and other damage to prolong their service life. Each ring 1716 can also be useful as a tie-down anchor point on top of the storage unit.

Referring to Figs. 7 and 8, the support beams 17 are each comprised of a central flattened aluminium tube 1710 of approximately rectangular cross-section which is able to receive extendible and retractable extension pieces 1713. The extension pieces 1713 0 are inserted into each end of the tube 1710. The extension pieces 1713 are of approximately rectangular cross-section and of a size which allows for easy sliding within the tube 1710. The extension pieces 1713 are of plastic and preferably of a kind which allows for easy sliding between the extension piece and the tube, e.g. glass filled nylon. The end of the extension piece 1713 is provided with a stopper 1714 to define the limit of retraction of the extension piece 1713 into the tube 1710.

As can be seen, the end of the tube 1710 is provided with a hole 1712 which allows passage of the fastener 171 therethrough. Each extension piece 1713 is provided with a series of spaced adjustment holes 1717 which are threaded and allow adjustment of the extension/retraction of the extension pieces 1713 beyond the ends of the tubes 1710.

The telescopic beams 17 permit the overall width of the unit 10 to be reduced for easy removal from the rear of the vehicle. Generally the width of the opening of a vehicle such as the boot opening, hatch or tailgate is less than the width inside the vehicle so this feature allows easy removal of the unit 10 from the vehicle.

Sundries compartment

As shown in Figs. 1-5 and Fig 10, extension panels 15 that are flush with the top panel are fixed to the beams 17 at the ends of both beams 17. On each side of the carcass 101, the extension panel 15, the inner wall of the vehicle body (not shown) and the adjacent divider panel 14 form a sundries compartment which is convenient for holding tools and articles. The extension panel 15 increases the flat extent of the top surface of the unit and makes it feasible to place luggage and other objects on top of the storage unit.

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The extension panel 15 has a U-shaped opening and is provided with a removable access panel 151 in the opening.

As shown in Fig. 10, the access panel 151 has a complementary profile to the U-shaped opening in the extension panel. In particular, the U-shaped opening has a ledge 152 below its top surface to seat the access panel 151 on the seat with the top surface of the access panel 15 flush with the top surface of the extension panel 15.

The access panel 151 is removably secured to the extension panel 15 through a grooved connection. There is a connecting groove 1521 on the inner edge of the Ushaped opening. The access panel 151 is designed with a connecting tongue (not 0 shown) on its corresponding edge, and the tongue can be downwardly inserted into the connecting groove 1521. The connecting groove 1512 and tongue connection prevents the access panel 151 from coming off the extension panel 15 due to car vibration. The access panel is so firmly attached that it can be taken off only by application of manual force.

The access panel 151 is provided with through holes or indentations 1513 for manual handling. Opening or closing of the access panel 151 can be realized by lifting it up or pushing it back down.

As shown in Figs. 1,4 and 6, at the front of each sundries compartment, front panels 16 are fixed to the divider panels 14 on both sides of the unit 10. The upper edge of the 0 front panel 16 is fixed to the top panel 12 and extension panel 15 through a grooved connection, and the lower edge is fixed to the bottom panel 13 through a grooved connection.

The front panel 16 is composed of a curved segment 161 and a flat baffling segment 162, which are unitarily molded in one piece. The curved segment 161 is fixed to the outer side of the divider panel 14, and installed into two arc-shaped grooves 120 on the undersurface of the top panel 12 and the top surface of the bottom panel 13, which are consistent with the curved segment 161 in shape.

The upper edge of the baffling segment 162 is fixed to the underside of the extension panel 15 through a grooved connection. There is a straight groove 150 (see Fig. 10) on 30 the underside of the extension panel 15, which matches with the upper edge of the baffling segment 162, and the upper edge of the baffling segment 162 is embedded in the straight groove 150.

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The curved segment 161 is convenient for fixing the front panel 16 to the divider panel 14, and the baffling segment 162 keeps the front of the unit flat. The front panel 16 can prevent articles in the sundries compartment from falling out and further improve the effectiveness of space partitioning.

The sundries compartment can be used for storing car repair tools. The detachable access panel 151 not only is convenient for looking for things, but also can prevent the tools from jumping out of the compartment and improve the tidiness of the car trunk.

