Patent Grant
11072926
This application is a continuation-in-part of U.S. application Ser. No. 16/364,000, filed Mar. 25, 2019. The entire disclosure of this prior application is incorporated by reference herein.
This invention relates to storage systems, and more specifically to overhead storage systems.
Ceilings in buildings—such as homes, apartments, and offices—provide the top-most surface(s) of a room and have numerous purposes, which can include visual appeal, structural strength, thermodynamic control, and dust isolation.
Above the bottom surface(s) of a ceiling is generally a floor and/or roof surface(s).
Between the bottom surface(s) of the ceiling and the floor/roof surface(s) there is generally a load bearing structure that supports the ceiling and floor/roof surfaces. Some designs—such as a truss system—use sparsely arranged structural members that result in significant open space between the ceiling and the floor/roof. This space can be used for additional purposed such as insulating between the ceiling and floor/roof surfaces; placement of utility systems such as plumbing, ducting, and wiring; and/or providing in-ceiling storage.
Accessible storage is often desirable for those using a room. While above ceiling storage is possible, accessing it is generally cumbersome and preference often seems to be given to storage and storage systems which are below the ceiling. This can result in underuse of open spaces within loadbearing support structures between ceiling and floor/roof surfaces.
In a first aspect, the disclosure provides an overhead storage system. The system includes an overhead frame and a storage box that fits within the frame. The storage box includes a bottom wall with a lower surface that provides a ceiling surface for a room and a structure with at least one loadbearing storage surface for the storage box. The system includes at least one raise/lower mechanism connected between the frame and the storage box. The at least one raise/lower mechanism includes a winch configured to wind up and let out a line and a pulley set with at least one pulley mounted to the frame or the storage box. The line is attached to the winch and attached to either the frame or the storage box. The winch, the line, and the at least one pulley of the at least one raise/lower mechanism cooperate to lower the storage box from a storage position to an access position and to raise the storage box from the access position to the storage position.
In a second aspect, the disclosure provides for the overhead storage system to be integrated into a modular building system.
Further aspects and embodiments are provided in the foregoing drawings, detailed description and claims.
The following drawings are provided to illustrate certain embodiments described herein. The drawings are merely illustrative and are not intended to limit the scope of claimed inventions and are not intended to show every potential feature or embodiment of the claimed inventions. The drawings are not necessarily drawn to scale; in some instances, certain elements of the drawing may be enlarged with respect to other elements of the drawing for purposes of illustration.
The following description recites various aspects and embodiments of the inventions disclosed herein. No particular embodiment is intended to define the scope of the invention. Rather, the embodiments provide non-limiting examples of various compositions, and methods that are included within the scope of the claimed inventions. The description is to be read from the perspective of one of ordinary skill in the art. Therefore, information that is well known to the ordinarily skilled artisan is not necessarily included.
Definitions
The following terms and phrases have the meanings indicated below, unless otherwise provided herein. This disclosure may employ other terms and phrases not expressly defined herein. Such other terms and phrases shall have the meanings that they would possess within the context of this disclosure to those of ordinary skill in the art. In some instances, a term or phrase may be defined in the singular or plural. In such instances, it is understood that any term in the singular may include its plural counterpart and vice versa, unless expressly indicated to the contrary.
As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to “a substituent” encompasses a single substituent as well as two or more substituents, and the like.
As used herein, “for example,” “for instance,” “such as,” or “including” are meant to introduce examples that further clarify more general subject matter. Unless otherwise expressly indicated, such examples are provided only as an aid for understanding embodiments illustrated in the present disclosure and are not meant to be limiting in any fashion. Nor do these phrases indicate any kind of preference for the disclosed embodiment.
As used herein, “output force” is meant to refer to the force exerted by a physical tool, mechanical device, or machine system on a body.
As used herein, “input force” is meant to refer to the force exerted on a physical tool, mechanical device, or machine system by a body.
As used herein, “mechanical advantage” is meant to refer to the force amplification of a physical tool, mechanical device, or machine system. This amplification is given as a number created by dividing the output force by the input force. Thus, a physical system that has an out put force of 4 Newtons (N) from an input force of 1 N would have a mechanical advantage of 4.
As used herein, “ideal” may be added to “mechanical advantage” to form the phrase “ideal mechanical advantage”. This phrase is meant to refer to the case where the physical tool, mechanical device, or machine has the same output power as input power. It is typically considered theoretical and is generally determined by using a simplified model of the tool, device, or machine. Such a model may neglect the effects of factors such as friction, deflection, and stretching, which factors may result in input power being transferred to heat or stored in the system instead of being perfectly transferred to the output.
As used herein, “degrees of freedom” refers to 6 types of motion available to a physical object. Three of the types of motion are linear directions which are perpendicular to each other. An example of this could be directions “x”, “y”, and “z” where each has the following definitions: x is forward/backward, y is right/left, and z is up/down. The three other types of motion are rotational wherein the object can rotate perpendicularly relative to any of the linear directions. In the x, y, and z example above, each of x, y, and z can each become an axis around which the object can rotate. Together, these 6 degrees of freedom define the motion of an object in physical space. As used herein, a “degree of freedom” is the individual consideration of any of these linear or rotational degrees of freedom. Additionally, degree or degrees of freedom can refer to the count of unrestrained degrees of freedom an object has after external factors limit one or more degree of freedom.
