U.S. patent application number 12/847595 was filed with the patent office on 2011-01-27 for adjustable shelving and storage system for vehicles.
Invention is credited to Dennis M. Futo, Dale A. Panasewicz, William D. Steiger.
Application Number | 20110018411 12/847595 |
Document ID | / |
Family ID | 37892965 |
Filed Date | 2011-01-27 |
United States Patent
Application |
20110018411 |
Kind Code |
A1 |
Steiger; William D. ; et
al. |
January 27, 2011 |
ADJUSTABLE SHELVING AND STORAGE SYSTEM FOR VEHICLES
Abstract
An adjustable storage system includes one or more adjustable
storage units. The storage units generally comprise opposing panels
comprising a polymer material and one or more shelf supports means
that are integral with the panels. Shelves and/or drawers, also
made from polymer materials, may then be disposed between the
panels. Storage units may be added to the storage system by adding
additional panels. In some embodiments, adjacent storage units of a
storage unit may share a panel.
Inventors: |
Steiger; William D.;
(Louisville, KY) ; Panasewicz; Dale A.;
(Strongsville, OH) ; Futo; Dennis M.;
(Strongsville, OH) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH LLP
Two Prudential Plaza, 180 North Stetson Avenue, Suite 2000
CHICAGO
IL
60601
US
|
Family ID: |
37892965 |
Appl. No.: |
12/847595 |
Filed: |
July 30, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11237189 |
Sep 28, 2005 |
7784885 |
|
|
12847595 |
|
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Current U.S.
Class: |
312/237 |
Current CPC
Class: |
B60P 3/14 20130101; B60R
11/00 20130101; B60R 11/06 20130101; B60R 2011/0029 20130101; B60R
2011/0052 20130101 |
Class at
Publication: |
312/237 |
International
Class: |
A47B 57/00 20060101
A47B057/00 |
Claims
1-54. (canceled)
55. A modular storage system for a vehicle, the storage system
comprising: a first panel having a top, a bottom, a front edge, a
rear edge, a first surface, and a second surface, the first surface
including a drawer support channel horizontally disposed between
the front and rear edges of the first panel; a second panel
generally parallel to and spaced from the first panel, the second
panel having a top, a bottom, a front edge, a rear edge, a first
surface, and a second surface, the second surface of the second
panel being in facing relationship to the first surface of the
first panel, the second surface of the second panel including a
drawer support channel horizontally disposed between the front and
rear edges of the second panel; a first shelf extending between and
coupled to each of the first and second panels; a second shelf
extending between and coupled to each of the first and second
panels, the second shelf being beneath the first shelf; a vertical
support post coupled at an upper end to the first shelf and coupled
at a lower end to the second shelf, the support post having a first
surface in facing relationship with the second surface of the
second panel, the first surface of the support post including a
horizontally extending drawer support channel, and the support post
having a second surface in facing relationship with the first
surface of the first panel, the second surface of the support post
including a horizontally extending drawer support channel; a first
drawer slidably supported in the drawer support channel in the
first panel and in the drawer support channel in the second surface
of the support post; and a second drawer slidably supported in the
drawer support channel in the second panel and in the drawer
support channel in the first surface of the support post; wherein
each of the panels, the support post, and the drawers are made of a
polymer material.
56. The modular storage system of claim 55, wherein the first shelf
is supported in a first shelf support channel in the first panel
and in a first shelf support channel in the second panel.
57. The modular storage system of claim 56, wherein the second
shelf is supported in a second shelf support channel in the first
panel and in a second shelf support channel in the second
panel.
58. The modular storage system of claim 55, wherein the first shelf
includes a bottom surface having a recess therein, and wherein the
upper end of the vertical support post includes a protrusion
received in the recess of the first shelf.
59. The modular storage system of claim 58, wherein the protrusion
is received in the recess with a snap-fit engagement.
60. The modular storage system of claim 55, wherein the second
shelf includes an upper surface having a recess therein, and
wherein the lower end of the vertical support post includes a
protrusion received in the recess of the second shelf.
61. The modular storage system of claim 60, wherein the protrusion
is received in the recess with a snap-fit engagement.
62. The modular storage system of claim 55, wherein each of the
drawers includes flanges slidably received in the respective drawer
support channels.
63. The modular storage system of claim 62, wherein at least one of
the drawer support channels includes a drawer stop that cooperates
with the flanges to limit travel of the drawers.
64. The modular storage system of claim 63, wherein the drawer stop
includes a stop wall formed in the drawer support channel.
65. The modular storage system of claim 64, wherein the stop wall
engages a projection on the drawer.
66. The modular storage system of claim 65, wherein the projection
on the drawer is integrally formed with a flange of the drawer.
67. The modular storage system of claim 55, wherein the first
surface of the first panel includes a second drawer support
channel, the second surface of the second panel includes a second
drawer support channel, and the first and second surfaces of the
vertical support post each include a respective second drawer
support channel, and wherein the modular storage system further
includes a third drawer slidably supported in the second drawer
support channel in the first panel and in the second drawer support
channel in the second surface of the support post; and a fourth
drawer slidably supported in the second drawer support channel in
the second panel and in the second drawer support channel in the
first surface of the support post.
68. The modular storage system of claim 55, wherein the vertical
support post is positioned about midway between the first and
second panels.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent
application Ser. No. 11/237,189 filed on Sep. 28, 2005, the entire
content of which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosures relates to a storage system for
vehicles. More specifically, the present disclosure relates to a
modular storage system for use in vehicles. It finds particular
application in conjunction with vehicles such as, for example,
cargo vans and the like, and will be described with particular
reference thereto. It is to be appreciated, however, that the
present exemplary embodiment is also amenable to other like
applications.
BRIEF DESCRIPTION
[0003] Service professionals, e.g., plumbers, contractors, cable or
telephone installers, electricians, etc., are commonly required to
carry in their vehicles a large number and variety of tools, parts,
equipment, and the like necessary to perform their work. The tools,
parts, equipment, etc., can range from large or bulky tools or
large spools of cable to smaller tools, fasteners, spare parts,
etc. As such, it is known to equip service vehicles with storage
units to house items of various sizes.
[0004] Many of the storage units known in the art are steel units
that include steel end panels, a back panel and steel shelving. The
shelves of these storage units are essentially tray structures
having a bottom and four sides extending perpendicular from and
perpendicular to the bottom. The shelves are fitted between the two
end panels adjacent the back panel to provide a storage unit. The
shelves are held in position by connecting the shelves directly to
each of the end panels and the back panel. The shelves may be held
in position by welding the sides of the shelves to the end panels
and the back panel or by mechanical fasteners connecting the
shelves to each of the end and back panels through the sides of the
shelves.
[0005] There are several disadvantages associated with these known
storage units. Storage units known in the art are essentially as-is
structures that are not easily reconfigurable or adjustable. It may
be advantageous or even necessary for a worker to house an item in
the vehicle for which no space currently exists. Therefore, it
would be beneficial for the worker to be able to reconfigure the
storage system in his vehicle by moving, adding or removing
shelving, drawers, etc. Shelves that are welded to the end and back
panels are not removable (or, at least, not easily removed). In the
storage unit described above, shelves or drawers are connected to
both back panels and the end panels and therefore cannot be
adjusted or reconfigured without either completely removing the
unit from the vehicle or unmounting the end panels and back
panel.
