Storage unit for modular workstation

Abstract

A storage unit is disclosed. The storage unit includes a pair of opposed side walls that are substantially parallel to each other, a rear wall that connects the side walls at rear portions thereof, and a top wall that connects the side walls at top portions thereof. The top wall and the side walls define an opening for receiving objects to be stored within the storage unit. The storage unit also includes a cross member that is connected to each side wall, disposed below the top wall, and cooperates with the top wall to define a door receiving space within the storage unit, and a door constructed and arranged to cover the opening when the door is in a closed position, and to be received by the door receiving space when the door is in an open position.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to modular workstations. More specifically, the present invention relates to a storage unit for a modular workstation.

2. Description of Related Art

Storage units with flipper-type doors that are used for modular workstations are typically classified in one of two categories. First, there are units that store the doors on the outside of the unit, i.e. above the unit, when the door is in an open position. Such a unit is described in, for example, U.S. Pat. No. 3,771,847. While such a design allows the full interior space to be utilized, objects may not be placed on top of such a unit without hindering the movement of the door.

Second, there are units that store the doors inside of the unit, as described in, for example, U.S. Pat. No. 6,394,566. Although such a design allows objects to be placed on top of the unit, without obstructing the door when the door is opened and closed, fill use of the interior is lost when the door is in an open position, because the door blocks one of the interior walls of the unit.

Moreover, doors that are stored in the interior of the storage unit have the risk of being scratched and dented, particularly at the top of the door, when the tolerance between the door and the lower edge of the roof of the storage unit is not large enough. If the door becomes misaligned, there is a risk that the top edge of the door may not quite clear the front edge of the roof, and damage to the door may occur.

BRIEF SUMMARY OF THE INVENTION

It is one aspect of the present invention to provide a storage unit with a flipper-type door that stores the door on the inside of the unit, yet optimizes the useable space within the storage unit.

In an embodiment of the invention, a storage unit is provided. The storage unit includes a pair of opposed side walls that are substantially parallel to each other, a rear wall that connects the side walls at rear portions thereof, and a top wall that connects the side walls at top portions thereof. The top wall and the side walls define an opening for receiving objects to be stored within the storage unit. The storage unit also includes a cross member that is connected to each side wall, disposed below the top wall, and cooperates with the top wall to define a door receiving space within the storage unit, and a door constructed and arranged to cover the opening when the door is in a closed position, and to be received by the door receiving space when the door is in an open position.

In an embodiment, a storage unit is provided. The storage unit includes a pair of opposed side walls that are substantially parallel to each other, a rear wall that connects the side walls at rear portions thereof, and a top wall that connects the side walls at top portions thereof. The top wall and the side walls define an opening for receiving objects to be stored within the storage unit. The storage unit also includes a cross member that is disposed below the top wall and cooperates with the top wall to provide a door receiving region therebetween, an accessory carried by the cross member, and a door constructed and arranged to cover the opening when the door is in a closed position, and to be received by the door receiving region when the door is in an open position.

It is an aspect of the present invention to provide a storage unit with a flipper-type door that stores the door on the inside of the unit with improved movement between the door and the roof of the unit so that the door is not damaged when moved between a closed position and an open position.

In an embodiment of the invention, a storage unit is disclosed. The storage unit includes a pair of opposed side walls that are substantially parallel to each other, a rear wall that connects the side walls at rear portions thereof, and a top wall that connects the side walls at top portions thereof. The top wall and the side walls define an opening for receiving objects to be stored within the storage unit. The storage unit also includes a door that is constructed and arranged to cover the opening when the door is in a closed position, and to be disposed substantially parallel to the top wall on an interior side of the top wall when the door is in an open position. The door includes a roller adjacent to a top edge thereof. The roller is constructed and arranged to engage a guide surface within the storage unit when the door is moved between the closed position and the open position.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

FIG. 1 is a top perspective view of a storage unit of the present invention with a door in a closed position;

FIG. 2 is a bottom perspective view of the storage unit of FIG. 1 with the door in a fully open position;