Mortice-tenon joints

As shown in Fig. 6, the upper edges, lower edges, and rear edges of all the divider panels 14 are provided with aligned tenons 181, and the bottom panel 13, top panel 12, and rear panel 11 are all provided with mortises 182 at the corresponding positions. The tenons 181 mate with the mortises 182 to form a roughly cuboid structure of the carcass 101. It is very easy to assemble the panels with mortise-tenon joints. When not in use, the carcass 101 can be disassembled for easy storage, thus giving users more autonomy and flexibility.

The mortises 182 are all of the same form and the tenons 181 are also all of the same form throughout the unit 10. The tenons 181 are integrally molded with the associated divider panel 14. Likewise, the material surrounding the mortices i.e. the mortise surrounds, are integrally molded with the associated panel.

As shown in detail in Fig. 11, the tenon 181 is formed as a projection extending from the panel, in line with the general plane of the divider panel 14. The tenon 181 has a hook profile. A distal portion 1811 of the tenon 181 defines a return 1813 which is closer to the panel 14 compared to an undercut 1814 on an adjacent less-distal portion 1812.

As shown in Fig. 12, the mortice surround 1820 defines a slotted mortice hole 1821 and cooperates with the hook profile of the tenon 181. The mortice surround 1820 defines a barrier portion 1822 such as an overhang, that partly blocks the mortice hole 1821. The barrier portion 1822 has a profiled face which faces away from the tenon 181 as the tenon 181 is being inserted into the opening.

The portion of the mortice hole 1821 which is not blocked by the barrier portion is sized to comfortably receive the tenon 181 or alternatively, the tenon 181 may require a force to bend the distal portion 1811 of the tenon to force the tenon through the mortice hole. However, the second alternative makes the unit difficult to disassemble.

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The profiled face of the barrier portion is complementary to the hook profile of the tenon 181. The profiled face defines a ledge or bump 1823, and an indent 1824. The return 1813 on the distal portion 1811 of the tenon 181 is received in the indent 1824 when the tenon 181 is pushed to the home position. The relative dimensions and shapes are such 5 that the tenon must resiliently deform slightly to travel up and over and thereby clear the ledge or bump 1823. Sufficient force must be applied to cause the deformation as the two parts slide relative to each other. The result is a snap action engagement of the return 1813 of the tenon 181 in the indent 1824 when the tenon 181 is pushed to the home position, that can be released only by insertion of a suitable pronged tool . The 0 ledge or bump 1823 is retained in the undercut 1814 of the less-distal portion 1812.

The depth of the indent 1824 is preferably half as much as that of the top panel 12, bottom panel 13, or the rear panel 11.

Preferably, the junction between the profiled face of the barrier portion 1822 and the side wall of the mortise surround 1820 is designed as smooth arc surfaces during manufacture.

Likewise, the profiled face of the barrier portion 1822 including the indent 1824 and the ledge or bump 1823 is designed as smooth arc surfaces. Additionally the return portion 1813 and the undercut 1814 of the hook portion are designed as smooth arc surfaces. This design makes the contact surface between each mortice hole and tenon projection 0 smooth, and the user can effortlessly finish the assembly. In addition, the design can reduce friction between components and prolong the product’s service life.

When assembling the carcass 101, the user should first assemble all the divider panels 14 on the bottom panel 13 by inserting the tenons 181 into the corresponding mortises 182 of the bottom panel, and then longitudinally pushing the divider panels 14 until each 25 hook profile is seated in its home position on the profiled face of the barrier portion

1822. Thus, the bottom panel 13 remains stationary while each divider panel 14 is pushed to seat the tenons 181 in the home position in the mortice 182. The rear panel 11 is then assembled with the divider panels with the tenons 181 at the rear edges of the divider panels received in the mortices 182 of the rear panel 11. The rear panel is pushed down to lock the tenons in place - and a longitudinal rib 118 (Figures 5A, 13 and 15) on the bottom edge of the rear panel seats in a groove 132 in the upper face of the bottom panel. The top panel 12 is overlaid onto the divider panels 14 to line up the tenons on the divider panels 14 with the mortices 182 in the top panel 12. The tenons

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181 must be all received in the top panel 12 before the top panel 12 is pushed so that the tenons 181 in the divider panels 14 seat in the home position in the mortices 182 in the top panel 12.

This structure is very simple to assemble, easy to operate, and rigid in final form.

Dismantling is possible if desired but requires individual prising apart of each tenon/mortice pair with a suitable pronged tool.

