Patent Application
20230059364
The present invention relates to an improved storage system for chest freezers. Specifically, the invention provides a storage system that can be used in any chest freezer with improved accessibility to items that are stored in the lower portions of a freezer.
Most chest freezers, particularly those intended for residential use, include a storage basket that can be moved from side-to-side but only fits at the top of the freezer. Storage baskets that fit at the top of a freezer commonly have extended flat rims on two sides that rest on an interior curb just below the lid of the freezer. The extended flat rims prevent these baskets from being hung lower in a freezer. One known model of chest freezer provides a storage basket that fits below the top of the freezer, but it can only be used in the top half of that specific model. In all known cases, storage baskets are designed to only fit into a specific freezer model and are not adjustable.
The primary benefit of residential chest freezers is their large storage capacity that allows a user to purchase and store food in bulk. But, the lack of easy access to the lower half of a freezer makes it tedious and difficult to reach the bottom half of a full freezer. As a result, food is stored longer than intended or is wasted, and the benefits of bulk food storage are not fully achieved.
The present invention provides compositions and methods relating to systems, kits, and methods that improve access to all areas of a chest freezer. Advantageously, the invention can be adjusted for in any type of chest freezer regardless of the freezer's age, make, or model. The invention allows for the universal adaptation of all brands and sizes of residential chest freezers to include mulitple tiers of sliding storage baskets that are easily accessible. Storage baskets of the invention can slide side to side to allow access to the lower tiers without removing the baskets. As a result, the invention provides improved access to the lower portions of a chest freezer.
More specifically, the invention combines an efficient storage design with lightweight, strong storage containers (baskets) that are easily and securely attached to the interior of a chest freezer. These lightweight storage containers can hold relatively large amounts of weight without breaking. Advantageously, the sizes of the storage containers are easily adjusted by hand without the use of any tools. Further, the parts of an assembled storage container interlock to each other so that the assembled container will not come apart without a user opening the interlocking mechanism.
The invention provides a system having (a) at least two railings; and (b) at least one basket comprising a first section and a second section, wherein the first section has a bottom, a short side, a rim along the top of the short side that has a flat upper surface and a lower surface from which vertical ribs extend downward and attach exteriorly to the short side, and two long sides, wherein each long side has (i) a horizontal slot that extends along most of the length of the first section and has an enlargement at the slot end that is nearest to the short side, and (ii) a projection extending away from the short side at the end of the long side that is distal to the short side, wherein the projection has a button that extends away from the interior of the basket; and wherein the second section has a bottom, a short side, a rim along the top of the short side that has a flat upper surface and a lower surface from which vertical ribs extend downward and attach exteriorly to the short side, and two long sides, wherein each long side has (i) a horizontal slot that extends along most of the length of the second section and has an enlargement at the slot end that is nearest to the short side, and (ii) a projection extending away from the short side at the end of the long side that is distal to the short side, wherein the projection has a button that extends towards the interior of the basket.
Each button of a projection comprises a neck that extends away from the long side of the basket section and is attached at its distal end to a knob. The knob fits within the enlargement of the slot in the other section of a basket. Importantly, while the neck can fit within the remainder of the slot of the other section, the knob cannot.
In addition, each projection in the first section has at least one horizontal rib on its surface facing the interior of the basket, and each projection in the second section has at least one horizontal rib on its surface facing the exterior of the basket. Preferably, each projection includes at least two horizontal ribs, more preferably each projection as three or four horizontal ribs, and most preferably each projection includes five horizontal ribs on its surface that is opposite the surface from which a button extends.
Those of skill in the art will appreciate that the projections and their parts form an interlocking mechanism. This interlocking mechanism can have many configurations (e.g. knobs may be round, oblong, square, etc. in shape). It is only necessary that the interlocking mechanism can perform the needed function of attaching a first section of a basket to a second section of the same basket such that the first section and second section are joined together and cannot separate from each other unless the interlocking mechanism is returned to the opening position. Thus, it will be understood that the interlocking mechanism illustrated and described herein represents a preferred embodiment.
Similarly, it will also be appreciated that while a preferred embodiment is described and illustrated herein, a similar result may be achieved by modifying the preferred embodiment. For example, rather than having a projection form part of a basket section, a similar result can be achieved by connecting a first and second section to each other with nuts, bolts, and washers or other known connectors to create an interlocking mechanism. While functional, such alternatives are less easily adjusted by a user and can require tools and greater effort to assemble into a basket than the present invention.
Preferred baskets of the system have a slot in the upper half of a long side. Skilled artisans will appreciate that slots may be located lower in a basket and achieve a similar result.