FIG. 3 a is another bottom perspective view of the storage unit of FIG. 2;

FIG. 3 b shows Detail A of FIG. 3a;

FIG. 4 is a right side view of a left side wall of the storage unit of FIGS. 1-3;

FIG. 5 is a front view of the door of the storage unit of FIGS. 1-3;

FIG. 6 a is a rear view of the door of FIG. 5;

FIG. 6 b shows Detail B of FIG. 6a;

FIG. 7 a is a cross-sectional view of the storage unit along line VII-VII of FIG. 2, with some of the features removed for clarity;

FIG. 7 b shows Detail C of FIG. 7a;

FIG. 8 a is a cross-sectional view of the storage unit of FIG. 7a, with the door in between the fully open and closed positions;

FIG. 8 b shows Detail D of FIG. 8a;

FIG. 9 a is a cross-sectional view of the storage unit of FIG. 8a, with the door in closer to the closed position;

FIG. 9 b shows Detail E of FIG. 9a;

FIG. 10 a is a cross-sectional view of the storage unit of FIG. 1 along line X-X, with some of the features removed for clarity; and

FIG. 10 b shows Detail F of FIG. 10a.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 show a storage unit 10 of the present invention. FIG. 1 shows the storage unit 10 with a door 12 in a closed position 14, and FIG. 2 shows the storage unit 10 with the door 12 in an open position 16. Movement of the door 12 between the closed position 14 and the open position 16 will be described in further detail below. For purposes of the discussion below, all references to orientation of parts of the storage unit 10 will be made with the storage unit 10 in its normal, upright position, from the perspective of facing the storage unit 10 on the side that includes the door 12, which is considered to be the front.

As shown in FIGS. 2 and 3a, the storage unit 10 also includes a pair of opposed side walls, including a left side wall 18, and a right side wall 20. The side walls 18, 20 are disposed substantially parallel to each other. Each of the side walls 18, 20 has a top portion 22, 24, respectively, and a rear portion 26, 28, respectively, as shown in FIG. 2. The storage unit 10 also includes a rear wall 30 that is connected to the left side wall 18 at the rear portion 26 of the left side wall 18, and to the right side wall 20 at the rear portion 28 of the right side wall 20. The side walls 18, 20 and rear wall 30 may be formed from sheet metal, or any other material known in the art. The rear wall 30 may be connected to the left and right side walls 18, 20 with fasteners (not shown), or with any other suitable connector, such as welds, etc. Preferably, the rear wall 30 is connected to the left and right side walls 18, 20 such that it is substantially perpendicular to each of the left and right side walls 18, 20. As shown, the rear wall 30 may include a peg board 31 that includes a plurality of holes 33 for receiving a plurality of hooked members, such as hooks, trays with hooks, etc., as would be understood by one of ordinary skill in the art.

The storage unit 10 also includes a top wall 32, or roof, that is connected to the top portion 22 of the left side wall 18 at one end, and is connected to the top portion 24 of the right side wall 20 at the opposite end. Preferably, the top wall 32 is also connected to a top portion of the rear wall 30 as well. Like the side walls 18, 20 and rear wall 30, the top wall 32 may be formed from sheet metal, or any other material known in the art. The top wall 32 may be connected to the other walls 18, 20, 30 with fasteners 35, as shown in FIG. 1, or with any other suitable connector, such as welds, etc. Preferably, the top wall 32 is connected to the left and right side walls 18, 20 such that it is substantially perpendicular to each of the left and right side walls 18, 20, as well as the rear wall 30. The top wall 32, the left side wall 18, and the right side wall 20 define an opening 34 into the storage unit 10.

Although the illustrated embodiment of the storage unit 10 is a hutch that has an open bottom 38, it is understood that in other embodiments (not shown), the storage unit 10 may be a fully enclosed unit that includes a bottom wall. The illustrated embodiment is not intended to be limiting in any way.