Seals may be provided to insert into the mortice holes from above the top panel 12 to seal the mortice holes and prevent entry of dirt and other debris.

In this embodiment, there are several sunken grooves 141 (see Fig. 6) on the upper 0 edges of the divider panels 14, and the support beams 17 are placed in the grooves 141 so as to avoid the situation that the beams 17 protrude over the upper edge of the divider panel 14, which would otherwise impair the tenon-mortise joint between the divider panel 14 and the top panel 12.

Rear panel

As shown in Figs. 13 and 14, the rear panel 11 is composed of an upper upright segment 111, an intermediate inclined segment 112, and a lower upright segment 113, which are molded unitarily. This structure makes the storage unit 10 adaptable to the trunk of various motor vehicles, such as recreational or utility vehicles (otherwise known 0 as pickups) and brings about a wider range of application for the storage unit 10.

Mounting in vehicle

As shown in Figures 5 and 5A, the rear edge of the bottom panel 13 has a margin 134 of reduced thickness, produced by recessing both the top and bottom surfaces from respective transversely extending shoulders 136, 137: bottom surface shoulder 136 is 25 more forward than top surface shoulder 137. This margin 134 does not extend the full width of the panel but only between two symmetrically positioned slots 138 from the rear edge. This leaves respective integral stopper tabs 139 at the rear corners of the panel.

To position the storage unit in a vehicle, reduced thickness margin 134 of bottom panel 13 is pushed with a firm fit into a channel portion of a matching hollow metal section135 30 that is fixed across the vehicle floor at the rear edge of bottom panel 13 (Figure 5A).

Stopper tabs 139 then prevent lateral movement along the channel by engaging the

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2019100052 17 Jan 2019 ends of the channel. Channel 135 is flush top and bottom with the rest of panel 13. If desired, the unit is fastened into place by suitable clamps or other releasable fasteners at the sides of outer divider panels 14 (not shown).

Drawers

As shown in Figs. 1 to 3, the drawers 200 of the vehicle-mounted storage unit proposed in this embodiment may be used for storing articles. Additionally, the drawer 200 may be utilised for placing a vehicle-mounted refrigerator 203 or insulated unit. In this particular embodiment, there is a large drawer 201 for accommodating a refrigerator 203 and a smaller drawer 202 for other articles. While the large drawer 201 is described here, the smaller drawer 202 is of substantially the same construction.

As shown in Figs. 16 to 18, the large drawer 200 consists of a bottom panel 24, a handle-bearing panel 21 in the front, a rear panel 23 at the back, and two upright panels 22 on each side. A clearance may be provided between the upper edge of the handlebearing panel 21 and the upper edge of the carcass 101. The clearance would not only prevent fingers being nipped due to incorrect operation, but would also extend operating space when placing a car refrigerator in the drawer 201.

The handle-bearing panel 21 is provided with a handle 211 which is lockable.

As shown in Figs. 20, 24 and 26, the rear panel 23 is provided with removable ventilation pieces 230, designed for promoting heat transfer of the refrigerator 203. The removable ventilation pieces 230 are described further below.

As shown in Fig. 18, the front edge of the upright panel 22 is provided with first tenons 223, and the back edge provided with second tenons 224 and the lower edge is provided with third tenons 225. There are first mortises 212 at the front of the handlebearing panel 21, three on each side, which match with the first tenons 223. The handle-bearing panel 21 is connected to the upright panels 22 through mortise-tenon joints. Front plates 213 disguise these mortice-tenon joints and depending on the selected material, can reduce vibration in the front mortice-tenon joints. An insulative or sound absorbent material such as cotton may reduce vibration and extend service life. There are second mortises 23a on the rear panel 23 which match with the second tenons 224 on the upright panel 22. There are third mortices 241 on the bottom panel which match with the third tenons 225 of the upright panel 22. The bottom panel 24

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2019100052 17 Jan 2019 and the rear panel 23 are thus connected to the upright panels 22 through mortisetenon joints.

The configuration of the tenon projections and the mortice holes and surrounds is the same for the drawers as that described above for the carcass 101 in connection with

Figs. 11 and 12. The resulting mortice-tenon joints are therefore the same.

The drawer may be provided with a stopper or limiting part engaging with a corresponding part on the carcass 101 to avoid the drawers from being excessively pushed into or pulled out of the storage compartments due to a force or accident.

