US20110233206A1

US20110233206A1 - Storage unit with coupling mechanism

Info

Publication number: US20110233206A1
Application number: US12/730,010
Authority: US
Inventors: Cheng Chi Yeung; Wai Kwok Cheung
Original assignee: Esselte Corp
Current assignee: Esselte Corp
Priority date: 2010-03-23
Filing date: 2010-03-23
Publication date: 2011-09-29

Abstract

A storage unit having a first sheet having a female connection member defining an opening, and a second sheet having a male connection member. The male connection member can have a neck portion dimensioned to be received in the opening, and can have a retaining portion that is wider than the opening and configured to couple the male and female connection members together. The retaining portion can have a concave edge opposite from the neck portion.

Description

FIELD OF THE INVENTION

The present disclosure relates to a storage unit that can be made of two or more sheets using a coupling mechanism for coupling the two sheets together.

BACKGROUND

Various storage units for office supplies, documents, magazines, papers, etc. have been provided. However, the storage space required for such storage units is usually large, and a large amount of office space is usually required to hold such units before use.
Paper file boxes have been provided that are flat, and require less storage. However, paper file boxes are generally constructed by gluing four side boards and a bottom board together. Although the paper file boxes may avoid environmental problems, the structure strength thereof is insufficiently strong in the gluing areas, and are tedious and take a long time to construct. A further drawback of the conventional file boxes is that they are not foldable after gluing and thus occupy a considerable space after being built.
Various molded storage containers are also provided that can break down and do not require storage space when unassembled. For example, as provided in U.S. Pat. No. 3,675,808, a shipping container formed from a mold is provided that has a flat rectangular bottom wall with four sidewalls hinged thereto by integral thin flexible hinge portions. Two of the sidewalls have slots adjacent their side edges and two of the other sidewalls have ears projecting from side edges for insertion into the slots. Another molded container is provided in U.S. Pat. No. 6,827,231, which provides a minivan box liner having a molded bottom plate and a continuous wall comprising a plurality of panels and a plurality of hinge portions therebetween for permitting bending of the continuous wall at the hinge portions at angles therebetween.
However, the molded versions of containers are often expensive, cost more to manufacture, and also cost more for shipping. These molded containers are also heavier, and are complicated to manufacture and assemble.

SUMMARY

In one embodiment, a storage unit is provided comprising a first sheet having a female connection member defining an opening, and a second sheet having a male connection member, the male connection member having a neck portion dimensioned to be received in the opening, and a retaining portion that is wider than the opening and configured to couple the male and female connection members together, the retaining portion defining a concave edge opposite from the neck portion configured for increasing the flexibility of the retaining portion to facilitate reception thereof into the opening.
In some embodiments, the concave edge can be configured for increasing the flexibility of the retaining portion to provide a snap lock connection in the opening. The retaining portion of the male connection member can be configured to removably snap into the opening of the female connection member. The neck portion can define an indentation between a body of the second sheet and the male connection member such that the neck portion has a narrower width than the retaining portion.
In some embodiments, the retaining portion can comprise two lateral protrusions on opposite lateral sides of the concave edge and extending beyond the width of the opening, wherein the concave edge is configured and dimensioned for increasing flexibility of the lateral protrusions with respect to each other. The neck portion of the second sheet can have approximately a similar width as the opening of the first sheet. The opening can have an axis that extends through the first sheet, and the male connection member is disposed at a periphery of the second sheet.
The storage unit can further comprise a tab portion protruding from an edge of the second sheet for a label to be provided. The first sheet can comprise two or more panels that are folded with respect to each other. The first and the second sheets can comprise an extruded polypropylene foam. The second sheet can comprise an extruded foam having outer layers and a middle layer therebetween, wherein the outer layers have a higher density than the middle layer. The first sheet can comprise the extruded foam, and the first and second sheets can have substantially uniform thicknesses. The outer layers can comprise a first and second layer, and the first and second layers can comprise different colors.
The storage unit when assembled can comprise a document tray, magazine file, pen holder or name card holder. The storage unit can further comprise a substantially flat sheet blank comprising at least the first or second sheet in an unassembled form, wherein the sheet blank is pre-cut to allow easy removal of the first or second sheet therefrom. The sheet blank can have a substantially uniform thickness.
In other embodiments, an office storage unit can be provided, comprising a first extruded foam sheet having a substantially uniform thickness and a female connection member defining an opening, and a second extruded foam sheet having a substantially uniform thickness and a male connection member defining a protrusion, wherein the at least one female connection member is configured to receive the protrusion of the at least one male connection member to connect the first and second extruded foam sheets to form a foam storage unit.
In some embodiments, one or both of the first and second extruded foam sheets can comprise score lines configured for allowing the first or second foam sheets to bend thereat. The first sheet can comprise a plurality panels separated by at least one of the score lines and foldable thereabout, at least two of the panels having a female connection member each comprising an opening near a periphery of the first sheet, wherein each opening is configured to receive a protrusion of a male connection member of the second sheet to retain the first sheet folded about the at least one score line. The second sheet can comprise a plurality of panels is foldable at least one of the score lines and foldable thereabout, allowing the panels of the second extruded foam sheet to be coupled with the first extruded foam sheet to form a storage unit. The first sheet can comprise a left panel, a right panel and a middle panel joining the left and right panels, each panel having at least one or more female connection member.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 shows a bottom view of a first sheet having one or more female connection members according to an embodiment;