As shown in FIG. 3a, the left side wall 18, the right side wall 20, and the rear wall 30 may each include a bottom flange, shown at 40, 42, 44, respectively. The bottom flanges 40, 42, 44 are constructed and arranged to receive fasteners for securely fastening the storage unit 10 to another unit, or any type of supporting surface, such as a countertop, table, etc. For example, the storage unit 10 may be attached to a lower unit (not shown) that is placed directly on the floor. The hutch allows for the top of the lower unit to be a work surface, as will be discussed in further detail below.

Also shown in FIG. 3a is a cross member 46 that is disposed below the top wall 32. In the illustrated embodiment, the cross member 46 is connected to the left side wall 18 at one end, and the right side wall 20 at the opposite end so that the cross member 46 is substantially parallel to the top wall 32, and substantially perpendicular to the left and right side walls 18, 20. By connecting the cross member 46 to both side walls 18, 20, the overall rigidity of the storage unit 10 may be improved. In the embodiment shown, the cross member 46 is connected to the left side wall 18 via a support assembly 48. It is understood that another support assembly (not shown) that mirrors the support assembly may be used to connect the cross member 46 to the right side wall 20.

As shown in FIG. 4, the support assembly 48 includes a pair of substantially vertical supports 50, 52 and a substantially horizontal support 54. A first vertical support 50 is connected to the left side wall 18 at or near a front edge 56 of the left side wall 18. A second vertical support 52 is connected to the left side wall 18 near the rear portion 26 in a manner that does not interfere with the rear wall 30. The vertical supports 50, 52 may be connected to the left side wall 18 with fasteners, or may be welded to the left side wall 18. The horizontal support 54 is supported by the vertical supports 50, 52 via slots 58, 60. Of course, the horizontal support 54 may be supported by or connected to the vertical supports 50, 52 by any other known method. The embodiment illustrated is not intended to be limiting in any way.

The cross member 46 may be supported by and connected to the horizontal support 54 by any known method. As shown in FIG. 3a, and in greater detail in FIG. 3b, the cross member 46 includes a U-shaped (in cross-section) channel 62 along a front edge 64 that is constructed and arranged to receive the horizontal support 54. The cross member 46 extends back towards the rear wall 30 such that an underside of the cross member 46 provides an unobstructed surface 66 that acts as a ceiling for the interior of the storage unit 10. In an embodiment, the cross member 46 is also connected to the rear wall 30.

As mentioned above, the cross member 46 is disposed so that it is substantially parallel to the top wall 32. The cross member 46 is spaced below the top wall 32 at a suitable distance so that a door receiving space 47 is formed between the cross member 46 and the top wall 32. The door receiving space 47 receives the door 12 when the door 12 is in the open position 16, as shown in FIG. 7a.

The arrangement of the cross member 46 allows for the storage of the door 12 within the storage unit 10 when the door 12 is in the open position 16. This allows items to be placed on top of the storage unit 10 without having to worry about any interference or obstruction by the door 12. The cross member 46 also provides for another surface, i.e. the underside 66 of the cross member 46, within the storage unit 10 to which parts may be attached.

In an embodiment, the storage unit 10 includes an accessory 67. The accessory 67 may be a light fixture 68 that is configured to be connected to the underside 66 of the cross member 46 so that the interior of the storage unit 10 may be illuminated. The light fixture 68 may include a power cord 69 that may be fed through the rear wall 30 and plugged into a standard wall outlet, or the light fixture 68 may be powered by batteries. Of course, the power cord 69 may be fed through any wall of the storage unit 10. Also, the accessory 67 may include a plurality of hooks 70, shown in greater detail in FIG. 3b, that are constructed and arranged to receive and hold tools and other items that may be hung from the cross member 46, thereby improving the flexibility of the storage space created by the storage unit 10. The hooks 70 may be connected to the cross member 46 with any known attachment device. For example, the hooks 70 may include magnets that are attracted to the cross member 46, the hooks 70 may be fastened to the cross member 46, or the hooks 70 may be connected to the cross member 46 with an adhesive. The hooks 70 illustrated are not intended to be limiting in any way.

