The present invention relates generally to sturdy boxes for holding various items, including, for example, toys, and more particularly, is directed to a box that can be easily assembled without the use of any tools, while retaining structural integrity.
The use of toy boxes, made from wood, plastic, etc., for holding children's toys are well known. These toy boxes are generally assembled using screws or bolts in order to provide structural integrity. However, such assembly is burdensome and time consuming. Further, over time, the screws and bolts can loosen, thereby reducing the structural integrity and possibly providing a hazard for the child.
It is also known to assemble different furniture pieces without the use of tools by using dovetail sliding joints and the like. However, the construction and assembly also tends to be rather difficult.
Accordingly, it is an object of the present invention to provide a toy box that overcomes the aforementioned problems.
It is another object of the present invention to provide a toy box that can be easily assembled without the use of any tools, while retaining structural integrity.
It is still another object of the present invention to provide a toy box that is easy and economical to use and manufacture.
In accordance with an aspect of the present invention, a box includes first and second spaced apart side walls, and first and second ends walls connected to opposite ends of the side walls. Each of the side walls has an elongated slot at a lower end of an inner surface thereof. At least one flooring member is inserted in the elongated slots of the side walls to form a bottom wall of the box. A closure member is inserted into a space adjacent the at least one flooring member to lock the at least one flooring member in the elongated slots of the side walls and the first and second end walls.
At least one of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the at least one end wall being coplanar with each other, and wherein the at least one flooring member is locked in the elongated slots of the side walls and the at least one end wall when the closure member is inserted into the space adjacent the at least one flooring member.
Preferably, each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, and wherein the at least one flooring member is locked in the elongated slots of the side walls and the end walls when the closure member is inserted into the space adjacent the at least one flooring member.
In one embodiment, the at least one flooring member includes first and second flooring members, each inserted in the elongated slots of the side walls to form the bottom wall of the box, and the closure member is inserted between the first and second flooring members. In a modification thereof, the at least one flooring member includes a single flooring member, and the closure member is inserted between an end of the single flooring member and one end wall.
The first and second side walls are in parallel, spaced apart relation to each other and the first and second end walls are in parallel, spaced apart relation to each other.
Each end wall has a vertically oriented narrow recess at opposite sides thereof, with one end of each recess being open, and each side wall has a connecting plate at opposite sides thereof, with each connecting plate removably locking within one narrow recess. Each narrow recess includes at least one side wall securing rib, and each connecting plate is L-shaped and engages with the at least one side wall securing rib to releasably lock each side wall to a respective end wall.
Each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, the elongated slots of the end walls open at opposite ends thereof into the narrow recesses at opposite sides thereof. Further, the elongated slots of the side walls open at opposite ends thereof into the connecting plates at opposite sides thereof.
There are also hand openings in upper ends of the end walls, and/or upper ends of the side walls.
Each side wall has a capturing recess for holding one end of the closure member in a position adjacent the at least one flooring member. At least one side wall has a ramp positioned below the respective capturing recess for aiding in inserting a respective end of the closure member in the respective capturing recess.
The closure member includes a first section that lies against an underside of the at least one flooring member.
In accordance with another aspect of the present invention, a method of assembling a box, includes a first step of assembling a first end of a first side wall having an elongated slot at a lower end of an inner surface thereof, with a first end of a first end wall at a lower end of an inner surface thereof; a second step of assembling a first end of a second side wall having an elongated slot at a lower end of an inner surface thereof, with a second end of the first end wall such that the first and second side walls are in spaced apart relation; a third step of sliding at least one flooring member into the elongated slots of the first and second side walls from second, opposite ends of the first and second side walls; a fourth step of assembling the second end of the first side wall with a first end of a second end wall; a fifth step of assembling the second end of the second side wall with a second end of the second end wall; and a sixth step of inserting a closure member into a space adjacent the at least one flooring member to lock the at least one flooring member in the elongated slots of the side walls.
At least one of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the at least one end wall being coplanar with each other, and further comprising the step of locking the at least one flooring member in the elongated slots of the side walls and the at least one end wall when the closure member is inserted into the space adjacent the at least one flooring member.
Preferably, each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, and further comprising the step of locking the at least one flooring member in the elongated slots of the side walls and the end walls when the closure member is inserted into the space adjacent the at least one flooring member.
In one embodiment, the at least one flooring member includes first and second flooring members, each inserted in the elongated slots of the side walls to form the bottom wall of the box, and the sixth step includes the step of inserting the closure member between the first and second flooring members.
In a modification, the at least one flooring member includes a single flooring member, and the sixth step includes the step of inserting the closure member between an end of the single flooring member and one end wall.
The first through fourth assembling steps results in the first and second side walls being in parallel, spaced apart relation to each other and the first and second end walls being in parallel, spaced apart relation to each other.
Each end wall has a vertically oriented narrow recess at opposite sides thereof, with one end of each recess being open, and each side wall has a connecting plate at opposite sides thereof, and each of the first through fourth assembling steps includes the step of removably locking each connecting plate within a respective narrow recess. Each narrow recess includes at least one side wall securing rib, and each connecting plate is L-shaped, and the step of removably locking includes the step of engaging each L-shaped connecting plate with a respective side wall securing rib to releasably lock each side wall to a respective end wall.
