Patent Application
20050225108
The present invention relates to storage units for vehicles and specifically to an adjustable storage system for use in vehicles.
Service professionals, e.g., plumbers, contractors, cable or telephone installers, electricians, etc., are commonly required to carry in their vehicles a large number and variety of tools, parts, equipment and the like necessary to perform their work. The tools, parts, equipment, etc., can range from large or bulky tools or spools of cable to smaller tools, fasteners, spare parts, etc. As such, it is known to equip service vehicles with storage units to house items of various sizes.
Many of the storage units known in the art are steel units that include steel end panels, a back panel and steel shelving. The shelves of these storage units are essentially tray structures having a bottom and four sides extending perpendicular from and perpendicular to the bottom. The shelves are fitted between the two end panels adjacent the back panel to provide a storage unit. The shelves are held in position by connecting the shelves directly to each of the end panels and the back panel. The shelves may be held in position by welding the sides of the shelves to the end panels and the back panel or by mechanical fasteners connecting the shelves to each of the end and back panels through the sides of the shelves.
There are several disadvantages associated with these known storage units. Storage units known in the art are essentially as-is structures that are not easily reconfigurable or adjustable. It may be advantageous or even necessary for a worker to house an item in the vehicle for which no space currently exists. Therefore, it would be beneficial for the worker to be able to reconfigure the storage system in his vehicle by moving, adding or removing shelving, drawers, etc. Shelves that are welded to the end and back panels are not removable (or, at least, not easily removed). In the storage unit described above, shelves or drawers are connected to both back panels and the end panels and therefore cannot be adjusted or reconfigured without either completely removing the unit from the vehicle or unmounting the end panels and back panel.
Additionally, several disadvantages are associated with the all steel construction of the storage units. First, the all steel construction may create a noisy environment. When empty, the steel units are prone to rattling during the operation of the vehicle. The noise level may be increased when the units are filled with various equipment including metal tools or parts. Second, the all steel units can be rather heavy, and added weight to a vehicle may increase fuel consumption for operation of the vehicle and increase the cost to operate the vehicle.
In view of the foregoing, it is therefore an object of the invention to provide storage units for vehicles having storage components, such as drawers, or the like, that are readily adjustable, reconfigurable and/or customizable by the user.
It is a further object to provide an adjustable storage unit wherein the means for adjusting or reconfiguring the shelving or drawers is easily accessible to the user.
It is still a further object to provide a storage unit that provides a reduced noise environment compared to conventional storage units.
It is yet another object to provide a storage system that is lighter in weight compared to conventional storage units.
The present invention achieves one or more of the foregoing objects and provides in one aspect an adjustable storage unit for a vehicle that includes a frame system fastened to a wall of a vehicle, at least one pair of opposing shelf supports releasably connected to the frame system, and at least one shelf formed from a polymer material disposed in the frame system. The frame system includes a pair of end panels opposite and parallel to one another. Each end panel has an inner surface, an outer surface, a front edge, a rear edge, a vertical row of apertures near the front edge and a vertical row of apertures near the rear edge. The frame system also includes at least one connecting member connected to each end panel adjacent the rear edges of the end panels. The at least one pair of opposing shelf supports is releasably connected to the frame system only through the apertures of the end panels. The at least one shelf is supported within the frame system by contacting the bottom surface of the shelf with a top surface of the shelf support.
The invention provides in another aspect, an adjustable storage unit for a vehicle comprising a pair of opposing end panels, a connecting member fixed to each end panel adjacent the rear edges of the end panels, at least one pair of opposing shelf supports releasably connected to the end panels, and at least one shelf formed from a polymer material disposed between the end panels. Each end panel has an outer surface, an inner surface, a rear edge, a front edge, a vertical row of apertures adjacent the rear edge, and a vertical row of apertures adjacent the front edge. The at least one pair of opposing shelf supports is releasably connected to the inner surface of the end panels only through apertures in the end panels. The storage unit is connected to a vehicle through at least one aperture in one of the end panels.
In yet another aspect, the invention provides an adjustable storage unit for a vehicle comprising a first end panel formed from a polymer material, a second end panel formed from a polymer material, a connecting member connecting the first and second end panels, at least one shelf support releasably connected to the first end panel, at least one shelf support releasably connected to the second end panel and positioned opposite the at least one shelf support releasably connected to the first end panel, and at least one shelf formed from a polymer material positioned between the end panels and supported by the bottom surface of the shelf resting on an upper surface of the shelf supports. Each of the first and second end panels has an inner surface, an outer surface, a front edge, a rear edge, a vertical row of apertures near the front edge, and a vertical row of apertures near the rear edge. The second end panel is positioned opposite and substantially parallel to the first end panel so that the inner surface of the second panel faces the inner surface of the first end panel. Each shelf support has an upper surface, and each at least one shelf has a bottom surface, and the at least one shelf is positioned between the end panels and supported by the shelf bottom surface resting on the upper surface of the shelf support.