The cross member 46 enables a downwardly projecting object carried by or associated with the accessory 67 to be used without interference from the door 12. For example, if hooks were provided on an underside of the top wall 32, such hooks would be difficult to access when the door 12 is opened. Similarly, if a light source was mounted to the underside of the top wall 32, light therefrom would be blocked by the door 12 when opened.

FIG. 5 shows an embodiment of the invention in which at least one roller 90 is disposed adjacent to a top edge 92 of the door 12. Preferably, at least two rollers 90 are used. In the illustrated embodiment, four rollers 90 are connected to the door 12 so that they are positioned adjacent to the top edge 92 of the door 12. The rollers 90 are constructed and arranged to roll along a guide piece 98, which is discussed in further detail below, as the door 12 is moved between the closed position 14 and the open position 16, thereby allowing for smoother movement of the door 12 between the two positions 14, 16. Movement of the door 12 relative to the rest of the storage unit 10 will be discussed in further detail below. The rollers 90 may also help prevent the marring of an outer door surface 94 of the door 12 during opening and closing of the door 12, particularly if the alignment of the door 12 relative to the top wall 32 changes.

Also shown in the figures are a pair of handles 96 that are configured to receive a person's hand so that the user may grasp at least one of the handles 96, and move the door 12 between the closed position 14 and the open position 16, i.e. from the closed position 14 to the open position 16, and vice-versa. The handles 96 may be of any known design, and the handles 96 illustrated are not intended to be limiting in any way.

As shown in FIG. 6a, the storage unit 10 may also include at least one door guide device 72 that guides the door 12 between the closed position 14 and the open position 16. In the illustrated embodiment, four door guide devices 72 are operatively connected to both the door 12, on a back side 73 thereof, and to the cross member 46 such that the door 12 both pivots and slides relative to the cross member 46. Any type of door guide device 72 may be used, so long as the door 12 is able to move between the closed position 14, as shown in FIG. 1, and the open position 16, as shown in FIG. 2, with relatively little effort by the user.

For example, in the illustrated embodiment, each door guide device 72 includes a hinge 74 that is connected to the front edge 64 and a bottom edge 65 of the cross member 46 when the door is installed, as shown in FIG. 3b, and a door slide 76 that is connected to the back side 73 of the door 12, as shown in FIG. 6a. A damper 78, shown in greater detail in FIG. 6b, is also included to provide a more controlled movement of the door 12 relative to the cross member 46. As shown, the damper 78 includes a hydraulic cylinder 80 that provides resistance when the door 12 is moved from the open position 16 to the closed position 14, and provide controlled assistance when the door 12 is moved from the closed position 14 to the open position 16. Such a door guide device is known in the art, and details of an example of such a device may be found in U.S. Pat. No. 5,758,937, which is incorporated herein by reference.

The storage unit 10 may also include a lock 82, shown in FIG. 6a, that is constructed and arranged to lock the door 12 when the door 12 is in the closed position 14. The lock 82 may be of a known construction that includes a pair of slidable arms 84 that engage the left and right side walls 18, 20 at a slot 86 contained in each wall 18, 20. The slidable arms 84 are connected to a rotatable barrel 88 that is configured to receive a key. Rotation of the barrel 88 actuates the slidable arms 84 either outwardly, thereby positioning the arms 84 into the slots 86, or inwardly, thereby allowing the door 12 to move relative to the rest of the storage unit 10. Of course, other types of locks that are known in the art may be used, and the illustrated embodiment is not intended to be limiting in any way.

FIGS. 7 a-10b illustrate the movement of the door 12 relative to the cross-member 46 and the top wall 32. As shown in the figures, the guide piece 98 may be provided to assist in guiding the rollers 90 of the door 12 as the door 12 moves between the closed 14 and open 16 positions. The guide piece 98 is preferably disposed adjacent to the top wall 32, and may be attached to the side walls 18, 20, or to the top wall 32 itself. The guide piece 98 provides a guide surface 100, 102 that includes a parallel surface 100 that is substantially parallel to the top wall 32 and the cross member 46, and a ramped surface 102 that is connected to the parallel surface 100 and extends toward the top of the top wall 32. Although the guide piece 98 is illustrated to be a separate piece, it may be integrated with the top wall 32 itself. The illustrated embodiment is not intended to be limiting in any way.