[0006] Additionally, several disadvantages are associated with the
all steel construction of the storage units. First, the all steel
construction may create a noisy environment. When empty, the steel
units are prone to rattling during the operation of the vehicle.
The noise level may be increased when the units are filled with
various equipment including metal tools or parts. Second, the all
steel units can be rather heavy, and added weight to a vehicle may
increase fuel consumption for operation of the vehicle and increase
the cost to operate the vehicle.
[0007] Therefore, there is a need for a storage system and storage
units for vehicles that are modular, reconfigurable, and/or
customizable by the user. Further, there is also a need for a
storage unit or system for vehicles wherein the means for adjusting
or reconfiguring the system is easily accessible to the user.
Additionally, there is also need for a storage system that is
lighter in weight compared to conventional storage units.
SUMMARY OF THE INVENTION
[0008] The disclosure provides in various embodiments thereof, a
modular storage system for a vehicle having a front, a back, a
curb-side, and a street-side, the storage system comprising a first
support panel having a top, a bottom, a front edge, a rear edge, a
first surface, and a second surface, the second surface comprising
one or more shelf support means disposed between the front and rear
edges of the second surface of the first panel; a second support
panel having a top, a bottom, a front edge, a rear edge, a first
surface oriented toward the second surface of the first panel, and
a second surface, the second panel disposed generally parallel to
the first panel and comprising one or more shelf support means
disposed between the front and rear edges of the first surface of
the second panel and opposite the shelf support means of the first
panel; and a shelf dimensioned for removable receipt between the
first and second panels, the shelf being supported by the shelf
support means, wherein the first panel, the second panel, and the
shelf are formed from a polymer material.
[0009] The disclosure also provides, in various embodiments
thereof, a modular storage unit for a vehicle having a front, a
back, a curb-side, and a street-side, the storage unit comprising
(a) a first panel having a top, a bottom, a front edge, a first
surface, and a second surface opposite the first surface, the
second surface comprising at least one channel recessed relative to
the second surface and horizontally disposed between the front and
rear edges of the first panel; and (b) a second panel generally
parallel and opposite the first panel, the second panel having a
top, a bottom, a front edge, a rear edge, a first surface, a second
surface, the first surface of the second panel being oriented
toward the second surface of the first panel, and at least one
shelf support channel recessed relative to the first surface of the
second panel and horizontally disposed between the front and rear
edges of the second panel; wherein the first panel and the second
panel comprise a polymer material.
[0010] Additionally, the disclosure provides, in various
embodiments, a kit for forming a modular storage system for a
vehicle comprising a plurality of panels having a top, a bottom, a
first surface, a second surface, a front edge, and a rear edge, at
least one of the first and second surfaces of the panels comprising
one or more shelf support means horizontally disposed between the
front and rear edges of the panels for receiving a shelf.
[0011] The disclosure also provides, in various embodiments
thereof, a modular storage unit for a vehicle having a front, a
back, a curb-side, and a street-side, the storage unit comprising
(a) a first panel having a top, a bottom, a front edge, a first
surface, and a second surface opposite the first surface, the
second surface comprising at least one drawer slide channel
recessed relative to the second surface and horizontally disposed
between the front and rear edges of the first panel; and (b) a
second panel generally parallel and opposite the first panel, the
second panel having a top, a bottom, a front edge, a rear edge, a
first surface, a second surface, the first surface of the second
panel being oriented toward the second surface of the first panel,
and at least one drawer slide channel recessed relative to the
first surface of the second panel and horizontally disposed between
the front and rear edges of the second panel, the drawer slide
channels dimensioned for receiving a drawer; wherein the first
panel and the second panel comprise a polymer material.
[0012] The disclosure also provides, in various embodiments
thereof, a modular storage system for a vehicle having a front, a
back, a curb-side wall, and a street-side wall, the storage system
comprising (i) a first storage unit disposed along the curb-side
wall, the first storage unit comprising (a) a first support panel
having a top, a bottom, a front edge, a rear edge, a first surface,
and a second surface, the second surface comprising one or more
shelf support means disposed between the front and rear edges of
the second surface of the first panel; and (b) a second support
panel having a top, a bottom, a front edge, a rear edge, a first
surface oriented toward the second surface of the first panel, and
a second surface, the second panel disposed generally parallel to
the first panel and comprising one or more shelf support means
disposed between the front and rear edges of the first surface of
the second panel and opposite the shelf support means of the first
panel; and (ii) a second storage unit disposed along the
street-side wall, the second storage unit comprising (a) a third
support panel having a top, a bottom, a front edge, a rear edge, a
first surface, and a second surface, the second surface comprising
one or more shelf support means disposed between the front and rear
edges of the second surface of the third panel; and b) a fourth
support panel having a top, a bottom, a front edge, a rear edge, a
first surface oriented toward the second surface of the third
panel, and a second surface, the fourth panel disposed generally
parallel to the third panel and comprising one or more shelf
support means disposed between the front and rear edges of the
first surface of the fourth panel and opposite the shelf support
means of the third panel; and wherein the support panels are formed
from a polymer material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective of the cargo bay of a vehicle
containing adjustable shelving systems with one swung away from its
normal position for clarity;
[0014] FIG. 2 is an exploded view of one segment of the shelving
system depicted on the left hand side of the vehicle in FIG. 1;
[0015] FIG. 3 is an enlarged cross sectional view of a portion of a
vertical panel of a storage unit and supported adjacent shelves on
either side of the panel;
[0016] FIG. 4 is a front plan view of a portion of a storage unit
having a number of drawers, the drawers being shown in phantom;
[0017] FIG. 5A is an enlarged cross sectional view of the upper
portion of the center drawer mounting system in FIG. 4;
[0018] FIG. 5B is an enlarged cross sectional view of the lower
portion of the center drawer mounting system in FIG. 4;
[0019] FIG. 6 is a cross sectional view of the storage unit of FIG.
4 taken along the lines 6-6 showing the drawers in a closed
position;
[0020] FIG. 6A shows the view of FIG. 6 with the drawers in an open
position;
[0021] FIG. 7 is an enlarged cross sectional view of the drawer
slide in FIGS. 6 and 6A taken along line 7-7;
[0022] FIG. 8 is a cross sectional view of the storage unit in FIG.