It is expected that systems of the invention comprise two or more different types of baskets. Specifically, systems of the invention include at least one basket that is a universal basket or a lower basket. Preferably, systems of the invention include at least one universal basket and at least one lower basket.
Universal baskets can be placed on any tier. Universal baskets have vertical ribs that extend downwards from the rims of their first and second sections offset from the distal edges of the rims such that the lower surfaces of the distal edges are flat. These flat distal edges allow the universal basket to rest on the freezer's curb and still allow the lid of the freezer to be closed as intended.
Lower baskets have the vertical ribs that project downwards from the rims of their first and second sections extended to the distal edges of the lower surfaces of the rims. Extending the vertical ribs to the distal edges of the rims allows the lower baskets to have even greater strength and to hold more weight as compared to the universal baskets. Lower baskets can be used on tiers within a freezer but are not intended for use on a top tier that requires the edges of the basket to rest on a curb in the freezer upon which the freezer's lid rests when the lid is closed.
Skilled artisans will recognize that a wide variety of suitable railings are available and can be used in the invention. Preferred railings are angle railings, preferably an “L” angle railing. Most preferred “L” angle railings are 1 inch×2 inch (H×W) and ⅛ inch in thickness. Railings can be comprised of a variety of materials such as injection molded polypropylene, aluminum, steel, unreinforced plastic, or combinations thereof. Fiber reinforced polymer (FRP) was found to be a superior material and is preferred because of its very high strength to weight ratio, ability to be structurally unaltered to −50° C., and non-porous surface that allows for very high binding (VHB) tape adhesion.
A preferred adhesive tape for use in the invention is 3M™ VHB™ Tape 5952. Those of skill in the art will appreciate that other adhesive tapes are available and can be used in the invention. Suitable tapes provide a consistent bond, durability, and excellent moisture resistance at low temperatures.
The invention also provides kits for an improved storage system. Kits of the invention have (a) at least two railings comprised of fiber reinforced polymer; (b) one or more placement guides, wherein the placement guide has at least one slot to accept a railing; (c) a magnetic white board with at least one marker pen; (d) at least one basket comprising a first section and a second section, wherein the first section has a bottom, a short side, a rim along the top of the short side that has a flat upper surface and a lower surface from which vertical ribs extend downward and attach exteriorly to the short side, and two long sides, wherein each long side has (i) a horizontal slot that extends along most of the length of the first section and has an enlargement at the slot end that is nearest to the short side, and (ii) a projection extending away from the short side at the end of the long side that is distal to the short side, wherein the projection has a button that extends away from the interior of the basket, and wherein the second section has a bottom, a short side, a rim along the top of the short side that has a flat upper surface and a lower surface from which vertical ribs extend downward and attach exteriorly to the short side, and two long sides, wherein each long side has (i) a horizontal slot that extends along most of the length of the second section and has an enlargement at the slot end that is nearest to the short side, and (ii) a projection extending away from the short side at the end of the long side that is distal to the short side, wherein the projection has a button that extends towards the interior of the basket; and (e) assembly instructions or an internet link to assembly instructions.
It will be appreciated that a variety of suitable placement guides are available in the arts. Preferred placement guides are molded from fiber reinforced polymer (FRP) and include at least one, more preferably two, slots into which a railing can be inserted so that the railing can be installed into a freezer at predetermined heights. It is envisioned that the slots in the placement guides are positioned so that the railings can be installed into a freezer at heights that allow for a first tier to be placed in the lower third of the freezer and a second tier to be placed in the middle third of the freezer.
Preferably, railings that are provided in a kit are provided in 36-inch lengths that can be cut with a handsaw to a desired length.
The invention also provides a method of using a chest freezer storage system comprising (a) measuring a freezer's interior length; (b) adjusting a first railing's length to be slightly less than the freezer's interior length; (c) placing two guides, wherein each guide has at least one slot to accept a railing, vertically into the freezer; (d) inserting the first railing into the slot of each guide so that the first railing is level; (e) removing a covering from the back of the first railing to expose an adhesive tape; (f) rotating the guides towards a first interior wall of the freezer until the back of the first railing touches the first wall; (g) pressing the first railing against the first interior wall so that the adhesive tape is affixed to the first wall; (h) removing the guides; (i) placing the two guides vertically into the freezer on a wall opposite the first wall; (j) placing a second railing into the slot of each guide so that the second railing is level; (k) removing a covering from the back of the second railing to expose an adhesive tape; (1) rotating the guides towards the opposite wall until the back of the second railing touches the opposite wall; (m) pressing the second railing against the opposite wall so that the adhesive tape is affixed to the opposite wall; (n) removing the guides; (o) interlocking a first basket section to a second basket section to form a basket; adjusting the basket's length to approximately equal to the distance between the installed railings; (p) placing the basket onto the railings; and (q) storing one or more items in the basket.