When used herein as a unit of measure for length, a “rod” is 16.5 feet. As used herein, a rectangular plot of land that measures 40 rods by 4 rods is a “perfect acre”. As used herein, a “square furlong” is 10 perfect acre plots of land placed side-by-side to form a square plot of land. As used herein, there are 640 acres in a square mile. As used herein, a “mile square” is a square that measures 1 mile in length and 1 mile in width.
As used herein, “smart phone” refers to any of a class of mobile personal electronic devices used to wirelessly communicate which primarily originated as cellular phones and grew to include such things as SMS text messaging, internet browsing, and mobile software applications generally referred to as “apps” or “mobile apps”. As used herein, “smart phone” also included devices that are similar to those mentioned above in software capability, but without cellular service capability.
Now referring to
Preferably, the frame 110 is made of stainless steel. The steel is preferably of rectangular tube, flat bar, and angles. More preferably, the rectangular tube has approximately 1/16″ thickness and is of 3 shapes: (1) ¾″ square, (2) 1.5″×¾″, and (3) 1.5″ square; the flat bar is 1.5″×¼″; and there is no angle. In one preferred embodiment, the ¾″ square tubes run along the perimeter edges of the frame, the flat bar generally runs along the perimeter faces as diagonals, and the 1.5″ tubes are generally used for the remainder of the frame. In an alternative preferred embodiment, the flat bar is replaced by ¾″ tubes. In an alternative preferred embodiment, the horizontal ¾″ tubes are replaced by either shape of 1.5″ tube.
In a preferred embodiment, the frame is fabricated as follows: the pieces of the frame are cut to size, jigged together, then robotically laser welded together. The robotic laser welding provides the finish of the weld. In the finished product, the rectangular tubes are arranged horizontally and vertically in a rectangular box shape that is 2 rods long, ½ a rod wide, and ¼ of a rod tall. The vertical tubes are generally spaced ¼ of a rod apart. The flat bars and some rectangular tubes are arranged diagonally between about half of the junctions where vertical and horizontal tubes meet, generally with 2 or more diagonals meeting at any junction. The diagonals are positioned on planes perpendicular to one of the length, width, or height and in such a way as to not hinder the desired motion of any storage box relative to the frame.
In alternative embodiments, the frame may be comprised of sub-frame sections with a system that holds the sub-frame sections in position relative to each other. In one preferred embodiment, the system is a cable or rope system. Preferably, the cable system uses stainless steel cable that is run through the rectangular tubes comprising the frame. The cable is tensioned and the force from that tension is transferred to the sub-frame sections in a manner which secures the sections in position relative to each other. More preferably, the cable is run through contiguous rectangular tubes. More preferably, a cable is run through multiple colinear rectangular tubes.
In alternative embodiments, there are guides or a guide system that fit within the rectangular tubes to help line up the sub-frame sections. These guides may also provide structural support within the frame. More preferably, the cable runs through openings within the guides.
In alternative embodiments, multiple frames and/or overhead storage systems may be secured together by means of a cable or rope system. In a preferred embodiment, guides may also be used in conjunction with the cable or rope system to secure multiple frames and/or overhead storage systems together. Securing multiple frames and/or overhead storage systems together may include the use of additional components which are part of a building component such as vertical components which support an overhead storage system above another overhead storage system.
Preferably, significant parts of storage box 120 are made of stainless steel or aluminum alloys. Preferably the steel is rectangular tube and c-channel. Preferably, the aluminum is angle and/or sheet metal. Preferably, the storage box uses at least one of the same sizes of stainless rectangular tube as the frame. Preferably, the c-channel measures ¾″ wide and has ½″ long legs. Preferably, the stainless and aluminum pieces are jigged and robotically laser welded together and/or bolted together. Preferably, the storage box is essentially the same size as the space between the frame pieces. More preferably, the height of the storage box is approximately ¼ of a rod tall (approximately ¼ of a rod −9″ or +9″). More preferably, the storage box has a rectangular horizontal perimeter that is nearly ¼ of a rod long on one side and either nearly ¼ or nearly ½ of a rod long on the other side (approximately 0″ to 6″ shorter than the described fractional rod lengths).
Preferably, a raise/lower mechanism and 2 raise/lower guides 140 are positioned on a nearly ¼ of a rod side of storage box 120. Preferably, on the opposing side of rectangularly shaped storage box 120 are another raise mechanism and 2 raise/lower guides 140. Preferably, the two remaining sides of storage box 120, which are either nearly ¼ or nearly ½ a rod long, are generally open for easy access of the storage space (i.e. without diagonal flat bar, c-channel, or insulating panels). In one preferred embodiment, two raise/lower mechanisms may be combined or share components such as sharing one motor and/or shaft.