4 taken along the line 8-8 showing a center drawer mounting system
disposed between two (2) shelves;
[0023] FIG. 9 is a side elevational view of the center drawer
mounting system in FIG. 8;
[0024] FIG. 10 is a front plan view of a storage unit having a door
between the top and middle shelves of the unit;
[0025] FIG. 10A is a front plan view of a storage unit with a door
between the middle and bottom shelves of the storage unit;
[0026] FIG. 10B is an enlarged cross sectional view of the storage
unit in FIG. 10A taken along the lines 10B-10B;
[0027] FIG. 11 is an enlarged cross sectional view of the storage
unit of FIG. 10 showing details of the door hinge;
[0028] FIG. 12 is an enlarged cross sectional view of a portion of
the storage unit in FIG. 11 taken along the lines 12-12 (with the
shelf face not being shown in cross section);
[0029] FIG. 13 is a side view of a storage unit (from the rear of
the vehicle) having a door, the door being shown in a fully opened
position;
[0030] FIG. 14 is a side view (looking into the back of the
vehicle) of storage units adjacent the curb-side and street-side
walls of the vehicle and showing the cargo or aisle space available
between portions of the units;
[0031] FIG. 14A is a side view (looking into the back of a vehicle)
comparing the storage capabilities of storage systems employing
conventional end panels to storage systems employing upright panels
having curved or arcuate segments as may be employed in various
embodiments of the disclosure;
[0032] FIG. 15 is a detail showing a retainer means for positioning
a back panel on an intermediate panel;
[0033] FIG. 16 shows the positioning of a back panel and the
retainer means of FIG. 15;
[0034] FIG. 17 is a detail showing a retainer means for positioning
a back panel along an end panel;
[0035] FIG. 18 is a cross sectional side view of a shelf;
[0036] FIG. 19 is a cross sectional side view of two (2) shelves in
a nesting configuration;
[0037] FIG. 20 is a front plan view of a cubby unit;
[0038] FIG. 21 is a side plan view of the cubby unit of FIG.
20;
[0039] FIG. 22 is a front plan view of another cubby unit; and
[0040] FIG. 22A is a front plan view of a panel formed by flipping
one of and then stacking the cubby panels of FIG. 22.
DETAILED DESCRIPTION
[0041] The present disclosure relates, in various embodiments
thereof, to a modular storage system for a vehicle and modular
storage units that form or make-up the storage system. The storage
system and storage units are particularly suitable for use in a
vehicle such as a van, cargo van, truck, or the like.
[0042] Vehicles such as vans, commercial vans, cargo vans, trucks,
and the like include a forward section, a back section, a
longitudinal center line, a street-side and a curb-side. Using the
American convention for driving, the area left of the longitudinal
center line of the vehicle is referred to as the street-side and
the area right of the longitudinal center line of the vehicle is
referred to as the curb-side. The terms "street-side" and
"curb-side" are merely used for purposes of convenience. It will be
appreciated that items defined as a street-side item or a curb-side
item can be switched along the longitudinal center line of the
vehicle without departing from the scope of the disclosure.
[0043] Generally, a storage system in accordance with the present
disclosure comprises one or more individual storage units, wherein
the individual storage units are formed by opposing, generally
vertical or upright, panels. The general upright or vertical panels
are also referred to herein as support panels. One or more shelves,
or one or more drawers, may be disposed between the panels. The
major components of a storage unit, i.e., the panels, the shelves,
and/or the drawers, are formed from non-corrosive or polymeric
materials. The panels include a means for supporting the shelves
and/or the drawers. The shelf support or drawer support means may
be integral with and molded as part of the upright panels.
[0044] With reference to FIG. 1, a vehicle 30, such as a van,
includes a cargo bay 31 with storage system 33 adjacent street-side
wall 32 and storage system 39 adjacent the opposite (curb-side)
wall. Storage system 33 comprises individual storage units 34, 36,
and 38. Storage unit 34 is formed from upright panel 40 and upright
panel 50, which may include one or more shelves, such as shelves
60a, 60b, and 60c, disposed between panels 40 and 50. Storage unit
36 is formed from upright panel 50 and upright panel 50', which may
include one or more shelves or one or more drawers disposed between
panels 50 and 50'. Storage unit 38 is a cubby unit formed from
upright panel 50' and a cubby panel 202.
[0045] With reference to FIG. 2, storage unit 34 of storage system
33 is shown. Generally, storage unit 34 includes a pair of opposing
panels 40 and 50 having one or more shelves removably disposed
between the panels. Panels 40 and 50 may be releasable connected to
one another by one or more connecting members such as, front
connecting member 80 and/or back panel 82.
[0046] Panels 40 and 50 each include a first surface 41 and 51,
respectively, a second surface 42 and 52, respectively, a top 43
and 53, respectively, a bottom 44 and 54, respectively, a front
edge 45 and 55, respectively, and a back edge 46 and 56,
respectively. For purposes of convenience, the first surfaces of
the panels are described as being oriented toward the back of the
vehicle, and the second surfaces of the panels are being described
as oriented toward the front of the vehicle. The panels 40 and 50
may be positioned adjacent a side wall of the vehicle, and are
oriented opposite and generally parallel to one another. As shown
in FIG. 2, the second surface 42 of panel 40 faces the first
surface 51 of panel 50. The second surface 42 of panel 40 is a
minor image of the first surface 51 of panel 50. By the previously
described convention, in a storage system comprising more than two
upright panels, the second surface of one panel faces the first
surface of the next successive panel.
[0047] Storage unit 34 contains shelves 60a, 60b, and 60c, disposed
between panels 40 and 50. Panels 40 and 50 include one or more
shelf support means, e.g., 70a, 70b, 70c, and 70d integral with
faces 42 and 51 of panels 40 and 50 respectively. As shown in FIG.
2 and FIG. 3, the shelf support means in panels 40 and 50 are
channels 70a, 70b, 70c, and 70d, each having a generally horizontal
lower surface and a generally horizontal upper surface extending
from the front of the panels to the back of the panels. The
channels are dimensioned to receive a shelf, such as, for example,
one of shelves 60a, 60b, or 60c, with the bottom of a shelf being
supported by the lower surfaces, such as, for example, lower
surfaces 72, 72' (FIG. 3), of the respective channels.
[0048] With reference to the embodiments in FIGS. 1 and 2, the
shelves such as shelves 60a, 60b, and 60c, are positioned between
panels 40 and 50, and supported by shelf support means such as
channels 70a, 70b, 70c, and/or 70d. As shown in FIG. 3, the bottom
of a shelf, such as shelves 60b and 60b' is (are) supported by the
lower surface of a channel, such as for example, lower surfaces 72
and 72' of channels 70c and 70c', respectively.
[0049] A panel may optionally include shelf support means on both
the first and second surfaces of the panel. For example, as
depicted in FIGS. 1, 2, and 3, panel 50 includes shelf support
means along each of the first and second surfaces of the panel. In
one embodiment, such as that shown in FIGS. 1, 2, and 3, the first
and second surfaces of a panel are mirror images of each other such
that the shelf support means are positioned at the same vertical
height within the panel. Thus, as shown in FIGS. 1 and 3, a panel
such as panel 50 may support one or more shelves on each side of
the panel. Panels having shelf support means along both (upright)
surfaces provides some of the modularity to a shelving unit/system.
In particular, a panel that can accommodate shelves or drawers on
both sides allows an additional storage or shelving unit to be
added such that the storage system may be expanded.