Methods of the invention further comprise installing a second set of railings into the freezer; assembling at least one second basket; placing the second basket on the second set of railings; and storing at least one item in the second basket. Preferably, at least one basket is a universal basket or a lower basket. More preferably, at least one basket is a universal basket and at least one basket is a lower basket.
The following drawings form part of the present specification and are included to further demonstrate certain aspects of the invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description presented herein. Unless specifically noted, articles depicted in the drawings are not necessarily drawn to scale.
The invention provides systems, kits, and methods that improve the access to all areas of a chest freezer. Advantageously, the invention is adjustable and can be used in any type of chest freezer regardless of the freezer's age, make, or model.
Systems and kits of the invention provide improved storage baskets that have adjustable lengths, greater strength under cold conditions, and a higher resistance to fracture as compared to known alternatives. Storage baskets of the invention are comprised of two pieces that are joined together by a telescoping design. See
The invention provides baskets 1 that are assembled from a first section 2 that is interlocked to a second section 3. The first section 2 has an outward facing button 5, and the second section 3 has an inward facing button 5. Both the first section 2 and second section 3 have a bottom 23, a short side 21, a long side 22, and a rim 9 along the top of the short side 21. The rim 9 has a flat upper surface and a lower surface from which vertical ribs 10 project downward and attach to the exterior of the short side 21. The vertical ribs 10 provide greater strength for the baskets.
Universal (or upper) baskets of the invention can be used in the upper, middle or lower levels of a system. These universal baskets are slightly longer than the lower baskets that are intended for use on the lower or middle tiers. The vertical ribs 10 on the universal (or upper) baskets are shorter than those on the lower (or middle) baskets to allow for the complete closure of a freezer's lid. Middle and lower baskets have full vertical ribs 10 under each rim 9. Compare
Each section (i.e. the first section 2 and the second section 3) of a basket has a long side 22 with a horizontal slot 8 that extends along most of the length of the respective section's long side. Each slot 8 has an enlargement 7 at the slot end that is nearest to the short side 21.
Each long side 22 has a projection 4 extending from its end that is most distal to the short side 21. This projection 4 has a button 5 that extends perpendicularly away from the projection 4. In a first section 2, the button 5 extends away from the interior of the basket 1. In a second section 3, the button 5 extends towards the interior of the basket 1. Each button 5 has a neck 6 that extends away from the long side 22 and is attached at its distal end to a knob 20. The knob 20 fits within the enlargement 7 of a slot 8, but the knob 20 cannot fit within the remainder of the slot 8. In contrast, the neck 6 of a button 5 can fit within the entirety of a slot 8.
In addition, each projection 4 has at least one horizontal rib 24 on its surface facing the interior of the basket 1, and each projection 4 in the second section 2 has at least one horizontal rib 24 on its surface facing the exterior of the basket 1. In a more preferred basket, it was determined that five horizontal ribs 24 provided the greatest strength to weight ratio to reinforce the area where a button 5 was located.
The basket sections are designed to interlock together by inserting the respective buttons 5 of a first section 2 through the enlargements 7 of a second section 3, and at the same time, inserting the respective buttons 5 of a second section 3 through the enlargements 7 of the first section 2. Importantly, the basket sections are designed to only allow the buttons to be inserted through the enlargements at the most minimal extension of a basket's length. In all known chest freezers, the usable length of a basket will be greater than its most minimal extension length. To achieve a usable length, after the respective knobs 20 are inserted through their corresponding enlargements 7, the first section 2 and second section 3 of a basket must be pulled away from each other. Pulling the two sections away from each other causes the necks 6 of the projections 4 to move into the bodies of the slots 8 and cause the two sections to interlock together to form a basket 1.
It is desirable that foods or other materials stored in a chest freezer have adequate ventilation. To provide ventilation, openings 11 are present in the short side 21, and slots 13 are present in the bottoms 23 of each respective basket section. The sizes and positions of ventilation openings was found to influence air movement. A preferred embodiment of the invention includes twenty eight 20 mm round openings 11 on each short side 21 and five slots 13 that are 17 mm×147 mm in a bottom 23.