Each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, and the elongated slots of the end walls open at opposite ends thereof into the narrow recesses at opposite sides thereof, and wherein the at least one flooring member also extends outwardly of the elongated slots into the narrow recesses. Also, the elongated slots of the side walls open at opposite ends thereof into the connecting plates at opposite sides thereof.
Each side wall has a capturing recess, and wherein the sixth step of inserting a closure member includes the step of inserting opposite ends of the closure member into the capturing recesses for holding the closure member in a position between the at least one flooring member. Further, at least one side wall has a ramp positioned below a respective capturing recess, and the sixth step of inserting a closure member includes the step of sliding one end of the closure member up the ramp for aiding in inserting the respective end of the closure member in the respective capturing recess. Also, the sixth step of inserting a closure member includes the step of inserting the closure member so that a first section thereof lies against an underside of the at least one flooring member.
The above and other objects, features and advantages of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings.
Referring to the drawings in detail, a toy box 10 according to a first embodiment of the present invention has a generally rectangular parallelepiped construction, although the present invention is not limited thereby.
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Reinforcing and guiding ribs 50 extend partially into recess 38 from inner vertical wall 44 in parallel, spaced apart relation to each other. Each reinforcing and guiding rib 50 extends the full height of inner vertical wall 44 and is also connected with bottom wall 48. Although four reinforcing and guiding ribs 50 are shown, the present invention is not limited thereby. Preferably, a lowermost reinforcing and guiding rib 50a extends in line with bottom surface 36. Furthermore, guiding ribs 50 can be eliminated, and need not be provided to define each recess 38.
In addition, side wall securing ribs 52 extend from outer vertical wall 46 in spaced apart relation to each other, preferably at positions between reinforcing and guiding ribs 50. However, unlike reinforcing and guiding ribs 50, side wall securing ribs 52 are spaced from bottom wall 48 of recess 38 to provide a capturing space 53 therebetween, as best shown in
An elongated board capturing slot 54 extends horizontally through inner surface 32 and exits at opposite ends thereof through inner vertical walls 44 of opposite recesses 38. Further, a hand opening 56 extends entirely through ends walls 16, 18 centrally at an upper end thereof. It will be appreciated, however, that hand openings can alternatively extend entirely through side walls 12, 14 centrally at upper ends thereof.
In order to increase the strength and rigidity of end walls 16, 18, a plurality of horizontally oriented recesses 58 are provided in inner surface 32 and extend partially through end walls 16, 18, at positions between elongated board capturing slot 54 and hand opening 56. In order to increase the strength and rigidity, a rectangular shallow recess 60 is provided in outer surface 30.
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An L-shaped connecting plate 74 extends outwardly from each side surface 72, and specifically, includes a first elongated plate 76 thereof that extends outwardly from each side surface 72 and a second elongated plate 78 that extends at a right angle from the free edge of first elongated plate 76 in a direction toward the outside of each side panel 62. First elongated plate 72 is spaced slightly from top surface 68 and bottom surface 70. In addition, the opposite ends of second elongated plate 78 include beveled edges 80.
An elongated board capturing slot 82 extends horizontally entirely through inner surface 66 and exits at opposite ends, continuing through first elongated plates 76 on opposite sides thereof.
A rod capturing recess 84 is formed centrally in inner surface 66 just below elongated board capturing slot 82 and in open communication therewith. A rod entry recess 86 is formed in inner surface 66, open at bottom surface 70 and extending toward rod capturing recess 84 but spaced therefrom by a land 88. Rod entry recess 86 includes a ramp surface 90 that decreases in depth from bottom surface 70 toward the opposite end thereof.
In order to increase the strength and rigidity of side walls 12, 14, a plurality of horizontally oriented recesses 92 are provided in inner surface 66 and extend partially through side walls 12, 14, at positions between rod capturing recess 84 and top surface 68. In order to increase the strength and rigidity, a rectangular shallow recess 94 is provided in outer surface 64.
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It will be appreciated that boards 22 and 24 can be replaced with a single board 223 or single equivalent flooring member, as shown in the modified embodiment toy box 210 of
Specifically, the differences are that, in addition to single board 223, rod capturing recess 84 is formed at one end of first and second side walls 12 and 14, in inner surface 66 just below elongated board capturing slot 82 and in open communication therewith. Further, rod entry recess 86 is formed in inner surface 66, open at bottom surface 70 and extending toward rod capturing recess 84 but spaced therefrom by a land 88. Rod entry recess 86 includes a ramp surface 90 that decreases in depth from bottom surface 70 toward the opposite end thereof.
A description of the assembly of toy box 210 will now be described.
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It will be appreciated that, although the present invention has been referenced in relation to a toy box, the present invention is not limited thereto, and can be used as a box for any purpose.
Having described a specific preferred embodiment of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to that precise embodiment and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined by the appended claims.
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