[0050] Further, the use of such panels allows adjacent storage
units, such as units 34 and 36 in FIG. 1, to share an upright
panel, which allows for reducing the number of parts used or needed
to create a storage system. This may be beneficial to reduce the
cost to create a system. A system with fewer parts should also have
a reduced weight.
[0051] The shelves may optionally be releasably attached to the end
panel to further secure or maintain the shelf in its position
between the panels. The panels may also be releasably attached to a
panel by fasteners, screws bolts, and the like via apertures or
bores in the panels. A panel capable of supporting a shelf at the
same vertical height on each surface of the panel may include an
aperture or bore extending through the first and second surfaces of
the panel. The aperture or bore is adapted to receive a fastener
extending through one side wall of a shelf positioned on one side
of the panel, through the apertures and through the side wall of a
shelf supported along the second surface of the panel. For example,
with reference to FIG. 3, panel 50 includes shelf support means 70c
recessed relative to first surface 51 and shelf support 70c'
recessed with respect to second surface 52. Shelf 60b is supported
by lower surface 72 of channel 70c, and shelf 60b' is supported by
lower surface 72' of channel 70c'. Channels 70c and 70c' further
include vertical walls 76 and 76', respectively. Vertical walls 76
and 76' include bosses 94 and 94' having an aperture 95 extending
therethrough. Fastener 96 is positioned through an aperture in side
wall 63a of shelf 60b, through aperture 95, through an aperture of
side wall 63b' of shelf 60b'; and secured with a tightening nut
97.
[0052] A shelf support means includes any aperture or channel
adapted to receive a portion of a shelf. The size and shape of the
shelf support means may be selected as desired for a particular
purpose or intended use. The shelf support means may be channels,
such as channels 70a-70d in FIG. 2, that extend from the front of a
panel to the back of a panel. In other embodiments, the shelf
support means is a channel having an opening along the front edge
of the panel such that a shelf may be positioned between two panels
or removed therefrom by sliding the panel along the channel from
the front of the panels. A shelf support means that is an elongated
channel extending from the front of a panel may extend the full
distance between the front and back of a panel (as shown in the
embodiment in FIG. 2). In another embodiment, a shelf support
channel may have a terminal end adjacent the back of a panel. A
terminal end may act as a stop when positioning a shelf in such a
shelf support means.
[0053] In still other embodiments, a shelf support means may
include a channel adapted to receive a shelf wherein the channel
does not fully extend to either the front or the back of a panel.
In such embodiments, a shelf may be positioned, such as by
snap-fitting the shelf into the channel.
[0054] In further embodiments, a shelf support means may comprise a
ledge extending from a surface of a support panel. A ledge may be
integrally molded as part of a support panel. In one embodiment, a
shelf support means on a given panel may comprise a generally
continuous ledge extending between a front surface and a back edge
of a support panel. A generally continuous ledge may extend
substantially the entire distance between the front and back edge
or it may have a length less than the distance between the front
and back edge of a support panel. In other embodiments, a shelf
support means on a given panel may comprise a plurality of ledges
disposed at generally the same vertical height so as to define a
generally horizontal surface for supporting a shelf. The shape,
size, length, and number of ledges used to form a shelf support
means is not critical and may be selected as desired for a
particular purpose or intended use.
[0055] In other embodiments, a shelf support means includes one or
more apertures adapted to receive a corresponding projection on a
shelf. Or, in the alternative, a shelf support means may comprise a
projection on a surface of a support panel adapted to mate with a
corresponding aperture on a shelf. In such embodiments, a shelf may
be positioned by, mating the apertures and projections (such as by,
for example, snap-fitting). The shape, size, and number of the
apertures and projections is not critical and may be selected as
desired for a particular purpose or intended use.
[0056] In an exemplary embodiment, a shelf support means is a
channel having an opening along the front of a panel such that a
shelf may be easily slid into or out of the shelf support channel.
This allows for quicker reconfiguration of a shelving unit or
system and may not require removal or movement of the support
panels to reconfigure a storage unit or system.
[0057] In other embodiments, a given shelf support means in one
panel is positioned at the same vertical height of a shelf support
means in the opposing face of the next successive panel such that
opposing shelf support means lie in the same horizontal plane. The
number, location, size and shape of the shelf support means is not
limited and may be chosen to accommodate a particular vehicle or
intended use. In other embodiments, the shelf support means in all
panels, or within an individual unit may be identical.
Additionally, opposing faces of successive panels may be minor
images of one another.
[0058] The support panels may include other apertures or channels
as desired for a particular purpose or intended use. For example,
and with reference to FIG. 2, the support panels may include a
vertical slot or channel, 90, adapted to receive a vertical member
92, or support member. Vertical member 92 may be used to provide
further support to the support panels such as panels 40 and 50. In
one embodiment, the vertical member 92 is made from a metal
material and includes one or more apertures such that the vertical
member may be releasably connected or attached to the upright
support panels such as panels 40 or 50. As shown in FIG. 2, the
apertures of the vertical member 92 may be located or positioned to
correspond with apertures of connecting member 93 that serves as a
means for attaching a panel to the wall or ceiling of the vehicle.
In this way, a fastener that connects connecting member 93 with a
panel such as panel 40 extends through apertures in panel 40 and
through the corresponding apertures in vertical member 92 so as to
provide a metal-to-metal contact in attaching the panel to the
vehicle.
[0059] The vertical members 92 are not limited in any manner and
may be shaped and sized for a particular purpose or intended use.
For example, the vertical member may extend the full height of the
panel, or may have a height that is less than the full height of
the panel. The vertical member may be any shape as desired for a
particular purpose or intended use including, but not limited to,
rectangular, a cylinder, quonset-shaped, and the like.
[0060] Additionally, the panels may include means for supporting
one or more drawers between successive upright support panels. The
drawer slide means may be formed as part of the support panels,
i.e., integral with the surface(s) of the support panels, or
provided via separate pieces such as is described in co-pending
U.S. patent application Ser. No. 10/821,366, the entire disclosure
of which is incorporated herein by reference. Drawer slide means
that are integral with a panel may include projections or recessed
grooves generally extending between the front and back of a panel.
Drawer slide means formed from recessed grooves will generally
define an opening at the front of the panel dimensioned for
receiving a drawer.
[0061] In the several embodiments shown in FIGS. 1, 2, and 4-9, the
panels comprise drawer slide means that are integral with at least
one surface of the panels. The drawer slide means generally include
recessed channels. The drawer slide means may be configured (as
shown in FIGS. 1, 2 and 4-9) in a manner similar to the drawer
slide configuration described in U.S. patent application Ser. No.
10/821,366. With reference to FIG. 4, an embodiment of storage unit
34 is shown that includes large drawers 100 and small drawers 102
disposed between panels 40 and 50. As shown in FIGS. 2 and 4,
panels 40 and 50 may comprise one or more drawer slide means 110
adapted to slidably receive a drawer. Drawer slide means 110 are
integral with panels 40 and 50 and recessed relative to first and
second surfaces thereof, respectively. With reference to FIGS. 6
and 6A, drawer slides 110 comprise a channel 112 having a lower
surface 116 and an upper surface 114. Channel 112 is adapted to
receive a portion of a shelf in sliding engagement with lower
surface 116 and/or upper surface 114. The number, location, shape,
and size of the drawer slide means 110 may be selected as desired
for a particular purpose or intended use. As previously described,
the opposing faces of successive panels are preferably mirror
images of one another and thus, in embodiments comprising one or
more drawer slides, drawer slides on opposing faces of successive
panels are preferably positioned at the same vertical height on the
panel.