Preferably, the bottom wall and its lower surface include a combination of aesthetic and utility features, of which there are many suitable options. The specific application will determine which combination of features is preferred. Selection of desirable features include: lifespan, rigidity, utility, aesthetics. (1) durability—selection of the bottom wall and lower surface will generally include consideration for how long the surface will remain in a usable condition given expected use and environment; (2) structural characteristics—static and dynamic loading, desired stiffness, cushion, and other mechanical specifications and requirements will vary across use cases and are generally a significant factor in selecting the bottom wall and lower surface; (3) aesthetic appeal—psychological factors are generally a part of the selection process.
Preferably, the bottom layer is selected from typical ceiling materials such as wood, plastic, drywall, gypsum, acoustic or ceiling tiles, metal ceiling tiles, wallpaper, fabric, stucco, tile, linoleum, vinyl, rubber, concrete, or stone. In one preferred embodiment, the bottom layer is a rigid plastic. In another preferred embodiment, the bottom layer is gypsum. In another preferred embodiment, the bottom layer is paint on a rigid surface such as wood or drywall.
In a preferred embodiment, the bottom wall has layers in addition to the bottom layer. Additional layers may include a top layer 126, structural layer 124, and other miscellaneous layers 127 such as a heating and/or cooling layer, a rubber layer, an insulating layer, and a woody or organic layer such as Masonite. Preferably, the structural layer is comprised of wood, metal, or plastic. In one preferred embodiment, the structural layer comprises sheet metal. More preferably, the sheet metal is shaped rather than flat. Even more preferably, the sheet metal is shaped in such a way that it has improved structural characteristics. In the most preferred embodiment, the structural layer is corrugated stainless steel. In one embodiment, an insulating layer 128 such as Styrofoam may be recessed within cavities in a corrugated metal layer.
In a preferred embodiment, the bottom wall is substantially encased on its sides by a sidewall 129. More preferably, the side wall helps hold the various layers of the bottom wall in the desired position. Preferably, the sidewall is of sheet metal, flat bar, or angle. In one preferred embodiment, the side wall is comprised of angle with one leg of the angle forming the sidewall and the other leg positioned parallel to the bottom wall to form a shelf to support layers in the bottom wall. Preferably, the components of the side wall are welded together. Preferably, the side wall is bolted or welded to the storage box and/or the corrugated metal. More preferably, the metal is stainless steel. Alternatively, the side wall can be made from aluminum. In one preferred embodiment, the bottom layer hides the side wall when viewed directly below the bottom wall. In another preferred embodiment, the side wall is visible from below the bottom wall.
In one preferred embodiment, when a storage box is in its raised position, its bottom wall and/or its side wall contact the frame.
In alternative embodiments, the overhead storage system can be configured with various sizes, shapes, and structures for an overhead frame, a storage box, a bottom wall, a lower surface, and/or a loadbearing storage surface. Alternative embodiments could also have the overhead storage system configured with a different number of raise/lower mechanisms to raise or lower a storage box relative to a frame. Alternatively, the overhead storage system can be configured with different quantities of storage boxes.
Preferably, the winch is selected to take the loading necessary to raise and lower the storage box. Preferably, the winch is selected and positioned to maximize the storage space above the bottom wall. In one preferred embodiment, winch 132a is the MyLifter® Basic Lifter which is described in various patents, including:
Preferably, the winch is controlled via wireless connection between itself and a portable electronic device. More preferably, the electronic device is a smart phone with software controls to raise/lower the one or more storage boxes. Preferably, when used in conjunction with other winches to lift a storage box, the winches are coordinated so they raise/lower the storage box together, more preferably evenly.
Most preferably, the raise/lower mechanisms are programmable. As one example, the mechanism can be programmed to raise and lower at predetermined times. As another example, the mechanisms can be programmed to raise and lower in sync with other mechanisms so that two or more storage boxes are lifted or lowered at the same time.
In alternative embodiments a raise/lower mechanism could be configured for a different ideal mechanical advantage; with a different quantity of pulleys, lines, or winches; with the winch attached to the storage box 120; and/or with the line attached to the storage box 120.
Preferably, a guide is comprised of components that nest within each other and which slide relative to each other to provide one direction of translational motion. Preferably, the nested components do not directly contact each other, but are separated by a system which comprises ball bearings and reduces loads that would hinder the translational motion. More preferably, a guide is a drawer slide which is sized to provide at least approximately ¼ of a rod of translational motion.
Alternatively, the system described herein can be modified and incorporated into other ceiling overhead storage applications.
All patents and published patent applications referred to herein are incorporated herein by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. Nevertheless, it is understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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| 2499791 | Spencer | Mar 1950 | A |
| 5535852 | Bishop | Jul 1996 | A |
| 7407150 | Bellantoni | Aug 2008 | B1 |
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| Number | Date | Country | |
|---|---|---|---|
| 20210032863 A1 | Feb 2021 | US |