FIG. 2 a shows a top view of a second sheet having one or more male connection members according to an embodiment;

FIG. 2 b shows a side view of one male connection member according to the embodiment of FIG. 2;

FIG. 3 shows a top view of a third sheet having one or more male connection members according to an embodiment;

FIG. 4 shows a perspective view of a storage unit constructed of the first, second and third sheets according to the embodiments of FIGS. 1, 2 a, 2 b and 3;

FIG. 5 shows a broken side view of a sheet according to an embodiment;

FIGS. 6 a and 6 b show side views of side members for a stacked document tray having female connection members according to an embodiment;

FIG. 7 shows a top view of an insert for a stacked document tray having male connection members according to an embodiment;

FIG. 8 shows a perspective view of a stacked document tray according to the embodiments of FIGS. 6 a, 6 b and 7;

FIGS. 9 a-9 d show members of an unassembled pen holder in accordance with an embodiment;

FIG. 9 e shows an assembled pen holder in accordance with the embodiment of FIGS. 9 a-9 d;

FIGS. 10 a and 10 b show members of an unassembled name card holder in accordance with an embodiment; and

FIG. 10 c shows an assembled name card holder in accordance with the embodiment of FIGS. 10 a and 10 b;

DETAILED DESCRIPTION

Referring to FIG. 1, a top view of a first sheet 100 is shown having one or more female connection members. A first sheet 100 is shown comprising three panels 110, 120 and 130. Panel 110 can be connected to middle panel 120, which can in turn be connected to panel 130. Scores 140 can be provided along the panel 100 which separate the panels 110, 120 and 130, which can allow the first sheet 100 to bend at the location of the scores 140. The first sheet 100 can also be scored along a border 150 of the first sheet 100, so that the first sheet 100 can be removed from a pre-cut sheet, such as a sheet blank, which can have a substantially uniform thickness, as will be explained below.
Panel 110 can have female connection members 160 a, 160 b, 160 c, 160 d and 160 e, and panel 130 can have female connection members 170 a, 170 b, 170 c, 170 d and 170 e. The female connection members define an opening, each having a particular width w1, and can be provided along a periphery or edge of the panels 110 and 130. The female connection members can be provide on various parts of the panels as may be required of the storage unit being constructed, and are shown near the periphery of the panels 110 and 130 in the particular embodiment of FIG. 1. One or more female connection members can be provided near the peripheries of the panels 110 and 130. In the embodiment of FIG. 1, five female connection members are shown per panel. Panel 120 can also have one or more female connection members if required, and are not provided in the embodiment shown in FIG. 1. The first sheet 100 can have a substantially uniform thickness, and can be easily removed from a sheet blank (not shown).
Referring now to FIG. 2 a, a top view of a second sheet 200 having one or more male connection members is shown. The second sheet 200 can also be scored along a border 205 of the second sheet 200, so that the second sheet 200 can be removed from a pre-cut sheet, such as a sheet blank, which can have a substantially uniform thickness, as will also be explained below. The second sheet 200 can have one or more male connection members. As shown in FIG. 2 a, three male connection members 210 a, 210 b and 210 c are shown along one side of the second sheet 200, and three male connection members 220 a, 220 b and 220 c are shown along an opposite side of the second sheet 200. The male connection members 210 a, 210 b and 210 c can be provided along a first edge 230 of the second sheet 200, and the male connection members 220 a, 220 b and 220 c can be provided along a second edge 240 of the second sheet, which can be opposite the first edge 230. The male connection members can be provided on other parts of the second sheet, but are shown along edges of the second sheet in the embodiment of FIG. 2 a. The male connection members can comprise protrusions along edges of the second sheet 200.