[0062] In one embodiment, the panels are adapted to receive one
drawer slidably positioned between opposing drawer support means.
In another embodiment, a drawer slide post, such as post 122, may
be positioned between adjacent panels, such as panels 40 and 50.
Post 122 (FIGS. 4, 5A, 5B, 8, and 9) includes drawer slide means
110' on each vertical surface of the post to allow drawers to be
positioned between panel 40 and post 122 and between panel 50 and
post 122 as seen in FIG. 4. The top and bottom of post 122 comprise
protrusions 124 and 126 respectively. The protrusions may be
knob-like protrusions of various shapes or elongated members of
various shapes. The post may be positioned between panels 40 and 50
by inserting protrusions 124 into a slot, recess, or groove 128 in
the bottom surface 68 of shelf 60b and inserting protrusion 126
into slot, recess, or groove 130 in the upper surface 69 of shelf
60c (FIGS. 5A and 5B). The protrusions are shaped to correspond to
the shape of the slot, recess, or groove into which the protrusions
are inserted. The protrusions may be sized such that the
protrusions are slightly smaller than the slot, recess, or groove
so that the protrusion may be snugly fitted into the slot, recess,
or groove, such as, for example, by snapping the protrusion into
the slot, recess, or groove.
[0063] With reference to FIGS. 5A, 5B, and 7, drawers 100 and 102
have outer walls 101a and 101b, and 103a and 103b, respectively.
Drawers 100 and 102 further include flanges 106a and 106b, and 107a
and 107b, respectively, substantially perpendicular to outer
surfaces of outer walls 101a/101b and 103a/103b, respectively. As
show in FIGS. 5A, 5B, and 7, flanges 106a/106b and 107a/107b are
integral with the outer surfaces of the respective drawer walls.
Channels 112, (FIGS. 6 and 6A) and 112' (FIGS. 8 and 9) of drawer
support means 110 and 110', respectively, are adapted to receive
flanges 106a/106b and 107a/107b respectively. The flanges 106a/106b
and 107a/107b are slidable along the lower surface 116 and 116' of
channel 112 and 112', respectively.
[0064] In one embodiment, the drawer slides may be configured to
provide a stop so that the drawer may not be pulled out beyond a
particular point. With reference to FIGS. 6, 6A, and particularly
7, a portion of panel 50 is shown depicting shelf support means 110
(FIG. 6) having channels 112 defined by upper surface 114 and lower
surface 116. The discussion with respect to the drawer support
means 110 on panels 40 and 50 is applicable to drawer support means
110' on post 122 as depicted in FIGS. 8 and 9. For ease of
discussion reference will be made to only one side of drawer 100;
it being appreciated that generally the same procedure and
operation may apply to the other side for installing/using a drawer
of this embodiment. As previously described, channel 112 is adapted
to receive a flange, such as, for example, flanges 106a and 107a,
of a drawer such as drawer 100. Drawer 100 is moved into an open or
closed position by sliding flange 106a along lower surface 116. A
drawer stop 118 is provided by a stop wall 120 integral with and
extending upwardly from the plane of lower surface 116. Stop wall
118 is integral with vertical surface 117 of channel 112 and offset
slightly from surface 51 of panel 50 such that flange 106a is
slidable along lower surface 116. Generally, a drawer may include a
protrusion or projection, such as, for example, flange 108a, along
the rear portion of the drawer. As shown in FIG. 7, flange 108a is
integral with flange 106a, and drawer 100 may be slid along lower
surface 116 until flange 108a contacts or engages stop wall 120 of
drawer stop 118. It will be appreciated that a drawer may also
include another flange (108b not shown) along the rear portion of
the drawer and adjacent or integral with flange 106b.
[0065] Optionally, the shelf support means may also include a rear
stop. For example, drawer slides 110 include rear stop 121 (FIGS. 6
and 6A).
[0066] To position a drawer such as drawer 100 in the drawer slides
depicted in FIGS. 1, 2 and 4-9, the rear portion of the drawer and
flanges 108a and 108b (not shown) are moved into upper slots 132
(FIG. 6) and 132' (FIGS. 8 and 9) until flanges 108a and 108b can
fit into an openings 133 (FIG. 6) and 133' (FIGS. 8 and 9),
respectively, defined by the distance between the edge of upper
surface 114 and the upper edge of stop wall 120 (114' and 120' in
FIGS. 8 and 9). Flanges 108a and 108b are then lowered through
openings 133 and 133', respectively, until flanges 108a and 106a
contact lower surface 116 and flanges 108b and 106b contact lower
surface 116'. At that point, the drawer, such as drawer 100, may be
slid into an open or closed position as desired along respective
lower surfaces 116 and 116' of channels 112 and 112'.
[0067] The size and shapes of the drawers and/or drawer slides are
not critical, and may be configured for a particular vehicle or
intended use. Drawer stops, e.g., 118 need not have angled walls as
depicted in FIGS. 6, 6A, 8, and 9, but may have any configuration
that will sufficiently engage a portion of a drawer to prevent the
drawer from opening or closing further. Additionally, a post
comprising drawer support means need not be utilized. Rather, in
other embodiments, drawers may be positioned using only opposing
shelf support means, and the drawers may be substantially the
entire width of a storage unit. Additionally, one or more posts
comprising shelf support means may be positioned between opposing
panels to provide more than two columns of drawers. There is no
limit to the configuration or permutations, and the embodiment in
FIGS. 4-9 is merely exemplary of one possible embodiment.
[0068] The panels may also comprise means for releasably attaching
a door to successive panels and provide a locker-type environment
in a unit. With reference to FIGS. 10-12, storage unit 34 is
depicted as having a door positioned between either shelves 60a and
60b or between shelves 60b and 60c. The door may include any
suitable means for attaching a door to the panels. For example, in
one embodiment, the doors may include pins projecting from the
sides of the doors for receipt in a corresponding slot in the
panels. One or both of the pins may be spring loaded such that a
pin may be inserted into a slot on one panel, and the (other)
spring loaded pin may be depressed such that the door may be
positioned between the panels and then the pin released into a
corresponding slot on the other panel.
[0069] With reference to FIGS. 10-12, another embodiment is shown
wherein the door comprises pins integral with and molded to the
sides of the doors. The panels each comprise slots 170 (FIG. 12)
integral with the upper surface 74 (FIGS. 11 and 12) of shelf
support means 70 so as to define an opening at the bottom of slot
170. Door 160 is positioned between panels 40 and 50 by inserting
pins 166 into the opening of slots 170. A door is held in place and
a shelf, such as, for example, shelf 60c, is positioned in the
shelf support means immediately below the slots into which the door
has been positioned. The upper surface of the front walls and/or a
portion of the side walls of the shelf maintain the door pins in
place within the slot such that the door is now rotatable between
an open and closed position about a horizontal axis.