Drawer slides

As shown in Figs. 16 to 19, each upright panel 22 of the large drawer 201 is provided with a reinforcing plate 221 on its internal side, and a protruding slide 222 on its external side.

As shown in Fig. 6, the divider panel 14 is provided with a slide track 142 that are mounted on the sides of the divider panel 14. The slide tracks 142 also improve the strength of the storage compartments.

Rollers 226 are mounted on the protruding slide for rolling engagement with the slide track 142. The rollers 226 enable the drawer 201 to be pulled or pushed smoothly in the storage compartment, and it is very convenient to operate.

Structure of panels

Figs. 20, 24 to 26A illustrate the unitary hollow structural form of a panel 23 constructed from plastic material e.g. polypropylene, using blow-moulding so the panel is of low weight and easy to manufacture. The panel illustrated is the rear panel 23 of the large drawer 201. However, the arrayed recess structure described below is similarly applied to all of the panels used in the storage unit 10. The removable pieces 230 in the recesses 237 provide ventilation openings when the large drawer 201 is used to house a refrigerator 203. These removable pieces 230 may be selectively removed by the end user. The feature of the removable ventilation pieces 230 may also be applied to the rear panel 11 of the carcass 101. The divider panels 14 in the carcass 101 may also have removable pieces within at least some of the recesses.

As shown in Fig. 26, the unitarily-moulded panel 23 is shaped to include an S-bend defining an upper portion 234, an inclined portion 235 and a lower portion 236. The

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2019100052 17 Jan 2019 panel is composed of an first wall 232 and an second wall 233 which follow the contours of the S-bend. The outer surface of the second wall 232 is planar, apart from the Sshape.

There is a cavity 233 enclosed by the first wall 231 and second wall 232, which reduces 5 the overall weight of the panel 23.

The outer surface of the first wall 231 is provided with an array of recesses 237 that are arranged at regular intervals transversely and longitudinally and sunken into the cavity 233. Each recess 237 is of rectangular or slotted shape with generally rounded ends as shown in Fig. 24. Each portion 234, 235 and 236 has an outer surface of the first wall 0 231 which is a plane surface.

The inner surface of the first wall in the region of the recess 237 may be closely connected to the second wall 232, or there a clearance may be provided between them. The cavity 233 is thus punctuated by the recesses 237.

Preferably, as shown in Fig. 20, the recesses 237 are arranged as a rectangular array with a number of transverse and longitudinal rows. In the rear panel 23 of the drawer 201 as shown, the lower panel portion 236 has an array of 12 recesses 237, 4 across and 3 down. The inclined panel portion 235 has an array of 4 recesses 2313, 2x2.

In the lower panel portion 234, there is a transverse 2311 or longitudinal ridge 2312 on the first wall 231 between any two of the transverse or longitudinal recess rows. The 0 transverse ridges 2311 and longitudinal ridges 2312 play a connecting and supporting role, and the transverse ridge 2311 has the same width as the longitudinal ridge 2312, leading to uniform load distribution across that portion 236 of the panel 23. The transverse and longitudinal ridges on the hollow structure greatly improve the bearing capacity of the panel 23. When the recess array is in other non-rectangular forms, various shapes of ridges can be obtained to meet diverse demands.

Preferably, the transverse dimension of the recess 237, across the width of the slotted or rectangular recess 237 is shorter than the longitudinal dimension to further improve the stability of the panel. The transverse dimension corresponds to the direction of loading of the panel 23.

The upper panel portion 234 of the rear panel 23 has a scooped cut-out 238 between two side portions 239. The scooped cut-out 238 allows for air flow between the inside of the drawer 201 and the inside of the compartment in the carcass 101 which houses the

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2019100052 17 Jan 2019 drawer 201. The two side portions 239 each provide for a mortise hole 23a for attachment to the adjacent upright panels 22 of the drawer.

Removable pieces in the rear drawer panel

As illustrated in Figs. 26 and 26A, some of the recesses 237 in the rear panel 23 are removable to create ventilation or cable openings. The pieces 230 in the recesses 237 in the lower panel portion 236 are all intended to be removed and are provided with markings in the form of indentations 2310 to indicate their special removable nature. The 4 recesses 2313 in the inclined panel portion 235 are not intended to be removed.