Referring now to FIG. 2 b, a male connection member 210 a is shown in more detail. Other male connection members 210 b, 210 c, 220 a, 220 b and 220 c can have a similar structure as male connection member 210 a. The male connection member 210 a can comprise a neck portion 280 and a retaining portion 290. The neck portion 280 connects the retaining portion 290 and the second sheet 200. For convenience of illustration, a phantom line is provided to show where the neck and retaining portions 280,290 connect with each other. The neck portion 280 and retaining portion 290 are a continuous part of the second sheet 200 in the embodiment.
The neck portion 280 can have indentations 250 defined by neck lateral edges 252, and can have a width w2 between the neck lateral edges 252. The neck lateral edges 252 can have a concave radius or other shapes, preferably providing concave lateral indentations.
The retaining portion 290 can have a width w3 which is larger than w2. The indentations 250 of the neck portion 280 provide a narrower width w2 of the neck portion 280 than the width w3 of the retaining portion 290. Further, the retaining portion 290 has lateral protrusions 260. One or more lateral protrusions 260 can be provided on the retaining portion 290, and two lateral protrusions 260 are shown in the embodiment of FIG. 2 b. A concave edge 270 can be provided between the two lateral protrusions 260. The concave edge 270 can provide an increased flexibility of the retaining portion 290, and the lateral protrusions extend beyond the width of the opening. The concave edge 270 can be configured and dimensioned for increasing flexibility of the lateral protrusions with respect to each other. For example, when the male connection member 210 a is inserted through a female connection member 160 a, e.g., the edges 262 of the lateral protrusions 260 when pushed downwards can resiliently bend in a direction A allowing the first sheet 100 to be inserted over the lateral protrusions 260 through the female connection member. The edges 262 of the lateral protrusions 260 are sloped outwardly from the concave portion 270 to facilitate insertion and sliding of the male connection members into the female connection members.
In an example embodiment, the width w2 of the neck portion 280 can range from approximately 5-25 mm, and preferably approximately 10-20 mm, and more preferably approximately 14 mm. The width w3 of the retaining portion 290 can range from approximately 5-30 mm, and preferably approximately 10-20 mm, and more preferably approximately 17 mm. The width w3 of the retaining portion 290 is preferably greater than the width w2 of the neck portion 280. The overall width w4 of the male connection member 210 a is preferably greater than the width w2 of the neck portion 280, and can be equal to or slightly longer than the width w3 of the retaining portion 290, and can range from approximately 5-30 mm, and preferably approximately 10-25 mm, and more preferably approximately 17.5 mm. The width w5 of the concave edge 270 can range from approximately 5-15 mm, and preferably approximately 8-14 mm, and even more preferably approximately 11 mm.
The width w1 of the openings of the female connection members can be approximately less than or equal to the width w3 of the retaining portion 290, and can be slightly larger than or equal to the width w2 of the neck portion 280. Preferably the width w5 of the concave edge 270 is less than the width w2 of the neck portion 280.
The depth r1 of the concave edges 270 can range from approximately 0.5-5 mm, and preferably approximately 1-3 mm, and even more preferably approximately 2 mm. The depth r2 of the indentations 250 can range from approximately 0.5-5 mm, and preferably approximately 1-3 mm, and even more preferably approximately 2 mm. The depth r3 of the lateral protrusions 260 can range from approximately 0.5-6 mm, and preferably approximately 1-5 mm, and even more preferably approximately 3 mm.
The overall height B1 of the male connection member 210 a can range from approximately 2-20 mm, and preferably approximately 5-15 mm, and even more preferably approximately 7 mm. The height B2 of the retaining portion 290 can range from approximately 0.5-6 mm, and preferably approximately 2-5 mm, and even more preferably approximately 3.5 mm. The height B3 of the neck portion 280 can range from approximately 0.5-6 mm, and preferably approximately 2-5 mm, and even more preferably approximately 3.5 mm. The ratio of the height B2 to the height B3 is preferably approximately 1. The ratio of the height B3 or height B2 to the depth r1 is preferably approximately 2. The ratio of the height B3 or the height B2 to the depth r2 is preferably approximately 2.
