US20080129158A1

US20080129158A1 - Storage case with internal frame

Info

Publication number: US20080129158A1
Application number: US11/947,839
Authority: US
Inventors: William C. KALKWARF
Original assignee: Master Lock Co LLC
Current assignee: Master Lock Co LLC
Priority date: 2006-11-30
Filing date: 2007-11-30
Publication date: 2008-06-05
Also published as: WO2008067508A3; CN101541212A; MX2009005718A; EP2091389A2; CA2670511A1; WO2008067508A2; EP2091389A4

Abstract

A storage case includes a U-shaped structural frame that forms three closed sides of the case. Decorative panels are fastened to the frame to form exterior surfaces of the case.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional application claims the benefit of U.S. Provisional Patent Application No. 60/861,877, entitled “Storage Container Frame,” filed on Nov. 30, 2006, the entire disclosure of which is incorporated herein by reference, to the extent that it is not conflicting with the present disclosure.

FIELD OF THE INVENTION

The present invention relates to a storage container frame and to a storage container frame for use with a tool chest or tool cabinet.

BACKGROUND OF THE INVENTION

Storage containers such as dressers, bureaus, and file cabinets having drawers are in popular use. Several exemplary storage devices include tool chests, tool cabinets, and combination tool chest and cabinet units. Tool chests, tool cabinets, and combination tool chest and cabinet units are in widespread use in residential, commercial and industrial settings.
The manufacture of tool chests and tool cabinets is well-known. Tool chests and cabinets typically are constructed by welding together pieces of metal panel sections formed by blanking and bending operations. The welded pieces form a multiple sided box-shaped housing having an open front. Additional exterior panels may be welding on the housing to form a finished unit. The interior of the box conventionally includes two or more cooperatively aligned horizontal slide carriers for installing a plurality of drawers. After the entire unit has been formed and assembled, the drawers are installed. Subsequently, the box is painted or otherwise finished to produce an end product having a uniform finish and exterior surface appearance.

SUMMARY

A storage case and method for assembling the same is provided. The storage case includes a U-shaped flame that forms three of the closed sides of the storage case. Decorative side and other exterior panels are fastened to the frame, preferably by means other than welding, to form exterior surfaces of the storage case.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of this invention will become apparent from the following detailed description made with reference to the accompanying drawings.

FIG. 1 a is a front perspective view of a tool chest constructed with a case frame in accordance with an embodiment of this invention;

FIG. 1 b is a bottom perspective view of a tool chest constructed with a case frame in accordance with an embodiment of this invention;

FIG. 2 a is a front perspective view of a tool cabinet constructed with a case frame in accordance with an embodiment of this invention;

FIG. 2 b is a bottom perspective view of a tool cabinet constructed with a case frame in accordance with an embodiment of this invention;

FIG. 3 a is an exploded perspective view of a case frame in accordance with an embodiment of the present invention;

FIG. 3 b is a top plan view of a metal panel that can be used to construct a case frame in accordance with an embodiment of the present invention;

FIGS. 4 a-4 d are various views of a decorative side panel that can be connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention;

FIG. 5 is a bottom perspective view of a decorative top panel that can be connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention;

FIG. 6 is a rear perspective view of a decorative rear panel that can be connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention;

FIG. 7 a is a cross section view of the side panel of FIG. 4 a and the rear panel of FIG. 6 connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention;

FIG. 7 b is an exploded cross section view of the side panel of FIG. 4 a and the rear panel of FIG. 6 connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention;

FIG. 8 a is a cross section view of the side panel of FIG. 4 a connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention;

FIG. 8 b is an exploded cross section view of the side panel of FIG. 4 a connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention; and

FIG. 9 is a cross section view of the side panel of FIG. 4 a, the rear panel of FIG. 6, and a front block panel connected to the case frame of FIG. 3 a to construct a tool chest or cabinet in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