In still a further aspect, the invention provides a method of providing an adjustable storage unit for a vehicle. The method includes providing a frame system that includes a pair of end panels opposite and parallel one another, and a connecting member connected to each end panel near the rear edge of the end panels. The end panels each have an inner surface, an outer surface, a front edge, a rear edge, a vertical row of apertures near the front edge, and a vertical row of apertures near the rear edge. The method also includes releasably connecting at least one pair of opposing shelf supports, having upper surfaces, only to the end panels, positioning at least one shelf having a bottom surface in the frame system so that the bottom surface of the shelf rests upon the upper surfaces of the shelf support. The at least one shelf is made from a polymer material. The storage unit is adjusted by removing at least one shelf, disconnecting the pair of shelf supports supporting the removed shelf, positioning the shelf supports at a different vertical position along the end panels, releasably connecting the shelf supports to the end panels, and positioning said at least one shelf on the shelf supports. The method also includes releasably connecting at least one of said end panels to a wall of the vehicle.
In another aspect, a method is provided for adjusting the load rating of a shelf made from a polymer material. The method includes providing at least one shelf formed from a polymer material, the shelf having a bottom surface, a front wall, a back wall, and a pair of opposing side walls. The shelf further includes a plurality of slots extending upwardly from the bottom surface of the shelf and running between the side walls of the shelf. The method further includes selectively inserting a support bar within at least one of the plurality of slots in the bottom surface of the shelf. The support bars are dimensioned to fit within at least one of the plurality of shelves. The loading rating of the shelf is adjusted by removing or inserting support bars from the plurality of slots.
a is an enlarged view of a portion of the storage unit in
a is an enlarged view of a portion of an end drawer mounting system of
b is an enlarged view of the bottom portion of the center drawer mounting system in
c is an enlarged view of the upper portion of the center drawer mounting system in
a is a side elevation of the inner portion of an end drawer slide in
b is a side elevation of the inner portion of an end drawer slide in
c is a cross-sectional top view of the drawer slide in
With reference to
With reference to
End panels 28 are preferably mirror images of one another. Thus, unless otherwise stated, references made to one end panel are also intended to describe the other, opposing, panel. However, end panels are sometimes altered to accommodate mounting in a particular vehicle or storage needs. A pair of end panels, therefore, may not always be a mirror image of one another. End panels 28 include an inner surface 30, an outer surface 32, a front edge 34, and a rear edge 36. The front edge 34 is substantially vertical over the entire height of the end panel. The rear edge 36 includes a substantially vertical portion 36a and an upper angled portion 36b toward the top of the panel. The angled portion 36b is angled away from the vertical plane of vertical portion 36a and toward the front edge of the panel. In preferred embodiments, the end panels include an angled portion, e.g., 36b, to more closely conform to the shape of the vehicle wall, which may taper or slightly round towards the roof of the vehicle. Thus, the use of back panels with an angled upper portion allows a user to better fit and position a storage unit of the invention within the van. This creates more storage space within the cargo area of the vehicle. However, storage units of the invention need not include an angled portion such as 36b, and the present invention contemplates storage units wherein the rear edge of the end panels is substantially vertical over the entire height of the panels.
End panels 28 are connected to each other along the rear edges of the panels by connecting members, such as back panels 44 and 46. In the embodiment in
Back panels 44 and 46 are merely exemplary of suitable connecting members to connect the end panels. Any suitable structure or configuration may be used to connect the end panels. Additionally, the connecting members need not be panels per se. That is the width of the connecting member may be any width suitable to provide a connection point, e.g., a thin bar. Further, any number of connecting members may be used as desired by the end user.