It was found that the size and positioning of the slots and projections and their respective parts influenced basket strength and telescoping function. Thus, while the specific locations and sizes of the different parts of a basket can be varied and still result in usable storage baskets, skilled artisans will appreciate that some of these baskets will be more desirable than others because some will have a greater strength to weight ratio, be easier to assemble or use, have better telescoping function, have better ventilation, or any combination of these or other desirable characteristics.
Testing of various prototypes determined that a most preferred embodiment of a basket has a maximum telescoping length of 583 mm and a minimum telescoping length of 411 mm. This embodiment has a usable depth of 197 mm to 200 mm, is 350 mm wide, and has a thickness of 3 mm. Most preferably, the basket is injected molded from acrylonitrile butadiene styrene (ABS). A less preferred basket can be injection molded from polypropylene or another thermoplastic polymer that is food safe.
A most preferred embodiment of a first basket section 2 has a depth of 197 mm so that it can be interlocked with a second basket section 3. Most preferably, tops of the projections 4 in a first basket section 2 begin 38 mm below the top of a long side 22, and the projections 4 extend 38 mm past the open end of the first basket section 2; and the tops of projections 4 in a second basket section 3 begin 36 mm below the top of a long side 22, and the projections 4 extend 38 mm past the open end of the second basket section 3.
In a most preferred embodiment, a button's neck 6 extends 9.5 mm away from a long side 22 and has a diameter of 19 mm (i.e. slightly less than the height of slot 8). Most preferably, a knob 20 has a diameter of 29.02 mm and is 3 mm thick. Those of skill in the arts will appreciate that these measurements can be varied and still form a usable interlocking mechanism.
Preferably, a long side includes a rim 25 along its top edge. This long side rim 25 can provide additional reinforcement that improves a basket's overall strength.
Those of skill in the art will appreciate that the vertical ribs 10 on a short side 21 can be varied in their numbers and sizes. A preferred embodiment of a basket has vertical ribs 10 that are 4 mm×4 mm and situated every 20 mm to reinforce the rim 9 and short side 21 of a basket. Most preferably the rims 9 of a lower basket extend 34 mm away from a short side 21, and the rims 9 of a universal basket extend 45 mm away from a short side 21.
Multiple different prototypes were tested to determine the greatest strength to weight ratios and identify the maximal strengths that could be achieved for the storage space that was lost to achieve a specific maximal strength. This testing found that a most preferred short side rim 9 had a horizontal length of 15.87 mm. Further, it was found that a most preferred slot 8 was 193.675 mm in length from its end nearest to the open end of a basket's section (either a first section 2 or a second section 3) to and including the enlargement 7 at the other end of the slot 8, 20 mm in height, and the slot 8 began 38 mm from the open end of a respective section. A preferred enlargement 7 has a diameter of 30 mm so that it can receive a preferred knob 20 with a diameter of 29.02 mm.
Baskets of the invention are installed into a freezer with a system that comprises two sets of railings that form the lower and middle tiers of the system. The system utilizes the curb area of a freezer that the freezer's lid rests upon to form the upper tier of the system. The railings of the lower and middle tiers of a system are essentially identical to each other and only differ in their relative positions within a freezer. Advantageously, systems of the invention also provide guides that are pre-measured so that lower and middle tiers are placed at preferred heights within a freezer for optimal use and storage.
Skilled artisans will recognize that a variety of railings are available and can be used to form usable surfaces upon which baskets of the invention can be placed. For example, railings may be comprised of aluminum, steel, unreinforced plastic, reinforced plastic, or combinations thereof. Most preferably, railings in the system are comprised of fiber reinforced polymer (FRP) because it has a high strength to weight ratio, is structurally unaltered to −50° C., and has a non-porous surface that allows for good binding by an adhesive tape.
While a variety of railing shapes and configuration can be used in the invention, a preferred railing 16 is illustrated in
It will be understood that a variety of tools and alternatives can be used in systems and methods of the invention to achieve the same or similar tier configurations. Preferred kits and methods of installing the invention use guides 14 that are made of FRP. These guides are preferred because they have good dimensional stability and a high strength to weight ratio. Guides are not intended to be permanent fixtures in a system of the invention and intended to only be used to install railings in tiers that are at preferred heights in a freezer.