Referring now to FIG. 3, a third sheet 300 can also be provided having one or more male connection members. In the embodiment shown in FIG. 3, male connection members 210 d, 210 e, 220 d and 220 e can be provided along a border 305 of the third sheet 300. Male connection members 210 d and 210 e can be provided along a first edge 310 of third sheet 300, and male connection members 220 d and 220 e can be provided along a second edge 320 of third sheet 300. Second edge 320 can be opposite first edge 310 of third sheet 300. Male connection members 210 d, 210 e, 220 d and 220 e can also have a similar structure as male connection member 210 a, as shown in FIG. 2 b. A tab portion 330 can also be provided on third sheet 300.
FIG. 4 shows a storage unit 400, which can be a magazine holder, constructed of first sheet 100, second sheet 200 and third sheet 300. The panel 100 can be folded downward along scores 140 such that panels 110 and 130 comprise the side walls of the storage unit 400 as shown in FIG. 400. Panel 120 can be the bottom surface of the storage unit 400. Second sheet 200 can be the back wall of the storage unit 400, and third sheet 300 can be the front wall of the storage unit 400. Male connection members 220 a, 220 b and 220 c of second sheet 200 couple together with female connection members 170 a, 170 b and 170 c of panel 130, respectively, and male connection members 210 a, 210 b and 210 c of second sheet 200 couple together with female connection members 160 a, 160 b and 160 c of panel 110, respectively, as shown in FIG. 4. Male connection members 220 d and 220 e of third sheet 300 couple together with female connection members 170 d and 170 e of panel 130, respectively, and male connection members 210 d and 210 e of third sheet 300 couple together with female connection members 160 d and 160 e of panel 110, respectively.
The width w1 of the openings of the female connection members 160 a-160 e and 170 a-170 e can be approximately the same as or slightly larger than the width w2 of the neck portion 280 of the male connection members 210 a-210 e and 220 a-220 e. The width w3 of the retaining portion 290 is even larger than the width w1 of the opening and the width w2 of the neck portion 280. Accordingly, the retaining portion 290 is first inserted into the openings of the female connection members, and a slight force is needed to push the retaining portions of the male connection members through the openings of the female connection members. Then, because the similarity of the widths w1 and w2, a tight coupling is formed between the male and female connection members. The lateral protrusions of the retaining portions of the male connection members extend beyond the width of the opening and face generally axially with respect to the opening.
Preferably, the male connection members and female connection members comprise a snap lock connection, such that once the retaining portion is pushed through the opening, a snap lock connection is made between the male and female connection members. Such a snap lock connection can be removable so that the storage unit 400 can be broken down into flat sheets 100, 200 and 300 again. The concave edge 270 of the retaining portion can also have an ergonomic design that allows the user to place his/her finger on the concave edge 270 and push the retaining portion 290 to release the male connection member from the opening of the female connection member, allowing a quick and easy disassembly of the storage unit 400.
FIG. 5 shows a broken side view of first sheet 100. Second sheet 200 and third sheet 300 can also have similar structure as first sheet 100 as will be described below. The sheet 100 can be made of a foam material, and can have three layers 510, 520 and 530, as shown in FIG. 5. The sheet 100 can be an extruded foam sheet, and can have a substantially uniform thickness. The foam material can be a polypropylene structural foam material. Polypropylene structural foam can be made of three layers of polypropylene material. The top layer 510 and bottom layer 530 can be for coloring and texture finishing, and the middle layer 520 can be recycled polypropylene in foam form, which can highly reduce the density and sustainability of the sheet 100.