This Detailed Description of the Invention merely describes embodiments of the invention and is not intended to limit the scope of the specification or claims in any way. Indeed, the invention as described by the specification and claims is broader than and unlimited by the preferred embodiments, and the terms used in the specification and claims have their full ordinary meaning.
The present invention will be described for use with a tool chest and a tool cabinet. It should be understood that this is for exemplary purposes only and the invention can be applied to a wide variety of storage cases and applications.
The invention is directed to a storage case frame and method of assembly of same. The invention provides flexibility in styling and aesthetic options for the resultant storage container. As a result, a variety of styles of non-welded, non-painted skin can attach directly to one frame. The performance of a storage case constructed in accordance with this invention compares favorably to existing storage cases. The invention further provides flexibility to allow manufacturing with a minimum of fabrication, weld, paint and assembly operations. The case frame produced without welding requires a lower skilled labor force and lower costs assembly techniques. The design however does not preclude the ability to weld the frame.
The storage case is assembled without welding using a joinery technique, such as for example, rivets, other hardware, or adhesive. A skin material can be subsequently applied to the frame to complete the assembly of the storage container. The skin may be attached without welding by press fitting the skin over flanges, by adhesive, or by other suitable methods.
The assembly method allows for a variety of different finishes for the outer skin, such as for example, brushed stainless, painted, anodized, clear coat, and stained. The assembly method also allows for a variety of different material selection for the outer skin, such as for example, stainless steel, aluminum, carbon fiber, plastic, and wood. One standard case frame can be used with a variety of materials with only a minimum of tooling revisions. This beneficial feature provides flexibility to apply the design concept to allow a variety of the finished products within a single frame platform. Further, different styles and outside shapes could be used based on the base platform of the box and drawer shells.
The invention allows for the manufacture of tool storage chest and cabinets without any painting equipment or finishing operations. This feature lowers capital equipment costs as compared to known designs and methods in the art. Any finishes or painting of the skin material can occur before blanking and forming. Alternatively, the material can be procured in pre-coat or mill finished form.
FIGS. 1 a and 1 b are views of a tool chest 10 that has been constructed with a case frame 100 (shown in FIG. 3 a) and decorative exterior panels including side panels 12, top panel 16, rear panel 24, bottom panel 20 and front finishing panels 13 a, 13 b. The tool chest includes drawers 15 that slide on slider carriers (not shown) mounted to the case frame 100. FIGS. 2 a and 2 b are views of a tool cabinet 50 that has been constructed with a case frame 100 (shown in FIG. 3 a) and decorative exterior panels including side panels 12′, top panel 16′, bottom panel 20′ and front finishing panels 13 a′, 13 b′. The tool cabinet includes casters 34 and drawers 15′ that slide on slider carriers (not shown) mounted to the case frame 100. The details of the slider carriers and drawers are not described herein, as this mechanism is known in the art.
FIGS. 3 a and 3 b illustrate an exemplary case frame 100 that is used to construct the tool chest and cabinet shown in FIGS. 1 a-2 b. The case frame 100 has a U-shape made up of two side segments 110 a, 110 b connected at an edge to an intermediate segment 110 c. In the described embodiment, the intermediate segment 110 c serves as the bottom surface of the tool chest or cabinet. However, in other embodiments, the intermediate segment may serve as the top or rear surface of the tool chest or cabinet. Various slider carrier mounting holes are shown in the side segments 110 a, 110 b. Slider carriers are connected to these holes in the side segments. The intermediate segment includes mounting holes 134 to which the casters 34 are mounted when the case frame 100 is used to construct a tool cabinet 50. The structure and construction of a tool chest frame is similar to a tool cabinet frame, with several common exceptions. A tool chest typically is without casters and has a bottom surface designed to accommodate resting on a flat surface, such as for example, a work bench or the top of a tool cabinet. The top surface of a tool chest may be hinged to allow for tool storage access within the tool chest.
It may be advantageous to form the entire case frame 100 from a single flat panel of heavy gauge metal, such as, for example, 18 gauge galvanized steel, as shown in FIG. 3 b. The material used for the case frame 100 can be selected to provide sufficient structural strength so that material selected for the decorative side, top, and rear panels need not provide significant structural strength. The vertical side frame segments include vertical frame flanges 115 a, 115 b on either edge of the vertical side frame segments and top frame flanges 121 a, 121 b. The vertical frame flanges extend away from the interior of the case frame 100 at a substantially right angle to the side segments 110 a, 110 b. The top frame flanges 121 a, 121 b extend toward the interior of the case frame 100 at a substantially right angle to the vertical side frame segments 110 a, 110 b. The intermediate segment 110 c includes front and rear flanges 117 a, 117 b that extend toward the interior of the case frame.
