Patent Application
20150123530
1. Field of the Invention
The disclosed and claimed concept relates to storage units and, more specifically, to a storage unit that includes a number of modular assemblies.
2. Background Information
Storage units, such as but not limited to storage units constructed primarily of sheet metal, are known. One common storage unit assembly includes a frame assembly to which a number of sheet metal panels are coupled. This configuration has several disadvantages. For example, a storage unit in this configuration typically requires the manufacturer to produces elements of a specific size for each size of storage unit. That is, for example, a storage unit with a floor space measuring four feet by eight feet requires the manufacturer to produce two four foot wide panels and two eight foot wide panels as well as corresponding frame members. The manufacturer must further produce a floor element measuring about four feet by eight feet. Further, if the manufacturer produces a storage unit measuring four feet by ten feet, the manufacturer must produce two four foot wide panels and two ten foot wide panels as well as corresponding frame members and a floor element measuring four feet by ten feet. The manufacture of specific sized elements is expensive.
Further, such storage units are commonly assembled by fasteners passed from the outer side of the panels into the frame members. In this configuration, the fastener heads are disposed on the outer side of the storage unit. Thus, a patient, but morally challenged person, may gain access to the storage unit's enclosed space by removing the fasteners and then removing a panel.
Further, the panels, typically, must be braced. Thus, the frame assembly requires additional members to assist in supporting the panels.
Further, the panels often include corrugations. When such panels are coupled to a frame member, such as but not limited to a square tubular frame member, there are gaps between the corrugations and the frame member that allow liquids and insects ingress into the storage unit.
There is a need for an improved storage unit that addresses such disadvantages.
These needs, and others, are met by at least one embodiment of this invention which provides a storage unit including a floor assembly, a sidewall assembly, and a lid assembly. The sidewall assembly includes a number of modular corner members and a number of modular panel members. The sidewall assembly includes a lower perimeter and an upper perimeter. The sidewall assembly lower perimeter is coupled to said floor assembly with the sidewall assembly extending upwardly from said floor assembly. The lid assembly is movably coupled to said sidewall assembly and is structured to move between a closed, first position and an open, second position. The floor assembly, the sidewall assembly and said lid assembly define an enclosed space. Use of the modular sidewall members and, in an exemplary embodiment a modular floor assembly, allows the manufacturer to produce storage units of different sizes at a minimal cost. That is, the size of the storage unit can be increased or decreased by adding or removing the modular sidewall units.
Further, the modular sidewall units include inwardly extending flanges that are coupled in an abutting interface. The abutting interface resists the ingress of liquids, insects and other undesirable environmental elements. The abutting interface is, in an exemplary embodiment, enhanced by a U-splice element that provides additional abutting interfaces as well as a seam cross member. The features of the U-splice element further resist the ingress of undesirable environmental elements.
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
Directional phrases used herein, such as, for example, clockwise, counterclockwise, left, right, top, bottom, upwards, downwards and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.
As used herein, the singular form of “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are directly in contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other. Accordingly, when two elements are coupled, all portions of those elements are coupled. A description, however, of a specific portion of a first element being coupled to a second element, e.g., an axle first end being coupled to a first wheel, means that the specific portion of the first element is disposed closer to the second element than the other portions thereof. Further, an object resting on another object held in place only by gravity is not “coupled” to the lower object unless the upper object is otherwise maintained substantially in place. That is, for example, a book on a table is not coupled thereto, but a book glued to a table is coupled thereto.
As used herein, the statement that two or more parts or components “engage” one another shall mean that the elements exert a force or bias against one another either directly or through one or more intermediate elements or components.
As used herein, the word “unitary” means a component is created as a single piece or unit. That is, a component that includes pieces that are created separately and which are then coupled together as a unit is not a “unitary” component or body.
As used herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).
As used herein, a “coupling assembly” includes two or more couplings or coupling components. The components of a coupling or coupling assembly are generally not part of the same element or other component. As such, the components of a “coupling assembly” may not be described at the same time in the following description.
As used herein, a “coupling” or “coupling component(s)” is one or more component(s) of a coupling assembly. That is, a coupling assembly includes at least two components that are structured to be coupled together. It is understood that the components of a coupling assembly are compatible with each other. For example, in a coupling assembly, if one coupling component is a snap socket, the other coupling component is a snap plug, or, if one coupling component is a bolt, then the other coup component is a nut.
As used herein, “associated” means that the elements are part of the same assembly and/or operate together, or, act upon/with each other in some manner. For example, an automobile has four tires and four hub caps. While all the elements are coupled as part of the automobile, it is understood that each hubcap is “associated” with a specific tire.