The top layer 510 and bottom layer 530 can be mostly brand new polypropylene material, which can be between approximately 90-99% polypropylene, and even more preferably approximately 97% polypropylene, and the remaining can be polyethylene material. The top layer 510 and bottom layer 530 can be mainly for coloring and texture finishing (similar to rigid polypropylene flat material). The top 510 and bottom layer 530 can be the same color, or can have different colors. The densities for the top layer 510 and bottom layer 530 can be between approximately 0.5-1.5 ton/m³, and preferably 0.85-0.95 ton/m³, and can even more preferably be approximately 0.91 ton/m³(e.g., same as rigid polypropylene), and the thickness 501 of the top layer 510 and the thickness 503 of the bottom layer 530 can be between 0.05-0.5 mm per layer, and preferably between 0-1-0.3 mm, and can even more preferably be approximately 0.2 mm per layer.
The middle layer 520 can be approximately 90-99% recycled polypropylene and the remaining can be polyethylene material and foam agency. The middle layer 520 can preferably be approximately 95% recycled polypropylene, and 3% polyethylene and 2% foam agency. The foam agency is to provide the carbon dioxide (CO₂) to make the polypropylene material of the middle layer 520 foamed to a density of approximately between 0.5-0.9 ton/m³, and preferably between 0.6-0.75 ton/m³, and even more preferably approximately 0.68 ton/m³. The thickness 502 of the middle layer 520 can be approximately between 1-3 mm, and preferably between 1.2-2.6 mm. Thus, the middle layer 520 can have a density less than the density of the top layer 510 and bottom layer 530, and the thickness 502 of the middle layer can be greater than the thickness 501 of the top layer 510 and thickness 503 of the bottom layer 530.
The polypropylene foam flat that comprises the sheets can be made by a three layer extrusion machine. Three extrusion screws extrude three kinds of material in three layers and stick together. After the polypropylene foam flat is extruded, a die-cutting machine can be used to cut the flat sheet to the requested shape required to construct a storage unit. The score lines can be made by a creasing line machine.
There are plenty of benefits of using polypropylene foam to make the storage unit instead of injection molding. There can be provided a lower density of material so that the material is of a lighter weight. Two or more colors can be applied on the same piece of material. Different colors can be applied for different layers. There are less molding and tooling costs compared to injection molding. Further, the product can be flattened easily, which allows for easy shipping, storage, assembly and disassembly.
One having ordinary skill in the art should appreciate that there are numerous shapes and sizes of the sheets that can be used, which will depend on the type of storage unit required. The storage unit can be a document tray, magazine file, trash bin, name card holder, accessory tray, office supplies holder, compact disc holder, storage box, or any other type of similar device required for storage of various articles.
For example, as shown in FIGS. 6-8, the storage unit can also be a stacked document tray. FIGS. 6 a and 6 b show side members 610, 620, 660 and 670 for a stacked document tray. Each side member can be made of an extruded foam sheet, or other sheet, and can have a substantially uniform thickness. Each side member can have a same thickness as all the side members. In FIG. 6 a, a top right tray 610 and a bottom right tray 620 are shown having female connection members 650 near edges or peripheries thereof. The female connection members 650 have openings and are similar to the female connection members described above. One or more female connection members may be used on each tray. The top right tray 610 is held by holding members 630 and 640 above the bottom right tray 620. The holding members are secured to the top right tray 610 and the bottom right tray 