[0070] The shape and configuration of the door is not limited in
any manner and may be selected as desired for a particular purpose
or intended use within a particular vehicle. For example, the door
may be configured to allow the door to open to a selected position.
With reference to FIGS. 11 and 13, door 160 comprises a groove or
indentation 168 along the front surface 161 of door 160. When the
door is moved into an open position the door is rotated downwardly
until the apex of the groove 168 contacts a portion of the shelf 60
thereby defining an angle .alpha.. The angle depends on the
thickness of the door panel and/or the depth of the groove 168. The
use of groove 168 allows door 160 to be opened to a position such
that the angle .alpha. is at least about 90.degree.. In the
illustrated embodiment, the angle .alpha. is greater than
90.degree., which is advantageous because it reduces the space
occupied by the door in an open position and may allow easier
access to the interior portion of the shelf. Aisle space in a truck
or van is valuable. The width of the truck or van is limited. This
limited width must often be allocated between storage units on each
side of the truck and the aisle between storage units. The aisle
must be sufficiently wide to allow excess. However, if the aisle
can be made one inch narrower by use of a door or doors that open
beyond 90.degree., the storage system can be made one inch
deeper.
[0071] The support panels (e.g., panels 40, 50, and 50') may be
sized, shaped, and configured as desired for a particular purpose
or intended use in a particular vehicle. For example, the panels
may be generally rectangular having a relatively flat front, back,
top, and bottom edges. In another embodiment, the panels may have a
generally vertical or flat front edge and a back edge that has a
generally vertical portion adjacent or near the bottom of the panel
and a curved or angled portion towards the top of the panel to more
closely mimic the shape of a vehicle's walls. In still another
embodiment, as shown in the embodiment in FIGS. 1 and 2, both the
front edge and the back edge of the panel may be curved or angled
to more closely mimic the shape of the vehicle walls. Having the
front edge of the panel mimic the shape or contour of the back edge
of the panel is desirable to maximize shelf space because the depth
of the panel would generally not decrease towards the top of the
panel. Consequently, shelves or drawers near the top of a unit
would not have to be less deep than those near the bottom.
Additionally, using panels that are contoured such that the depth
of the panel is essentially the same at different vertical points
aids a given panel's modularity in that a shelf at one position can
be moved to any other selected position without the need for
obtaining or locating a different sized shelf for the unit.
[0072] The support panels may also include a cut-out portion
adjacent the bottom of the panels. With reference to FIG. 2,
cut-out 190 of panel 40 is recessed relative to the front edge 45
of panel 40 and includes lower surface 192, upper surface 194, and
vertical surface 196. The shape and size of a cut-out portion is
not critical and may be selected as desired for a particular
purpose or intended use. In one embodiment, a cut-out has a square
or rectangular shape. Generally, the depth of a cut-out is not
limited except to the extent that the depth should not compromise
the structural integrity or stability of the panel(s).
[0073] The cut-out portions provide extra space in the cargo area
between storage units or systems on opposite walls of the vehicle.
With reference to FIG. 14, the effect of employing a cut-out
portion in the support panels is depicted. As shown in FIG. 14, the
vertical portions of front edge 45 of panel 40 and the front edge
of panel 39a are separated by a distance D1. A distance D2 is
provided between vertical surface 196 of cut-out 190 and vertical
surface 196' of cut-out 190' that is greater than the distance D1
between the vertical front edges of panels 40 and 39a. The cut-out
portions 190 and 190', which provide distance D2, may allow for
objects such as sheets or boards to be positioned between the
storage units 33 and 39 that would not fit within the distance D1
of the support panels. The distance D2 may be selected as desired
for a particular purpose or intended use and depends on the
distance between the support panels of opposing storage
units/systems, and the shape and depth of the cut out portions 190
(and 190'). For example, the panels may be provided to provide a
distance D2 to allow for items such as 4' by 6', or 4' by 8' boards
or sheets to be horizontally stored between the storage systems
such as storage system 33 and 39.
[0074] A plug-member may be provided to cover or generally fill-in
a cut-out area, such as, for example, cut-out 190. A plug-member
may be dimensioned for receipt in a cut-out. A plug-member may be
adapted for releasable connection to a panel member. For example,
as shown in FIG. 2, plug-member 197 includes a tab 198 with
apertures 199 adapted to receive a fastener. To fill the open area
of cut-out 190, plug-member 197 is positioned in cut-out 190. Tab
member 198 overlaps a portion of a panel, such as panel 40, and the
plug-member is releasably connected to the panel by a fastener
inserted through apertures 199 and into a surface of a panel.
[0075] While the support panels may have any shape as desired or
selected for a particular purpose or intended use, FIG. 14A
demonstrates the advantage of employing support panels having
curved or arcuate portions along the front and/or back edges of the
panels toward the top of the panels. As previously described, the
front and back ends of the support panels may be curved to more
closely mimic the shape or contour of the vehicle walls. FIG. 14A
shows how storage space may be maximized in a vehicle, such as
vehicle 400, using panels 420 and 420', in accordance with an
embodiments of the present disclosure, as compared to using
conventional panels 410 and 410'. The designation SS refers to the
street-side of the vehicle, and CS refers to the curb-side of the
vehicle. For ease of discussion in describing the shape of the
support panels, panels 410 and 410' are mirror images, and panels
420 and 420' are mirror images, and reference will be made to the
panels on one side of the vehicle. Conventional panel 410 comprises
a vertical front edge 412, a vertical back edge 414, and an edge
416 that angles out of the vertical plane of back edge 414 and
toward the top edge of panel 410. As shown in FIG. 14A, the storage
space in a system using a conventional panel, such as panel 410,
decreases toward the top of the panel because the distance between
vertical front edge 412 and edge 416 continues to decrease toward
the top of the panel. Conventional panels are also generally formed
from a metal material, and it may be expensive to form contoured or
shaped panels by stamping.
[0076] A panel, such as panel 420, that is formed from a polymer
material, however, is more amenable to molding into desired shapes,
and a shape may be provided that provides more storage space. In
FIG. 14A, panel 420 comprises a polymeric material and is shaped
similar to the embodiments shown in FIGS. 1-14. Panel 420 comprises
a generally vertical portion 421 along a front edge of the panel,
and a generally vertical portion 422 along a back edge of the
panel. The generally vertical portions 421 and 422 extend from the
bottom of the panel toward the top of the panel. The back of panel
420 includes a curved or arcuate portion 424 that extends or curves
inwardly toward the longitudinal center line of the vehicle and
upwardly toward the top and front edge of the panel. Additionally,
the front edge of the panel includes a curved or arcuate portion
426 that extends inwardly toward the longitudinal center line of
the vehicle 400 and upwardly toward the ceiling 402 of the vehicle.