After the storage unit 10 has been placed at its desired location, it may be attached to the lower unit, table, or any other support on which it sits. As discussed above, fasteners may be used with the holes provided in the bottom flanges 40, 42, 44 of the side walls 18, 20, and the rear wall 30. Once the storage unit 10 is securely fastened to its support, items may be stored within the storage unit 10, either directly on the support surface, or attached to the cross member 46 via the plurality of hooks 70, or attached to the peg board 31 on the rear wall 30 with a plurality of hooked members. When not in use, the door 12 of the storage unit 10 may be moved to the closed position 14, and the lock 82 may be engaged to lock the door 12 in the closed position 14.

FIG. 7 a shows the door 12 in the fully open position 16. As shown in FIGS. 7a and 7b, in this position, the door 12 is within the door receiving space 47 and rests on the cross member 46, and the roller 90 does not engage any surface of the storage unit 10. When the user would like to close the storage unit 10 and move the door 12 to the closed position 14, the user may grasp the handles 96, and start to pull the door 12 outward and toward the front of the unit 10, as shown in FIG. 8a. Once the door 12 is pulled out of the door receiving space 47 a sufficient amount, the door 12 is allowed to pivot via the hinge 74 until the roller 90 engages the parallel surface 100 of the guide piece 98, which is shown in greater detail in FIG. 8b. At this position, guidance of the door 12 is provided by the roller 90 and the door guide device 72 along the door slide 76.

As the user continues to pull the door 12 towards the closed position 14, the roller 90 engages the ramped surface 102 of the guide piece 98, as shown in FIGS. 9a and 9b. This allows the door 12 to pivot relative to the cross member 46 a greater amount, as can be seen in the figures. As the door 12 continues to slide along the door slide 76 and the roller engages the underside of the top wall 32, the door 12 may fully pivot and finally rest in the closed position 14, as shown in FIG. 10a. As shown in greater detail in FIG. 10b, when the door 12 is in the closed position 14, the damper 78 is positioned at the top of the slide 76, and the roller 90 does not engage any surface. The lock 82 may be used to lock the door 12 in the closed position 14.

To access items in the storage unit 10 and/or use the support surface as a work surface, the lock 82 may be disengaged, thereby allowing the door 12 to be moved to the open position 16. The user may grasp one or, preferably both, of the handles 96, and pivot the door 12 so that the bottom of the door 12 is pulled outward from the rest of the storage unit 10. Once the door 12 has been pivoted a sufficient amount, the door 12 may be slid along the door slides 76 so that the door 12 slides relative to the cross member 46. The rollers 90 help guide the door 12 relative to the top wall 32 along the guide piece 98 in a manner in reverse of the movement discussed above, so that the door 12 opens smoothly. The door 12 moves into the door receiving space 47 between the top wall 32 and the cross member 46 as it is slid, and rests on the cross member 46 when in the fully open position 16. Once the door 12 is in the open position 16, the items that have been stored in the storage unit 10 may be accessed easily, and the support surface may be used as a work surface.

While preferred embodiments of the invention have been shown and described, they are not intended to be limiting in any respect. To the contrary, the invention is intended to encompass all variations and modifications within the spirit and scope of the appended claims.

Claims

1. A storage unit comprising: a pair of opposed side walls that are substantially parallel to each other; a rear wall connecting the side walls at rear portions thereof; a top wall connecting the side walls at top portions thereof, said top wall and said side walls defining an opening for receiving objects to be stored within said storage unit; a cross member connected to each side wall and disposed below said top wall and cooperating with said top wall to define a door receiving space within said storage unit; and a door constructed and arranged to cover said opening when said door is in a closed position, and to be received by said door receiving space when said door is in an open position.

2. A storage unit according to claim 1, further comprising a door slide for hingedly mounting said door to said cross member, said door slide allowing sliding and pivoting movement of said door relative to said cross member when said door is moved between said closed position and said open position.