As used herein, “correspond” indicates that two structural components are sized and shaped to be similar to each other and may be coupled with a minimum amount of friction. Thus, an opening which “corresponds” to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction. This definition is modified if the two components are said to fit “snugly” together or “snuggly correspond.” In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases. If the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening. This definition is further modified if the two components are said to “substantially correspond.” “Substantially correspond” means that the size of the opening is very dose to the size of the element inserted therein; that is, not so close as to cause substantial friction, as with a snug fit, but with more contact and friction than a “corresponding fit,” i.e., a “slightly larger” fit. Further, as used herein, “loosely correspond” means that a slot or opening is sized to be larger than an element disposed therein. This means that the increased size of the slot or opening is intentional and is more than a manufacturing tolerance. Further, with regard to a surface formed by two or more elements, a “corresponding” shape means that surface features, e.g. curvature, are similar.
As used herein, “structured to [verb]” means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb. For example, a member that is “structured to move” is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies.
As used herein, “at” means on or near.
As used herein, a “modular” element is one element of a number elements wherein the “modular” elements have substantially the same configuration and/or wherein the “modular” elements are interchangeable.
As used herein, a “brace” is a construct capable of transferring more than a minimal load. Further, as used herein, a “brace” includes a construct having a planar assembly with a flange, or flanges, extending generally perpendicular to the plane of the planar assembly.
As used herein, a “U-shaped” element, or an element with a “U-shaped cross-section,” includes two tines, which correspond to the vertical elements of the “U” and a “bight” which corresponds to the generally horizontal element of the “U.” That is, as used herein, it is inherent that a “U-shaped” element includes a bight and two tines. Further, a “U-shaped” element, or an element with a “U-shaped cross-section,” includes elements wherein the tines and the bight are at generally right angles. That is, “U-shaped” does not require the bight to be curved.
As used herein, an “abutting interface” is a construct wherein two substantially planar surfaces are coupled, or directly coupled, with the planar surfaces disposed generally parallel to each other and overlapping each other. Further, a “partially abutting interface” is a construct wherein two generally planar surfaces, e.g. a planar member with corrugations, are coupled with the planar surfaces disposed generally parallel to each other and overlapping each other.
As used herein, a “linear interface” is a construct wherein a curved surface is coupled, or directly coupled, to a generally planar surface along a line.
As used herein, a “corner body” is a body including two generally planar members disposed generally perpendicular to each other. The two planar members meet at a vertex, i.e. the planar members do not intersect each other.
As shown in
As shown in
As shown in
In an exemplary embodiment, each lower channel assembly channel member body 52 has a thickness, i.e. each lower channel assembly channel member body bight 54 has a height, corresponding to the total thickness of a modular floor element body 30. Stated alternately, the lower channel assembly channel member body tines 56, 58 are spaced to correspond to the thickness of a modular floor element body 30. When the lower channel assembly 24, as a whole, has a generally rectangular shape, the lower channel assembly 24 includes a first lateral channel member 62, a second lateral channel member 64, a front channel member 66, and a rear channel member 68. It is noted that on one pair of opposing lower channel assembly channel members 50, i.e. either the first lateral channel member 62 and the second lateral channel member 64, or, the front channel member 66 and the rear channel member 68, at least one set of lower channel assembly channel member body tabs 60 do not extend to the ends of the associated lower channel assembly channel members 50. As shown in
Further, in another exemplary embodiment, the lower channel assembly 24 includes a number of “feet” 70. The feet 70 are similar and only one is described. A foot 70 includes a body 72 and a coupling 74. The foot body is, in an exemplary embodiment, rigid or semi-rigid. Further, in an exemplary embodiment, each foot body has a generally square cross-section of about 1.0 inch2 and a height of about 0.25 inch. Each foot 70 is coupled to the lower side of the lower channel assembly 24. In an exemplary embodiment, each foot coupling 74 includes a passage, such as, but not limited to a circular passage that is structured to be coupled to a lug or bushing extending from the lower channel assembly 24 (neither shown.
As shown in
Each modular panel member 100 is substantially similar and, as such, only one will be described. Each modular panel member 100 includes a generally planar body 102. In an exemplary embodiment, the modular panel member body 102 is generally rectangular. Each modular panel member 100 further includes a first lateral flange 104 and a second lateral flange 106. Each modular panel member lateral flange 104, 106 extends generally perpendicular to the modular panel member body 102. In an exemplary embodiment, each modular panel member lateral flange 104, 106 has a width of between about between about 0.25 and 2.0 inches or about 0.81 inch. Each modular panel member 100 further includes an upper flange 108 and a lower flange 110. Each modular panel member upper and lower flange 108, 110 extends generally perpendicular to the modular panel member body 102. In an exemplary embodiment, each modular panel member upper and lower flange 108, 110 has a width of between about 0.25 and 2.0 inches or about 0.81 inch.