Providing a panel with front and back edges that are curved or
arcuate provides additional storage space, such as the shaded space
450, as compared to conventional panels 410. By providing arcuate
front and back edges having similar degrees of curvature, the
distance between the front and back edges does not decrease. Thus,
in panel 420, for example, there is more space near the top of the
panels 420 that can be utilized for storage.
[0077] Employing panels with curved or arcuate portions allows for
tighter tolerances in fitting a shelving unit in a vehicle. For
example, providing panels with a curved or arcuate surface near the
top of the panels allows for the creation of taller panels to
better utilize the overhead space in a vehicle. While conventional
panels, such as panel 410, could be made taller, there is a
limiting return in useful storage space because the depth of the
panel decreases toward the top of the panel. The limited additional
storage space may not outweigh the cost to provide a taller unit.
With the shaped polymer panels, such as panel 420, that have curved
or arcuate edges toward the top of the panel, however, because more
useful storage space is provided and there is more incentive to
employ taller panels. Thus, the panels can be made taller to extend
into the overhead space of the vehicle. In one embodiment, for
example, a panel having curved or arcuate portions along the edges
may be provided such that there is a distance of less than two
inches between the top of the panel and the ceiling of the vehicle.
In another embodiment, this distance may be one inch or less.
Comparatively, conventional panels typically have a distance of
about five to about seven inches between the top of the panel and
the vehicle ceiling. Similarly, panels having a curved or arcuate
back edge allow for tighter tolerances along the vehicle walls.
[0078] The degree or severity of the curvature of an edge of a
panel may be selected as desired for a particular purpose or
intended use.
[0079] FIG. 14A also demonstrates the storage space that may be
available with a polymer storage panel having a cut-out portion as
compared to conventional panels without such a feature. As shown in
FIG. 14A, there is a distance 430 between the front edges of
conventional panels 410 and 410'. In certain vehicles, for example,
this distance may be about 37 inches. The use of polymer panels
having a cut-out portion, such as cut-out portions 433 and 433 in
panels 420 and 420', respectively, provides extra space 434 between
certain areas of the opposing storage units. The space 434 may be,
for example, to provide a space to store 4'.times.8' sheets.
[0080] A back panel may be provided adjacent to successive support
panels. A back panel may be provided as merely a backing to a
storage unit and/or to connect adjacent support panels. A back
panel may be held in position by any suitable means including, but
not limited to, clips, fasteners, bolts, rivets, pop rivets, and
the like. In some embodiments, a back panel is releasably connected
to a shelving unit.
[0081] In one embodiment, a back panel may be retained or
positioned adjacent the back surface of a panel by a retainer clip
molded to the back edges of the support panels. With reference to
FIGS. 15 and 16, a retainer clip on an intermediate panel, such as
for example panel 50, is shown. The retainer clip 140 includes a
base member 142 extending from and integral with rear surface 56 of
panel 50. The retainer clip includes enlarged outer member 144
extending beyond the sides of the base member 142 such that a
channel 146 is provided between back surface 56 of panel 50 and the
underside of outer member 144. Channel 146 is sized to receive a
back panel, such as back panel 82'. As show in FIGS. 15 and 16, the
retainer clip 140 provides a channel adjacent each of the first and
second surfaces of the support panel. The shape of the base member,
e.g., member 142, and/or the shape of the enlarged outer member,
e.g., member 144, may be selected as desired for a particular
purpose or intended use. For example, the sides of the base member
may be, but are not limited to, parallel, curved, or angled,
diverging sides. Similarly, the undersides of the elongated outer
member may be, but not limited to, parallel, curved or angled
relative to the back surface of the support panel.
[0082] Clips may optionally be provided, such as clip 150 in to
FIG. 17, that only include one channel for receiving a back panel.
With reference to FIG. 17, outer portion 156 of clip 150 is set off
from back surface 46 of panel 40 by walls 152 and 154 of clip 150
so as to define a channel 158 between back edge 46 of panel 40 and
the underside of outer portion 156. As shown in FIG. 17, clip 150
includes a bottom wall 152. Bottom wall 152 may be suitable for
supporting a bottom portion of a back panel and preventing the
panel from moving downwards. It will be appreciated that
intermediate panels, such as panel 50, may include clips with
bottom walls. Employing a clip having a bottom wall may eliminate
the need for further means such as fasteners or bolts to retain a
back panel in place. Even if clips with bottom walls are used, a
back panel may be fastened or bolted to a panel.
[0083] The back panels may have a height that extends from the top
of a storage unit to the bottom of a storage unit. In other
embodiments, a back panel may have a height that does not extend to
the bottom of the storage unit to accommodate any objects on the
floor including, for example, a wheel-well of the vehicle.
[0084] A back panel may include an aperture, such as aperture 84
(FIG. 2). Aperture 84 may be dimensioned for receiving a light or
fan or any other desirable feature. A light may be particularly
desirable for placement in aperture 84. A cargo area may not be
sufficiently lit, or the light may be blocked by a person moving
around in the cargo area or standing between a main light source
and a storage unit. Thus a light source disposed in aperture(s) 84
may provide sufficient lighting to a storage unit or a particular
area of the storage unit. The extra light source in a storage unit
allows a person to operate in or search through a storage unit
without having to handle an extra light source such as a flash
light.
[0085] A back panel may be formed by any suitable material,
including, but not limited to, pressboard, cardboard, plastic,
fiber reinforced plastic, and the like.
[0086] The shelves are not limited in any manner and may be shaped
and sized as desired for a particular purpose or intended use.
Generally, a shelf includes a front wall, a back wall, opposing
side walls, a shelf surface, and a bottom surface. One of the side
walls may include an aperture for releasably receiving a fastener
to secure the shelf to a respective panel.
[0087] In one embodiment, shelves may have a configuration such
that two shelves may be stacked or stored in a nesting arrangement.
This may be accomplished, in one embodiment, by providing a shelf
configuration wherein a portion of a shelf s side panels have a
height less than the height of the front and back walls of the
shelf. For example, with reference to FIG. 18, shelf 60 comprises
front wall 61, back wall 62, and side walls 63. As shown in FIG.
19, side wall 63 includes hollows 64a and 64b recessed relative to
the upper edge of side wall 63 and separated by section 65. Section
65 includes projection 66 adapted to receive a fastener to connect
a shelf to a panel. It will be appreciated that a shelf does not
have to include section 65 and could include a generally continuous
hollow or recessed area along a side wall. By providing a side wall
having a portion or portions, such as hollows 64a and 64b, with a
height less than the height of the front walls and back walls of
the shelf, a shelf may be inverted and nested with another self
such as shown in FIG. 19. In FIG. 19, shelf 60' is inverted and
positioned on shelf 60 such that the upper surface of back wall 62'
of shelf 60' contacts portion 64b of shelf 60 and portion 64b' of
shelf 60' contacts the upper surface of back wall 62 on shelf 60.
Providing shelves of a configuration that allows for two shelves to
be nested allows shelves to be stored in a manner that requires
less space than if the shelves were merely stacked on top of one
another. This is beneficial because space may be limited in many
vehicles that are already filled with tools, parts, and the
like.