The end panels may also be connected along the front edge by a connecting member such as, for example, front panel 96. Front panel 96 is connected to end panels 28 along the base of each front edge 34 of end panels 28. The embodiment in
Storage unit 14 contains a plurality of shelves 72 disposed between end panels 28, i.e., disposed within the frame system. End panels 28 include a first vertical row of apertures 52 nearer to the rear edge (relative to the front edge), and a second vertical row of apertures 54 nearer to the front edge (relative to the rear edge). Preferably, the vertical rows of apertures are parallel to one another and positioned opposite one another so that opposing apertures within a given end panel lie in the same horizontal plane. Additionally, it is preferred that a given aperture in one panel have a corresponding aperture in the opposing end panel so that corresponding apertures in opposing end panels lie in the same horizontal plane. The number and location of the apertures is not limited and may be chosen to accommodate a particular vehicle or intended use. Shelves 72 are supported within the unit by shelf supports 58. Shelf supports 58 include a vertical portion 60 running parallel to the inner surface 30 of the end panels, and a flange 64 substantially perpendicular to and integral with vertical portion 60. Flange 64 has a top surface 65 that defines a substantially horizontal surface. Shelf supports 58 are releasably connected to the end panels, and particularly inner surface 30 of the end panels, by fasteners 68, which are inserted through opposing apertures in the first and second vertical rows 56 and 54 and through corresponding apertures 68 positioned in vertical portion 60 of shelf support 58. The shelf supports in all units, or within an individual unit may be identical. As shown in
A plurality of shelves 72 are disposed between end panels 28. Shelves 72 include a bottom surface 74 and outer vertical walls 78. The shelf is positioned between the end panels, i.e., within the frame system, such that bottom surface 74 rests on the top surface 65 of shelf supports 58. In preferred embodiments, shelves 72 have a width just slightly less than the distance between the inner surfaces of opposing end panels 28 so that outer vertical walls 78 of the shelves contact respective inner surfaces 30 of the end panels to provide a snug fit in the frame system. The outer walls may also be configured with protrusions or other configurations capable of engaging the inner surface of the end panels. Optionally, and as shown in
Shelves 72 have opposing side walls, a rear wall, a front wall and a large horizontal area 80 with a top surface and a bottom surface. The bottom surface may be offset upwardly relative to the bottom edge of the shelf walls. The top surface of the large horizontal area is offset downwardly from the upper surface of the shelf walls such that the shelf walls preferably have inner surfaces, e.g., 82 and 86. The height of the shelf outer walls and/or the height of the inner surfaces of the wall, i.e., the distance from the shelf tray, (e.g., 80) to the top surface of the shelf walls, may be selected as desired for a particular vehicle or intended use. Each wall defines a thickness T that may also be selected as desired by for a particular vehicle or intended use. The depth of the shelf from the upper surface of the walls to the top surface of the horizontal area provides extra storage area. Having a bottom surface of the horizontal area offset upwardly relative to the bottom edge of the shelf walls provides more space in between successive shelves by increasing the distance between the top surface of the horizontal area of a first shelf and the bottom surface of the horizontal area of a second shelf positioned above the first shelf. Shelves 72 may be configured in any shape as desired for a particular vehicle or intended use.
As shown in the embodiment in
Additionally, the shape of the shelves is generally not limited in any manner. As seen in the embodiment in
With reference to
The use of support bars positioned in widthwise slots of a shelf provides a method for adjusting the load rating of a shelf. Specifically, a shelf that is not further supported by support bars, such as U-shaped bar 67a and 67b, has a first load rating. A shelf that is supported along the width of the shelf by one bar has second load rating, and so forth. Thus, a shelf may have N+1 load ratings were N is the number of widthwise slots in the shelf bottom surface to accommodate bars such as, for example, bars 67a and 67b. The load rating may, therefore, be adjusted by either adding or removing bars as needed for the intended use. Thus, for example, in
The support bars 67a and 67b are not limited in any manner. The support bars may be configured in any shape and made from any material to provide the desired support for a particular use. For example, the support bars may be made from steel or extruded aluminum or a fiber reinforced composite. Alternatively, the support bars may be molded inside the shelves. That is, the bars may be encapsulated within a shelf. While encapsulating support bars in the shelves may increase the load rating of a particular shelf, encapsulating the support bars within the shelf does not allow for the load rating of the shelf to be adjusted.
With reference to
Storage unit 100 includes a plurality of drawers 106 and 108 disposed between end panels 102. Drawers 106 and 108 are positioned in the storage unit by drawer slides 110 and 126 (
Drawers 106 and 108 have outer walls 119a and 119b (
In preferred embodiments, the drawer slides are configured to provide a stop so that the drawer may not be pulled out beyond a particular point.
To position the drawers in the drawer slides, the rear portion of the drawer and flange 125 are moved into front opening FO1 until flange 125 can fit into the opening FO1a, which is defined by the distance between the edge 118c of upper groove surface 118a and the edge of stop wall SW1. Flange 125 is then lowered through opening FO1a until flange 125 and 124 contact lower wall 118b. At that point, the drawer, such as drawer 108, may be slid into an open or closed position as desired.