To provide additional structural strength, cross members 135 a, 135 b, 135 c are connected between the vertical side segments to provide strength to the top of the case frame. Four L brackets 142 are installed at the bottom corners of the case frame behind the front and rear flanges 117 a, 117 b and on an exterior surface of the vertical frame flanges 115 a, 115 b. The L, brackets 142 maintain the relative position of the side segments 110 a, 1110 b and the intermediate segment 110 c. The connection of the cross members and L brackets to the case frame can be performed by welding or without welding by using rivets or other fasteners.
FIGS. 4 a-4 d are various views of a decorative side panel 12 that can be connected to the case frame 100. The side panel 12 forms an exterior surface of the tool chest or cabinet. The side panel 12 includes a top side panel flange 12 with mounting holes 153 that align with holes on the top frame flanges 121 a, 121 b. The side panel is thus connected to the frame with fasteners inserted through top frame flange and top side panel flange. The side panel also includes a first vertical side panel flange 12 b that is formed into a J shape with respect to the side panel 12. The first vertical side panel flange 12 b includes a front mounting surface with mounting holes 151 to which the front finishing panel 13 a is connected, mounting holes 143 and a clearance slot 144. An L bracket 155 protrudes through the slot 144 as shown in FIG. 4 a. The L bracket is connected to the side panel 12 through the mounting holes 143 in the side panel. The L bracket 155 is thus used to connect the side panel to the lower front finishing panel 13 b as will be described in connection with FIGS. 7-9. A top flange ear 12 e protrudes from a top of the first vertical side panel flange. The side panel includes a second side panel flange 12 d to which the rear panel 24 is attached and a bottom side panel flange 12 c.
FIG. 5 illustrates the decorative top panel 60 as viewed from below the panel. The top panel 60 includes bent down top panel side flanges 60 a and a bent down top panel rear flange 60 b. The top panel side flanges 60 a include top mounting flanges 61 that connect to top frame flanges 121 a, 121 b (FIG. 3 a). The top panel rear flange 60 b includes mounting flanges 60 c that connect to the rear cross member 135 b (FIG. 3 a). FIG. 6 illustrates the decorative rear panel 24. The rear panel 24 includes side flanges 24 a that are connected to the second side panel flange 12 d (FIG. 4 d) on either side panel 12. The rear panel 24 includes a top flange 24 c that is connected to the mounting flanges 60 c on the top panel (FIG. 5). The rear panel also includes a bottom flange that is connected to the rear flange 117 b on the frame (FIG. 3 a).
As already discussed above, the connections between the case frame 100 and the decorative external panels such as the side panels 12, the rear panel 24, and the top panel 60 can be made by welding or without welding using fasteners. In addition, because sufficient structural strength is provided by the frame 100, L brackets 142, and cross members 135 a, 135 b, 135 c, the decorative external panels may be constructed of thin or flexible material that provide pleasing aesthetic qualities without providing significant structural strength.
FIGS. 7 a and 7 b illustrate the connection of the side panel 12 and the rear panel 24 to a rear portion of the frame 100. As can be seen in FIG. 7 a, the L, bracket 142 is connected to the rear flange 117 b on the intermediate frame segment 110 c with rivets or fasteners. In this manner, the side panel 12 is connected at its bottom to the frame 100 and provides an exterior surface that covers the side vertical frame segment 110 a. The rear panel 24 is connected with rivets or other fasteners to the second side panel flange 12 d. FIGS. 8 a and 8 b illustrate the relative position of the side panel 12 and a front side of the frame 100. As can be seen in FIG. 8 a and also FIG. 9, the first vertical side panel flange 12 b fits against an end of the front flange 117 a on the frame and fits adjacent the L bracket 142 that is installed on the vertical frame flange 115 a on the side frame segment 110 a.
FIG. 9 shows further details of the connections between the side panels 12, rear panel 24, and front finishing panel 13 b to the frame 100. A strengthening bracket 175 is installed between the side frame segment 110 a and the intermediate frame segment 110 c. The front finishing panel 13 b is connected to the L bracket 155 that protrudes from the side panel 12.
While several embodiments of the invention has been illustrated and described in considerable detail, the present invention is not to be considered limited to the precise constructions disclosed. Various adaptations, modifications and uses of the invention may occur to those skilled in the arts to which the invention relates. It is the intention to cover all such adaptations, modifications and uses falling within the scope or spirit of the specification filed herewith.