In this configuration, the modular corner member lateral flanges 88, 90 and the modular panel member lateral flanges 104, 106 are substantially similar and are identified collectively by the term “lateral flange.” As described below, a modular corner member lateral flange 88 or 90 may be coupled to another modular corner member lateral flange 88 or 90 or to a modular panel member lateral flanges 104 or 106. Similarly, a modular panel member lateral flanges 104 or 106 are coupled to a either modular corner member lateral flange 88, 90, or are coupled to another modular panel member lateral flanges 104, 106. Any pair of coupled lateral flanges, 88, 90, 104, 106 is identified, and as used herein, as a “flange coupling 120” as shown in
As shown in
As shown in
In an exemplary embodiment, the sidewall assembly 14, when assembled as described below, has a generally rectangular shape. The upper channel assembly 160 corresponds to the shape of the sidewall assembly 14 and, therefore, is generally rectangular. In this configuration, the upper channel assembly 160 includes a first lateral channel member 180, a second lateral channel member 182, a front channel member 184 and a rear channel member 186. In an exemplary embodiment, the upper channel member body bight 166 of the first lateral channel member 180 and the second lateral channel member 182 extend beyond the associated upper channel member body tines 168, 170.
The lid assembly 116 includes a generally planar member 190, a number of modular brace members 192, and a number of fasteners (discussed below). The lid assembly planar member 190 is shaped to correspond to the shape of the assembled sidewall assembly 14. Thus, in an exemplary embodiment, the lid assembly planar member 190 is generally rectangular. In this configuration the lid assembly planar member 190 includes a front side 193, a rear side 194, a first lateral side 196 and a second lateral side 198. In an exemplary embodiment, the lid assembly planar member front side 193 and rear side 194 are formed into channels. That is, the lid assembly planar member front side 193 defines an inwardly facing U-shaped channel 200 including a bight 202 and two tines 204, 206. Similarly, the lid assembly planar member rear side 194 defines an inwardly facing U-shaped channel 210 including a bight 212 and two tines 214, 216. Hereinafter, the lid assembly planar member front side 193 is identified as the “front channel side 193” and the lid assembly planar member rear side 194 is identified as the “rear channel side 194.” In an exemplary embodiment, the bights 202, 212 of the front channel side 193 and the rear channel side 194 are sized to correspond to the total thickness of a lid assembly modular brace members 192 which, as described below, is about 0.75 inch. One tine 204, 214 of the front channel side 192 and the rear channel side 194 are unitary with the planar portion of the lid assembly planar member 190. In this embodiment, each of the bights 202, 212 and the tines 206, 216 are generally planar.
In another exemplary embodiment, shown in
As shown in
In an exemplary embodiment, the lid assembly 16 includes a first lid cap 240 and a second lid cap 242. The first lid cap 240 and second lid cap 242 are generally similar and, as such, only one will be described. The first lid cap 240 includes an elongated body 250 having a U-shaped cross-section. Thus, the first lid cap body 250 includes a bight 252 and two tines 254, 256. The first lid cap body bight 252 has a width that corresponds to the width of the front channel side bight 202. That is, the first lid cap body tines 254, 256 are spaced to correspond to the front channel side bight 202.
The fasteners 22, 130 discussed above may be any type of fastener. It is understood that the elements of the floor assembly 12, the sidewall assembly 14 and the lid assembly 16 include openings or passages that are aligned and through which the fasteners 22, 130 are disposed. In an exemplary embodiment, the floor assembly fasteners 22 and the lid assembly fasteners (not shown) are threaded fasteners such as, but not limited to, screws or nuts and bolts. The sidewall fasteners 130 are, in an exemplary embodiment, a fastener 130 that includes a pin 21 made from a resilient material and having an elongated body 23 with conical extensions 25, as shown in
The storage unit 10 is assembled with the various elements discussed above in the following configuration. A shown in
The lower channel assembly 24 is coupled to the modular floor elements 20 as follows. The front channel member 66 oriented so that the U-shaped channel faces the front modular floor element 46 and the tab 60 extends generally vertically. In this configuration, as shown in
The first lateral channel member 62 is coupled to the assembled modular floor elements 20 as follows. The first lateral channel member 62 is oriented so that the U-shaped channel faces the modular floor elements 20. The first lateral channel member 62 is moved over the modular floor elements 20, i.e. the modular floor elements 20 are disposed with the first lateral channel member 62 channel. In this configuration, the upper surfaces of each modular floor element body bight 32 form an abutting interface 300 with the inner surface of the lower channel assembly channel member body tine 56 with the tab 60. Further, as the distal end of the tine 58 without the tab 60 is rolled, the coupling of the wings 38, 40 to the lower channel assembly tine 58 without the tab 60 form a linear interface 302. The second lateral channel member 64 is coupled to the assembled modular floor elements 20 in a substantially similar manner. Thus, the lower channel assembly 24 is coupled to the modular floor elements 20 in a partially abutting interface.