The drawers and/or drawer slides are not limited to any shapes or sizes, and may be configured for a particular vehicle or intended use. Drawer stops, e.g., S1b (
As shown in
Storage unit 100 also includes a door 142 hingedly connected to base plate 146 so that door 142 opens by rotating about a horizontal axis near the bottom of the door. A hinge (not shown) is releasably connected to the base plate through apertures in the base plate and corresponding apertures in the hinge. Alternatively, the door may be hingedly connected to the unit such that the door opens horizontally. In such an embodiment, the hinge would be releasably connected to the front edge of an end panel. Door 142 may include latch assembly 146 to enable the user to lock the door into the closed position. A preferred latch assembly is described more fully herein.
Storage unit 100 also includes dividers 148 positioned in a shelf 104 to provide separate storage compartments within a shelf. Dividers 148 may be held in place in a manner similar to that used to position drawer slide 126. That is, dividers 148 have a bottom portion with a bottom surface that may include a plurality of protrusions adapted to fit into corresponding recesses of the shelf tray. For example, a protrusion may be a longitudinal oval shaped protrusion adapted to fit in a slot in the shelf tray. Alternatively, the bottom portion of the divider may further have an upper surface and a plurality of apertures extending through the top and bottom surfaces of the dividers bottom portion. Fasteners may then be fitted through the apertures and directly into either the tray of the shelf or a corresponding aperture or bore located in the shelf tray.
With reference to
One or more shelves 176 are positioned between end panels 152, i.e., disposed within the frame system formed by connecting the end panels via the connecting members. Shelves 176 are positioned between the end panels by resting bottom surface 178 of the shelves onto the upper surface 171 of shelf support 166. Fasteners 179 may be used to further secure the shelves to the shelf supports. Fasteners 179 may be inserted through apertures in flange 170 and either directly into the bottom of the shelf or into a threaded bore (not shown) adapted to receive such a fastener.
Shelves 176 have two side walls 182, a rear wall (not shown) and front wall 184. Shelves 176 further include a horizontal tray surface 180 recessed from the upper surface of the walls. Thus, the walls include an inner surface perpendicular to tray 180. Shelves 176 each include two flanges 186 adjacent to and extending from front wall 184 one at either end of the front wall. The outside surfaces of the flanges 186 are coplanar with the outside surfaces of the side walls 182. Flange 186 preferably extends to or almost to the front edge of an end panel 152. Thus, front wall 184 of shelf 176 is recessed relative to the front edge of the end panels. This allows for the front edge of the end panels to accommodate a door 196, which is hingedly connected to an end panel while providing outer side surfaces engaging almost the full depth of the end panels 152. Hinge 194 is releasably connected to a front flange 197 that extends substantially perpendicular to and is integral with a front edge of the panel. Each end panel may include a front flange. As shown in
Locker assembly 150 may also include an upper shelf 188, with a top horizontal surface 190 offset downwardly relative to the upper surface of the shelf walls and a plurality of grooves or protrusions in the surface of the tray. Generally, the upper most shelf in storage units according to the invention are positioned on shelf supports in the same manner as other shelves in the unit. That is, the upper shelf may be supported by shelf supports that are mounted through apertures in the end panels. Alternatively, or in addition to being supported by shelf supports, the upper most shelf may be positioned by fasteners inserted directly into the side walls of the shelf.
With reference to
As previously described with respect to
Storage units of the present invention provide a modular system that is capable of being quickly reconfigured as desired by the user. To reconfigure a unit, a shelf or shelves are removed from the unit as desired. This is done by either simply lifting the shelf out of its supports or by removing fasteners holding the shelf on the supports. Either operation can be performed from the front of the unit. The shelf supports that supported the removed shelf or shelves are removed by disconnecting the fasteners from the end panels and the shelf supports. This can be done from the front or sides of the unit. If desired, a shelf or shelves may be repositioned by changing the vertical position of the shelf supports along the vertical rows of apertures. After a new location for a shelf is chosen, a pair of shelf supports are again releasably connected, opposite one another, to opposing end panels to define a substantially horizontal surface. A shelf is then positioned between the end panels by positioning the bottom surface of the shelf on the top surface of the shelf supports. The reconfigurable aspect of storage units according to the invention also allows the end user to create new storage compartments of different sizes if needed. For example, while in the field, a user may wish to add drawers to accommodate certain tools or parts. Provided the user has the necessary components, i.e., drawers, drawer slides and appropriate hardware, drawers may quickly be added by releasably attaching drawer slides to the end panels at a desired location. If necessary, a center-post drawer slide may also be added to accommodate, for example, two columns of drawers and allow the user to employ different sized drawers. For example, storage unit 100 may be viewed as a potential reconfiguration of unit 14 and vice versa. Thus, the components, i.e., shelving, supports, etc., of the storage units are readily removed and interchangeable. Because the shelves are removable independent of the shelf supports, and the shelf supports are releasably connected only through the end panels (and not through the back panels or connecting members), the system can be easily reconfigured as desired via the end panels without having to disconnect the entire unit from the vehicle wall and floor and dismantle the entire unit. Thus, storage units of the present invention allow users to reconfigure storage units on the fly, even while in the field, which may reduce down time associated with waiting for a different vehicle to accommodate or supply the necessary equipment.