Preferred guides 14 are “U” shaped guides. See
The ¾ inch depth of a slot 15 is designed to accept the 1 inch long and ¾ inch thick side of the preferred “L” angle railing 16 and to hold angle railing 16 securely while it is affixed to a freezer wall. Those of skill in the art will recognize that railings can be secured to a freezer wall through a variety of known means. Preferably, angle railings 16 are affixed to a freezer wall with adhesive tape 15. Many adhesive tapes may be suitable for use in the invention. A most preferred adhesive tape is 3M™ VHB™ Tape 5952 that is 2 inches wide and 1/1 mm thick. 3M™ VHB™ Tape 5952 has a foam density of 590 kg/m3 and a static shear strength greater than 1500 g at 0° C.
In preferred embodiments of the invention, adhesive tape 15 is first affixed to the 2 inch side of an “L” angle railing 16 and then the adhesive tape 15 is attached to a freezer's interior wall.
It will be understood that systems of the invention can be installed in a variety of configurations and orders to achieve the same or similar results. Herein is described a preferred installation method that works well with the present invention.
Preferably, a system of the invention is installed in a freezer that is completely defrosted and has dry, interior side walls so that railings can be installed securely. Railings that are applied to dry surfaces can quickly attain very high adhesive strength.
To prepare to install a first railing 16 for a tier, a user measures the interior length of the freezer. In many freezers, a box condenser box is present in or near the bottom third of the freezer. In such freezers, the user must account for this condenser box when taking the interior measurement for the lower tier. If the interior measurement is shorter than the railings provided in a kit, then the user can shorten the bottom railings by cutting the railing 16. Alternatively, if the interior measurement is greater than the length of the railings provided in the kit, then a user can cut additional railings for the bottom rail to increase the overall length. Preferably, a bottom railing's full length is about 1 inch shorter than the interior length so that the railing can be easily installed.
To install a railing at the desired height for a lower tier, place a railing 16 into the lower slot 15 of a set of placement guides 14. Preferably, a set of two guides is used so that the railing is level. A user slides the short side of the “L” angle railing 16 into the lowest slots 15 of the placement guides 14. While keeping the railing 16 in the slots 15 of the railing guides 14, remove the back of the adhesive tape 17. With both lower ends of the placement guides 14 set on the bottom of the freezer, rotate the guides 14 toward the intended wall of the freezer until the back of the railing 16 touches the wall. The railing will be at the correct height for the lower tier and will be level. With the guides 14 still in place, press the back of the railing 16 very firmly against the railing so that the adhesive tape 17 affixes to the wall. Remove the placement guides 14. Repeat the procedure on the opposite wall of the freezer to complete the installation of the lower tier.
To install and place a middle tier in all but the smallest freezers, the length of the tier will be longer than 36 inches. Preferred kits of the invention provide angle railings in 36 inch lengths. A user can make a longer tier by using two pieces of angle railing. Preferred angle railings can be cut to desired length by hand (for example a hacksaw can be used).
To install a middle tier, place the short side of a complete (uncut) railing 16 in the set of top slots 15 in the set of placement guides 14. Place the lower set of slots 15 over the already installed lower tier's railing while rotating the railing 16 toward the desired freezer wall. This motion will ensure that the railing is placed at the desired height above the lower tier. Remove the back covering from the adhesive tape 17 and affix the railing 16 to the desired freezer wall. Repeat this installation procedure on the opposite freezer wall. Repeat these installation steps as needed to place additional railings and complete the middle tier. Once the adhesive has completely cured, approximately 24 hours, each tier of a system can hold up to 25 lbs. per basket and 100 lbs. per tier.
Baskets of the invention are adjustable and designed to fit all chest freezers. The preferred way to adjust a basket's length is for the user to place their fingers through the ventilation holes 11 in the middle of the short sides 21 of a basket 1 and pull the sections away from each other. The basket sections will slide away from each other while remaining interlocked.
Kits of the invention include a magnetic white board 18 with at least one marker pen 19. Advantageously, the magnetic white board 18 can be easily attached to most chest freezers so that a user can readily check the contents and organization of a freezer, as well as, modify the inventory record as needed.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs at the time of filing. Terminology used herein is for the purpose of describing particular embodiments of the invention and is not intended to be limiting. The meaning and scope of terms should be clear; however, in the event of any latent ambiguity, definitions provided herein take precedent over any dictionary or extrinsic definition. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular unless the content clearly dictates otherwise. Herein, the use of “or” means “and/or” unless stated otherwise. Furthermore, the use of the term “including”, as well as other forms such as “includes” and “included” is not limiting. As used herein, “each” refers to each member of a set or each member of a subset of a set.
This application claims the benefit of U.S. Provisional Patent Application No. 63/259,860 that was filed Aug. 20, 2021.
| Number | Date | Country | |
|---|---|---|---|
| 63259860 | Aug 2021 | US |