The sidewall assembly 14 is, in an exemplary embodiment, a rectangular shape. That is, as shown, the front and rear sides include three modular panel members 100 and the lateral sides each include a single modular panel member 100. A modular corner member 80 is disposed at each corner of the rectangle. Each of the modular corner members 80 and modular panel members 100 are oriented so that the lateral flanges, 88, 90, 104, 106 extend inwardly, i.e. into the enclosed space 118. In this configuration, each modular panel member first flange 104 is coupled to one of an adjacent modular panel member second flange 106 or an adjacent modular corner member second flange 90. Further, each modular corner member first flange 88 is coupled to an adjacent modular panel member second flange 106. In an exemplary embodiment, the lateral flanges, 88, 90, 104, 106 each include a number of passages 290 disposed in substantially similar patterns. Thus, sidewall assembly fasteners 130 are passed through the lateral flange passages 290 coupling the modular corner members 80 and modular panel members 100. The fastener body 23 extends generally perpendicular to the associated lateral flanges, 88, 90, 104, 106. In this configuration, the lateral flanges, 88, 90, 104, 106 are coupled in flange coupling 120. Each flange coupling 120 forms an abutting interface 300.
In an exemplary embodiment, each flange coupling 120 also includes a U-splice element 140, as shown in
Further, in this configuration, the modular corner member upper flange portions 92A, 92B and the modular panel member upper flanges 108 are disposed generally in a plane. That is, the sidewall assembly 14 includes a substantially planar upper perimeter 320 (
That is, the upper channel members 162 are oriented in an inverted orientation, i.e. the U-shaped channel faces downwardly. The upper channel members 162 are then moved downwardly over the sidewall assembly upper perimeter 320. That is, the modular corner member upper flange portions 92A, 92B and the modular panel member upper flanges 108 are disposed within the upper channel members 162. In this configuration, the modular corner member upper flange portions 92A, 92B and the modular panel member upper flanges 108 form an abutting interface 300 with the upper channel members bight 166. As before, passages disposed in similar patterns extend through both the modular corner member upper flange portions 92A, 92B, the modular panel member upper flanges 108, and the upper channel members bight 166 so that the upper channel members 162 are fixed to the sidewall assembly upper perimeter 320. It is noted that in this configuration the upper channel assembly 160 also defines a substantially planar upper perimeter.
The sidewall assembly 14 is further coupled to the floor assembly 12 and, as shown, to the lower channel assembly 24. That is, as noted above, the lower channel assembly channel member body tine 56 with the tab 60 includes an upper, outer surface 61. The lower channel assembly channel member outer surface 61 is generally planar and extends about the lower channel assembly 24. The sidewall assembly 14 is coupled to the lower channel assembly channel member outer surface 61. That is, the modular corner member lower flange portions 94A, 94B and the modular panel member lower flanges 110 are disposed over, and coupled to, the lower channel assembly channel member outer surface 61. As before, the modular corner member lower flange portions 94A, 94B, the modular panel member lower flanges 110 and the lower channel assembly channel member outer surface 61 includes passages (not shown) disposed in similar patterns and through which fasteners are disposed. As the lower channel assembly channel member outer surface 61 and the modular corner member tower flange portions 94A, 94B and the modular panel member lower flanges 110 are all generally planar, the interface between the lower channel assembly channel member outer surface 61 and the sidewall assembly 14 forms an abutting interface.
The lid assembly 16 is assembled with each modular brace member body 220 coupled to the lid assembly planar member 190. That is, each modular brace member 192 is oriented to extend from the front channel side 193 to the rear channel side 194. In an exemplary embodiment, each modular brace member body first end 222 is disposed with the channel defined by the front channel side 193, and, each modular brace member body second end 224 is disposed with the channel defined by the rear channel side 194. Passages (not shown) in the front channel side 193, the rear channel side 194, the each modular brace member body first end 222, and each modular brace member body second end 224 allow for fasteners to fix each modular brace member 192 to the lid assembly planar member 190. Additional support members 258 extend between the outer most modular brace members 192 and the first lid cap 240 and second lid cap 242. As shown in
In this configuration the storage unit 10 includes several advantages. First, when assembled as described above, all fasteners are disposed inside the enclosed space 18. As such, when the lid assembly 16 is in the first position, and when the lockable latch 274 is in the second position and locked, the storage unit fasteners 22, 130 are not accessible. Further, in this configuration, each flange coupling 120 acts as a brace for the associated modular corner members 80 and modular panel members 100. That is, each flange coupling 120 is a brace 330.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.