620 by rivets 625. This allows the top right tray 610 and the bottom right tray 620 to pivot at an angle θ about rivets 625 with respect to each other, and allows the top right tray 610 to rest on the bottom right tray 620. It also allows the top right tray 610 to be held above bottom right tray 620, as shown in FIG. 6 a. FIG. 6 b shows a top left tray 660 and a bottom left tray 670 having female connection members 650. The female connection members 650 have openings and are similar to the female connection members described above. One or more female connection members may be used on each tray. The top left tray 660 is held by holding members 680 and 690 above the bottom left tray 670. The top left tray 660 and bottom left tray 670 have similar rivets 625 and pivot at an angle θ about rivets 625 the same way as top right tray 610 and bottom right tray 620. The trays 610, 620, 660, 670 and holding members 630, 640, 680, 690 can be removed from a flat sheet, which can be a foam sheet similar to the foam sheets described above.
FIG. 7 shows a top view of an insert for a stacked document tray having male connection members. The insert can have a substantially uniform thickness, can be made of an extruded foam sheet, or other sheet. The insert can have the same thickness as the side members. An insert 700 is provided having male connection members 710 at edges or a periphery thereof. The male connection members 710 can be similar to the male connection members described above. The insert 700 can have end portions 720 and 740, and a middle portion 730. The end portions 720, 740 can be separated from middle portion 730 by score lines 750, that allow the insert to bend at the location of the score lines 750. A tab portion 760 can be provided at end portion 740 for providing a label. The end portions 720 and 740 can have a similar thickness as middle portion 730, and can provide various different angles with respect to the middle portion 730.
FIG. 8 shows a perspective view of a constructed stacked document tray 800. Top tray 810 can be provided above bottom tray 820. One insert 700 is provided in between top right tray 610 and top left tray 660, which comprises top tray 810, and another insert 700 is provided in between bottom right tray 620 and bottom left tray 670, which comprises bottom tray 820. The inserts 700 are secured to the trays using the male connection members and female connection members similarly as described above with respect to storage unit 400. The end portions 720 of each tray can be vertical so as to provide a secure end for any documents placed in the tray 800, and end portions 740 can be held at an angle so as to allow documents to be easily placed therein on the tray 800. The top tray 810 and bottom tray 820 can pivot and rotate about rivets 625 to adjust the height of the top try 810 with respect to the bottom tray 820. Of course, various modifications to the angles and number/location of male and female connection members can be made, as well as to the number of trays needed. More or less trays can be stacked above the two trays shown in FIG. 8.
FIGS. 9 a-9 d show members of an unassembled pen holder in accordance with an embodiment. FIG. 9 a shows a sheet 900 having end panels 901 and 903, and center panel 902. The end panels 901 and 903 can have female openings 905 similar to the female openings described above, e.g., with respect to FIG. 1. Score lines 925 can be provided between panel 901 and 902, and 902 and 903, as shown in FIG. 9 a, so that sheet 900 can bend at the score lines 925 so that panels 901 and 903 can be folded along score lines 925 with respect to panel 902, and can be provided at various angles with respect to panel 902. Panel 902 can have a length L1. The sheet 900 can have a substantially uniform thickness, and can be made of a foam sheet, such as an extruded foam sheet.