Claims

1. A storage case having four closed sides, a top side, and an open side, the storage container comprising:

a substantially U-shaped case frame comprising first, second, and third frame segments joined to one another along an edge to form an interior surface of three of the closed sides of the storage case, wherein the first and third segments form vertical frame sides of the case and include vertical frame flanges disposed along both vertical edges of the first and third segments, the vertical frame flanges extending away from the interior surface of the closed sides at substantially a right angle; and

first and second decorative side panels connected to the vertical frame sides, each side panel having a substantially flat main portion configured to span and rest proximate to outside ends of the vertical frame flanges, each side panel including two side flanges disposed along parallel edges of the side panel and including a perpendicular flange portion configured to rest adjacent to outside faces of the vertical frame flanges;

wherein the side panels are connected to the case frame such that the side panels form an exterior surface of two of the closed sides and exterior edges of the open side of the storage case.

2. The storage case of claim 1 wherein the case frame comprises a single sheet of material that is bent to form the first, second, and third segments and the vertical frame flanges.

3. The storage case of claim 1 wherein the side panels comprise a single sheet of material that is bent to form the main portion and the side flanges.

4. The storage case of claim 1 wherein the second frame segment forms a bottom of the storage case.

5. The storage case of claim 4 further comprising one or more cross members connected between top end portions of the vertical frame sides.

6. The storage case of claim 4 wherein the second frame segment includes caster mounting structure.

7. The storage case of claim 4 wherein the side flanges include a parallel flange portion disposed at an end of the perpendicular flange portion, the parallel flange portion extending parallel to and spaced from the main portion, the storage case further comprising a rear decorative panel that includes rear panel flanges configured to connect to the parallel flange portion of each of the side panels.

8. The storage case of claim 1 wherein the side panel includes a top flange that extends from a top edge of the main portion toward the interior surfaces of the case and substantially perpendicular to the main portion, the top flange configured to connect to a inwardly disposed top flange on the vertical frame sides.

9. The storage case of claim 8 further comprising a top panel that is configured to connect to the inwardly disposed top flange on the vertical frame sides.

10. The storage case of claim 1 wherein the side panel includes at least one decorative surface and wherein the side panel is connected to the frame such that the decorative surface forms an exterior surface of the storage case.