The first and/or second walls are shaped to define the removable piece 230. The shape 0 is created by the blow-moulding dies (not shown). The recesses 237 are defined by one or more side walls 2315 formed from depressing the first wall 231 into the recess 237. The removable piece 230 has a scored perimeter formed by the blow-moulding dies forming a depression 2314 surrounding the removable piece 230, with the resultant material thickness of the panel 23 around the end wall being thin and therefore frangible 5 or breakable. In the depression 2314, the first wall 231 meets or is closely proximate to the second wall 232. The blow-moulding dies also form the indentations 2310 in the first wall 231. The first wall 231 is therefore push into the cavity 233 to form the recess 237 while the second wall 232 remains substantially planar. However, in other panels such as the rear panel 11 and the divider panels 14 of the carcass 101 and the side panel of 0 the drawer, both the first wall and the second wall may be depressed by the blowmoulding dies to form the removable piece.

This makes the end walls easy to remove, either by simple manual detachment, or using a hand-tool such as a knife or punch.

The other recesses 2313 in the inclined panel portion 235 are not intended to be removed and do not include a removable piece bordered by a depression. Accordingly, theses recesses 2313 contain no markings.

Removable pieces in the rear panel of the carcass

Similarly, the rear panel 11 of the carcass 101 as shown in Figs. 13 to 15A also contains removable pieces 115 which are likewise marked as removable. In the rear panel 11, aligned recesses 116 are formed in the outer surface of both side walls as can be seen in the cross-section of Figs. 15 and 15A. Thus, each removable piece 115 is centrally disposed between the two recesses 115. Similarly, each removable piece 115

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2019100052 17 Jan 2019 is bordered by a score line, groove or notch rendering the connection as frangible or breakable so that the removable pieces 115 can be easily removed.

The removable pieces are disposed in the lower portion 113 and the upper portion 111 but only on the side of the rear panel 11 which is adjacent the large drawer 201. This is 5 because the large drawer 201 is intended to house the refrigerator 203 for which ventilation is required.

While only some of the recesses in the panel 11 are intended to have removable pieces, it is possible that all of the recesses in the panel 11 could have removable pieces.

Removable pieces in the divider panels of the carcass

Additionally, as shown in Fig. 15B, some of the recesses 143 formed in the divider panels also have removable pieces, at a substantially central depth relative to the first and second walls of the divider panel 14. These removable pieces 144 are likewise marked 145 as removable.

Removable pieces in the upright panels of the large drawer

Additionally, the upright panels 22 of the large drawer 201 also contain removable pieces 227 within some of the recesses 228 as marked on Figs. 21 and 22. Figs. 2323B illustrate the particular form.

The foregoing describes only one embodiment of the present invention and modifications may be made thereto without departing from the scope of the present invention.

Claims (5)

1. An ancillary storage unit for a vehicle including:

a plurality of interlockable panels adapted for assembly into one or more drawer storage

5 compartments forming part of the unit, the panels including:

a plurality first panels, each provided with a tenon projection extending from the panel, the tenon projection having a hook-profile defined by a distal portion of the tenon projection returning towards the panel compared to an adjacent less-distal portion; and a second top panel provided with a mortise hole adapted to receive the tenon

0 projection, the mortise hole defined by a mortise surround which cooperates with the hook profile of the tenon projection, wherein the tenon projection of the first panel is receivable in the mortice hole of the second top panel to provide a flat extent of the top surface of the second top panel.

2. The ancillary storage unit as claimed in claim 1 wherein the tenon projection

5 includes a main portion which is attached to the first panel and a cantilevered portion which incorporates the distal portion and the adjacent less-distal portion and the cantilevered portion preferably defines the hook profile facing the first panel where the hook profile includes a return provided on the distal portion facing the first panel and an undercut provided on the less-distal portion.

0

3. The ancillary storage unit as claimed in claim 1 or claim 2 wherein the mortise surround also defines a barrier portion which partially blocks the mortise hole the barrier portion having a profiled face which is complementary to the hook profile of the tenon projection.

4. The ancillary storage unit as claimed in claim 3 wherein the junction between

25 the profiled face of the barrier portion and the side wall of the mortise surround is a smooth arc surface.

5. The ancillary storage unit for a vehicle as claimed in any one of the preceding claims further including: at least one support beam which is extendible and retractable, the at least one support beam being supportable by the plurality of first; and

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2019100052 17 Jan 2019 one or more extension panels supportable on the beam(swherein the extension panel(s) are adapted to lie flush with the top panel when assembled.