The interior storage components of storage units according to the invention, i.e., shelves, drawers, and drawer slides, are made from polymer materials such as plastic materials. Suitable plastic polymers include, but are not limited to polyethylenes, polypropylenes, polystyrene, acrylonitrile-butadiene-styrene resins and the like. The polymer materials may also be composite materials, i.e., a polymer matrix reinforced with a fiber or other reinforcing material having a sufficient length to thickness ratio to provide a desirable reinforcing function in one or more directions. A suitable composite material is a co-extruded polypropylene. The polymer materials used to form the shelves, drawers, drawer slides, etc., and/or the end panels are not limited in any manner. A wide range of polymer materials are commercially available from various sources. The polymer materials may have various strengths and other properties as needed for a particular application or intended use. The storage unit formed from a polymer material components are made by molding the polymer material into the desired shape for the particular component, and may be made by suitable molding methods such as injection molding, blow molding or the like. The shape and/or configuration of the shelves or drawers for drawer slides is not limited in any manner and may be configured to suit a particular vehicle or end use.
The end panels may be made from either steel or polymer materials. End panels formed from polymer materials may be made by processing techniques known in the art. As such, end panels made from polymers or composites may be formed into one particular shape as desired for a particular vehicle or intended use, and/or for aesthetic purposes. For example, plastic end panels made from polymer materials may have a configuration substantially similar to the configurations of the end panels in the first, second, and/or third embodiments. End panels made from polymer materials may further include ribbing or other surface configurations to impart strength to the end panels and/or to achieve a desired aesthetic appearance. Additionally, end panels may be formed from stock sheets of plastic or composite and cut and/or welded to the configuration desired for a particular vehicle or intended use. Any polymer material suitable for the shelves, drawers, etc. may also be used to form the end panels.
In preferred embodiments, the entire storage unit, at least with respect to the frame or end panels, the drawers and/or shelves, is made from a polymer material. In a particularly preferred embodiment, storage units, end panels, shelves, drawers and drawer slides are made from composite materials. The components are formed and welded with a co-extruded polypropylene (CPP) material, and have adjustment apertures in all connection point locations. The unit is 3-5 lbs lighter compared to an all steel construction of a similar configuration.
The use of polymer materials to form the shelves, drawers, drawer slides, end panels, etc., offers several advantages over the all steel construction of known storage systems. Polymer constructions are lighter in weight, which may improve the fuel economy of the vehicle. Polymer materials also dampen the noise associated with such storage units and are more quiet under normal load than the all metal constructions. Polymer constructions, hybrid constructions of light weight polymer materials, and, in particular, composite constructions exhibit strengths equivalent to or greater than steel constructions with the added advantage that such polymer constructions of being more resilient than steel. The formable nature of polymer materials allows for more variation or flexibility in design of the components and still provides a strong, rigid structure. For example, the use of plastic or composite materials may allow for the reduction of two full end panels from a complete system employing several storage units of the invention, such as shown in
The use of polymer materials may result in a lower production cost in that the plastic materials are generally less expensive than metal constructions. The plastic units are also more resilient than metal units and will not have to be replaced due to damage or wear as often as steel units, which may also provide an overall decrease in cost. Further, the polymer components allow for more flexibility in adjusting the shelves and also allows for more bulk head room and utilization of the space around the wheel well areas.
Additionally, the relatively low part count of the units also contributes to noise reduction. Specifically, there is a lower part count compared to conventional units because the supports and shelves are not connected through the back and/or front connecting members of the unit. There are therefore fewer contact points which may become loose and rattle.
The dimensions of the storage unit are not limited in any particular manner, except by the size and/or shape of the payload/cargo area of a vehicle. Thus, the present invention contemplates storage units of various heights and widths.
The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