3. A storage unit according to claim 2, wherein the door slide comprises a damper for dampening movement of the door relative to the cross member.

4. A storage unit according to claim 1, wherein the door rests on a top side of the cross member when the door is in the open position.

5. A storage unit according to claim 1, wherein an underside surface of the cross member is constructed and arranged to receive a light fixture.

6. A storage unit according to claim 1, wherein an underside surface of the cross member is constructed and arranged to receive a plurality of storage hooks.

7. A storage unit according to claim 1, wherein each side wall comprises a support assembly for supporting the cross member.

8. A storage unit according to claim 7, wherein each support assembly comprises a pair of substantially vertical supports and a substantially horizontal support connected to said vertical supports, said cross member being connected to said horizontal support of each side wall.

9. A storage unit according to claim 1, wherein said door comprises a roller adjacent to a top edge thereof, said roller being constructed and arranged to roll against a guide surface within the storage unit when the door is moved between the closed position and the open position.

10. A storage unit according to claim 9, wherein the door comprises a plurality of rollers adjacent to a top edge thereof.

11. A storage unit comprising: a pair of opposed side walls that are substantially parallel to each other; a rear wall connecting the side walls at rear portions thereof; a top wall connecting the side walls at top portions thereof, said top wall and said side walls defining an opening for receiving objects to be stored within said storage unit; and a door constructed and arranged to cover said opening when said door is in a closed position, and to be disposed substantially parallel to said top wall on an interior side of the top wall when said door is in an open position, said door comprising a roller adjacent to a top edge thereof, said roller being constructed and arranged to engage a guide surface within the storage unit when said door is moved between said closed position and said open position.

12. A storage unit according to claim 11, wherein the door comprises a plurality of rollers adjacent to the top edge thereof.

13. A storage unit according to claim 11, further comprising a cross member connected to each side wall such that the cross member is substantially parallel to and spaced away from said top wall to define a door receiving space within said storage unit, said door being supported by said cross member when said door is in said open position.

14. A storage unit according to claim 13, further comprising a door slide for hingedly mounting said door to said cross member, said door slide allowing sliding and pivoting movement of said door relative to said cross member when said door is moved between said closed position and said open position.

15. A storage unit according to claim 14, wherein the door slide comprises a damper for dampening movement of the door relative to the cross member.

16. A storage unit comprising: a pair of opposed side walls that are substantially parallel to each other; a rear wall connecting the side walls at rear portions thereof; a top wall connecting the side walls at top portions thereof, said top wall and said side walls defining an opening for receiving objects to be stored within said storage unit; a cross member disposed below said top wall, said cross member cooperating with said top wall to provide a door receiving region therebetween; an accessory carried by the cross member; and a door constructed and arranged to cover said opening when said door is in a closed position, and to be received by said door receiving region when said door is in an open position.

17. A storage unit according to claim 16, further comprising a door slide for hingedly mounting said door to said cross member, said door slide allowing sliding and pivoting movement of said door relative to said cross member when said door is moved between said closed position and said open position.

18. A storage unit according to claim 17, wherein the door slide comprises a damper for dampening movement of the door relative to the cross member.

19. A storage unit according to claim 16, wherein the door rests on a top side of the cross member when the door is in the open position.

20. A storage unit according to claim 16, wherein the accessory comprises a light fixture carried by an underside surface of the cross member.

21. A storage unit according to claim 16, wherein the accessory comprises an underside surface of the cross member that is constructed and arranged to received a plurality of storage hooks.

22. A storage unit according to claim 16, wherein each side wall comprises a support assembly for supporting the cross member.

23. A storage unit according to claim 22, wherein each support assembly comprises a pair of substantially vertical supports and a substantially horizontal support connected to said vertical supports, said cross member being connected to said horizontal support of each side wall.

24. A storage unit according to claim 16, wherein said door comprises a roller adjacent to a top edge thereof, said roller being constructed and arranged to roll against a guide surface within the storage unit when the door is moved between the closed position and the open position.

25. A storage unit according to claim 24, wherein the door comprises a plurality of rollers adjacent to the top edge thereof.