FIGS. 9 b, 9 c and 9 d show a front plate 910, middle plate 920 and back plate 930, respectively, for forming a pen holder in accordance with an embodiment. Each plate has one or more male connection members 915, similar to the male members described above, e.g., with respect to FIGS. 2 a and 2 b. Each plate can have a substantially uniform thickness, and can be made of a foam sheet, such as an extruded foam sheet, and each plate can have a similar thickness to each other, and to sheet 900, and be made of a similar material. The front plate 910 can have a similar length L1 and width as middle plate 920, and plate 920 can have a similar length L1 and width as back plate 930. The length L1 of the plates 910, 920 and 930 can be similar to the length L1 of the panel 902. The heights h1, h2 and h3 of the front plate, middle plate and back plate 930, respectively, can be different and can be such that h1<h2<h3. Each plate can have a tab portion 940 to provide a label thereon.
FIG. 9 e shows an assembled pen holder 945 in accordance with the embodiment of FIGS. 9 a-9 d. As shown, male portions 915 of the front plate 910, middle plate 920 and back plate 930 connect with openings 905 of panels 901 and 903 so that an assembled pen holder 945 is formed. Panel 900 is folded such that panels 901 and 903 comprise side walls of the assembled pen holder 945, and panel 902 forms a bottom surface of the assembled pen holder 945.
FIGS. 10 a and 10 b show members of an unassembled name card holder in accordance with an embodiment. FIG. 10 a shows a sheet 950 having end panels 951 and 953, and center panel 952. The end panels 951 and 953 can have female openings 955 similar to the female openings described above, e.g., with respect to FIG. 1. Score lines 975 can be provided between panel 951 and 952, and 952 and 953, as shown in FIG. 10 a, so that sheet 950 can bend at the score lines 975 so that panels 951 and 953 can be folded along score lines 975 with respect to panel 952, and can be provided at various angles with respect to panel 952. Panel 952 can have a length L1. The sheet 950 can have a substantially uniform thickness, and can be made of a foam sheet, such as an extruded foam sheet.
FIG. 10 b shows a front plate 960 and back plate 970. Each plate has one or more male connection members 965, similar to the male members described above, e.g., with respect to FIGS. 2 a and 2 b. Each plate can have a substantially uniform thickness, and can be made of a foam sheet, such as an extruded foam sheet, and each plate can have a similar thickness to each other, and to sheet 950, and be made of a similar material. The front plate 960 can have a similar length L1 and width as back plate 970. The length L1 of the plates 960 and 970 can be similar to the length L1 of the panel 952. The front plate 960 can have a tab portion 980 to provide a label thereon.
FIG. 10 c shows an assembled name card holder 990 in accordance with the embodiment of FIGS. 10 a and 10 b. As shown, male portions 965 of the front plate 960 and back plate 970 connect with openings 965 of panels 951 and 953 so that an assembled name card holder 990 is formed. Panel 950 is folded such that panels 951 and 953 comprise side walls of the assembled name card holder 990, and panel 952 forms a bottom surface of the assembled name card holder 990. Back plate 970 can be provided at an angle as shown in FIG. 10 c.
Additionally, one having ordinary skill in the art will appreciate that although the preferred embodiments illustrated herein a file magazine, document tray, pen holder or name card holder, the storage unit can have a variety of shapes and sizes. The male and female connecting members can be placed on different sheets and/or panels, and are interchangeable between various sheets and/or panels. The sheets that comprise the parts of the storage units can be flat and made of various materials, such as a foam as described above, or various other materials. The sheet can have various layers of material, where each layer can have a different density or hardness.
As used herein, the terms “front,” “back,” and/or other terms indicative of direction are used herein for convenience and to depict relational positions and/or directions between the parts of the embodiments. It will be appreciated that certain embodiments, or portions thereof, can also be oriented in other positions.
In addition, the term “about” should generally be understood to refer to both the corresponding number and a range of numbers. In addition, all numerical ranges herein should be understood to include each whole integer within the range. While an illustrative embodiment of the invention has been disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention.