11. The storage case of claim 8 wherein the side panels are connected to the case frame with rivets.

12. The storage case of claim 8 wherein the side panels are welded to the case frame.

13. A metal storage case having two vertical sides, a vertical back, a top side, a bottom side, and an open front side, the storage container housing one or more drawers that slide on drawer slides within the storage case, the storage case comprising:

a substantially U-shaped case frame comprising:

first, second, and third frame segments formed by bending a single sheet of metal to form an interior surface of three of the closed sides of the storage case;

wherein the second segment forms an interior surface of the bottom side; and

wherein the first and third segments form an interior surface of the vertical sides of the case and include vertical frame flanges disposed along both vertical edges of the first and third segments, the vertical frame flanges extending away from the interior surface of the closed sides at substantially a right angle and wherein the first and third segments include mounting openings configured to accept co-acting fastening features on the drawer slides, the first and third segments further comprising a top frame flange extending toward an interior of the storage case at a top edge of the first and third segments, the top frame flange extending at substantially a right angle to the first and third segments;

at least one cross member connected between top end portions of the first and third segments;

first and second decorative side panels connected to the first and third frame segments, each side panel comprising:

a substantially flat main portion configured to span and rest proximate to outside ends of the vertical frame flanges;

two side flanges disposed along parallel edges of the side panel, the side flanges including a perpendicular flange portion configured to rest adjacent to outside faces of the vertical frame flanges and a parallel flange portion disposed at an end of the perpendicular flange portion that extends parallel to and spaced from the main portion; and

a top flange that extends from a top edge of the main portion toward the interior surfaces of the case and substantially perpendicular to the main portion configured to rest on top of and be connected to the top frame flange;

wherein the side panels are connected to the frame such that the side panel forms an exterior surface of two of the closed sides and an exterior edge of the open side of the storage case;

a decorative rear panel that includes rear panel flanges configured to connect to the parallel flange portion of each of the side panels; and

a top panel that is configured to connect to the top frame flange and to a rear mounting flange on the rear panel.

14. The metal storage case of claim 13 wherein the second frame segment includes caster mounting structure.

15. The metal storage case of claim 13 wherein the side panel comprises aluminum.

16. The metal storage case of claim 13 wherein the side panel includes at least one decorative surface and wherein the side panel is connected to the frame such that the decorative surface forms an exterior surface of the storage case.

17. The metal storage case of claim 13 wherein the side panels are connected to the case frame with rivets.

18. The metal storage case of claim 13 wherein the side panels are welded to the case frame.

19. A method of constructing a storage case comprising:

providing a substantially U-shaped case frame comprising first, second, and third frame segments joined to one another along an edge to form an interior surface two vertical sides and a bottom of the storage case, wherein the first and third segments form the vertical sides of the case and include vertical frame flanges disposed along both vertical edges of the first and third segments, the vertical frame flanges extending away from the interior surface of the closed sides at substantially a right angle;

installing first and second decorative side panels on the first and third frame segments by positioning a substantially flat main side portion on outside ends of the vertical frame flanges such that the main side portion spans the vertical frame flanges; and

fastening a top flange portion of the first and second decorative side panels to a top frame flange that extends inwardly from a top end portion of the first and third frame segments;

wherein the side panels are connected to the case frame such that the side panels form an exterior surface of two of the closed sides and an exterior edge of the open side of the storage case.

20. The method of claim 19 wherein the step of providing a case frame is performed by bending a single piece of metal to form the panel portions and vertical frame flanges.

21. The method of claim 19 wherein the side panel flange includes a perpendicular flange portion configured to rest adjacent to outside faces of the vertical frame flanges and a parallel flange portion disposed at an end of the perpendicular flange portion that extends parallel to and spaced from the main portion to the case frame, the method comprising the step of installing rear panel flanges of a rear decorative panel to the parallel flange portion of each of the side panels.

22. The method of claim 20 comprising the step of installing a top panel to the top frame flange.

23. The method of claim 20 wherein the step of fastening the top flange portion to the top frame flange is performed by riveting.

24. The method of claim 20 wherein the step of fastening the top flange portion to the top frame flange is performed by welding.