Claims

1. A storage unit, comprising:

a first sheet having a female connection member defining an opening; and

a second sheet having a male connection member, the male connection member having a neck portion dimensioned to be received in the opening, and a retaining portion that is wider than the opening and configured to couple the male and female connection members together, the retaining portion defining a concave edge opposite from the neck portion configured for increasing the flexibility of the retaining portion to facilitate reception thereof into the opening.

2. The storage unit of claim 1, wherein the concave edge is configured for increasing the flexibility of the retaining portion to provide a snap lock connection in the opening.

3. The storage unit of claim 2, wherein the retaining portion of the male connection member is configured to removably snap into the opening of the female connection member.

4. The storage unit of claim 1, wherein the neck portion defines an indentation between a body of the second sheet and the male connection member such that the neck portion has a narrower width than the retaining portion.

5. The storage unit of claim 4, wherein the retaining portion comprises two lateral protrusions on opposite lateral sides of the concave edge and extending beyond the width of the opening, wherein the concave edge is configured and dimensioned for increasing flexibility of the lateral protrusions with respect to each other.

6. The storage unit of claim 1, wherein the neck portion of the second sheet has approximately a similar width as the opening of the first sheet.

7. The storage unit of claim 1, wherein the opening has an axis that extends through the first sheet, and the male connection member is disposed at a periphery of the second sheet.

8. The storage unit of claim 1, further comprising a tab portion protruding from an edge of the second sheet for a label to be provided.

9. The storage unit of claim 1, wherein the first sheet comprises two or more panels that are folded with respect to each other.

10. The storage unit of claim 1, wherein first and the second sheets comprise an extruded polypropylene foam.

11. The storage unit of claim 1, wherein the second sheet comprises an extruded foam having outer layers and a middle layer therebetween, wherein the outer layers have a higher density than the middle layer.

12. The storage unit of claim 11, wherein the first sheet comprises the extruded foam, and the first and second sheets have substantially uniform thicknesses.

13. The storage unit of claim 11, wherein the outer layers comprise a first and second layer, and the first and second layers comprise different colors.

14. The storage unit of claim 1, wherein the first and second sheets have substantially uniform thicknesses.

15. The storage unit of claim 1, wherein the storage unit when assembled comprises a document tray, magazine file, pen holder or name card holder.

16. The storage unit of claim 1, further comprising a substantially flat sheet blank comprising at least the first or second sheet in an unassembled form, wherein the sheet blank is pre-cut to allow easy removal of the first or second sheet therefrom.

17. The storage unit of claim 16, wherein the sheet blank has a substantially uniform thickness.

18. An office storage unit, comprising:

a first extruded foam sheet having a substantially uniform thickness and a female connection member defining an opening; and

a second extruded foam sheet having a substantially uniform thickness and a male connection member defining a protrusion,

wherein the at least one female connection member is configured to receive the protrusion of the at least one male connection member to connect the first and second extruded foam sheets to form a foam storage unit.

19. The storage unit of claim 18, wherein one or both of the first and second extruded foam sheets comprise score lines configured for allowing the first or second foam sheets to bend thereat.

20. The storage unit of claim 18, wherein the first sheet comprises a plurality panels separated by at least one of the score lines and foldable thereabout, at least two of the panels having a female connection member each comprising an opening near a periphery of the first sheet, wherein each opening is configured to receive a protrusion of a male connection member of the second sheet to retain the first sheet folded about the at least one score line.

21. The storage unit of claim 20, wherein the second sheet comprises a plurality of panels is foldable at least one of the score lines and foldable thereabout, allowing the panels of the second extruded foam sheet to be coupled with the first extruded foam sheet to form a storage unit.

22. The storage unit of claim 20, wherein the first sheet comprises a left panel, a right panel and a middle panel joining the left and right panels, each panel having at least one or more female connection member.