[0088] A shelf surface may have any design or configuration as
desired for a particular purpose or intended use. For example, a
shelf surface may be generally flat or smooth. In another example,
a shelf may include one or more projections or grooves or channels.
Projections or channels or grooves may have any shape, height,
depth, and/or width, and may be oriented in direction as desired
for a particular purpose or intended use. As an example, a shelf
surface such as surface 69 may include projections 128 (FIG. 1). A
shelf surface such as upper surface 69 may also include slots or
grooves such as slots 130 (FIG. 1) for receiving various add on
pieces such as, for example, drawer support posts 122 (FIGS. 4, 5A,
and 5B), dividers 180 (FIGS. 1, 10, 10A, and 10B) or the like.
[0089] In one embodiment, the shelves may comprise a means for
adjusting the load rating of the shelf as is described in
co-pending application U.S. patent application Ser. No. 10/821,366,
the entire disclosure of which is incorporated herein by reference.
Shelves used in storage units in accordance with the present
disclosure are generally formed from polymer materials such as, for
example, plastics or composite materials. Because the size of the
storage units is not limited and may be any length as desired for a
particular vehicle or intended use, the shelves may have widths of
several feet or greater. Depending on the thickness of the shelf
walls and horizontal support areas, along with the strength of the
particular polymer plastic used to form the shelf, shelves several
feet long may not be able to withstand a particular load. As shown
in FIG. 18, additional supports may be used to provide additional
support to a shelf within a storage unit. Specifically, FIG. 18
shows a shelf 60 having a bottom surface 68. Shelf 60 includes
slots 67a, 67b, and 67c offset upwardly from bottom surface 68.
Slots 67a-c extend lengthwise (between the side walls of the shelf)
along the bottom of the shelf. As shown in FIG. 18, slots 67a-c are
dimensioned to mate with and surround three sides of the square
tube or bar 240. Preferably, bar 240 is dimensioned to snap into
slots 67a-c and fit snugly therein. Preferably, the support bars
are dimensioned so that the lower (exposed) extremity of the bar is
substantially coplanar with the bottom surface of the shelf such
that the support bar will contact the upper surface of a shelf
support. The support bars may also be dimensioned so that the lower
extremities of the bar are not coplanar with the bottom surface of
the shelf but slightly recessed. In that case, the bar would not
contact the upper surface of the shelf support. The bars, such as
bars 240, provide further support across the width of the shelf so
that the shelf is able to support a greater load. Bars or beams
having different cross-sectional shapes, such as, but not limited
to, a u-shape, rectangle, quonset-shape cylinder, or the like can
also be used.
[0090] The use of support bars positioned in widthwise slots of a
shelf provides a method for adjusting the load rating of a shelf.
Specifically, a shelf that is not further supported by any support
bars has a first load rating. A shelf that is supported along the
width of the shelf by one bar has second load rating, and so forth.
Thus, a shelf may have N+1 load ratings were N is the number of
widthwise slots in the shelf bottom surface to accommodate bars
such as, for example, bar 240. The load rating may, therefore, be
adjusted by either adding or removing bars as needed for the
intended use. Thus, for example, in FIG. 19, shelf 60 would have
four load ratings, i.e., one load rating without any support bars,
and three additional load ratings depending on whether one, two or
three bars are positioned within slots 67a, 67b, or 67c. There is
no limit as to the number of widthwise slots that a shelf may have
(on the bottom surface). Because the supports are tightly
restrained in the slots 67a-c, they are prevented from
rattling.
[0091] The support bar 240 is not limited in any manner. A support
bar may be configured in any shape and made from any material to
provide the desired support for a particular use. For example, a
support bar may be made from steel or extruded aluminum or a fiber
reinforced composite. Alternatively, a support bar may be molded
inside the shelves. That is, the bars may be encapsulated within a
shelf. While encapsulating support bars in the shelves may increase
the load rating of a particular shelf, encapsulating the support
bars within the shelf does not allow for the load rating of the
shelf to be adjusted.
[0092] A storage system in accordance with the present disclosure
may optionally include a cubby unit. A cubby unit may be a
completely separate structure or it may be formed using a wall of
another storage unit. In one embodiment, for example, a cubby unit
may be formed by closely spacing two support panels.
[0093] With reference to FIG. 1, cubby unit 38 is formed by closely
spacing cubby panel 202 adjacent a support panel such as panel 50'.
The height of cubby panel 202 may be selected as desired for a
particular purpose or intended use. In one embodiment, cubby panel
202 is about 50% of the height of support panel 50'. In another
embodiment, cubby panel 202 is greater than about 50% of the height
of a support panel such as panel 50'.
[0094] In another embodiment, a cubby unit may be an individual
unit separate from the other shelving units in a shelving system.
With reference to FIGS. 20 and 21, a cubby unit is shown comprising
an upright cubby panel 202a and an upright cubby panel 202b
opposite and generally parallel to cubby panel 202a. Each of the
cubby panels includes a first surface, a second surface, a front
edge, a rear edge, a top, and a bottom. The cubby panels 202a and
202b may be connected by a connecting member such as connecting
member 210 along the bottom of the cubby panels. The cubby unit 200
may include shelf support means such as shelf support means 70 and
one or more shelves such as shelves 220a and 220b supported by the
shelf support means. The cubby panels may also include drawer
slides such as drawer slides 110.
[0095] Cubby panels 202a-202d in FIGS. 20 and 21 have a different
configuration than cubby panel 202 in FIG. 1. In FIG. 1, cubby
panel 202 comprises shelf and drawer support channels on only one
face of the panel. Cubby panels 202a-202d are shown having shelf
and drawer support channels on both the first and second surface
such that another storage unit panel or other cubby panels may e
added on either side of the cubby unit.
[0096] The cubby panels in FIGS. 20 and 21 have a configuration
that allows a panel to be stacked on top of the other panel in a
mating relationship, which allows for creating for a taller cubby
unit if desired. As shown by the dashed lines in FIGS. 20 and 21,
cubby unit 200 may include cubby panel 202c stacked on top of cubby
panel 202a and cubby panel 202d stacked on cubby panel 202b. Cubby
panel 202a includes an upper surface 204a and a ledge 205a, and a
bottom surface 206a and an inverted ledge 207a. Cubby panel 202c is
identical to cubby panel 202a and includes and upper surface 204c
and an upper ledge 205c as well as a lower surface 206c and an
inverted ledge 207c. The upper surface 204a and ledge 205a are
shaped and dimensioned to mate with the inverted ledge and lower
surface of another panel, e.g., inverted ledge 207c and lower
surface 206c, respectively, of cubby panel 202c. Cubby panel 202d
is stacked on top of cubby panel 202b in a manner similar to the
stacking of panel 202c on panel 202a. The interaction of the ledges
and upper surfaces prevents the top cubby from sliding sideways
with respect to the bottom cubby.
[0097] Cubby panels may also include one or more apertures adjacent
each of the top and bottom ledges of the panels to allow stacked
cubby panels to be releasably connected together and prevent
stacked cubby panels from sliding forward and/or backward relative
to each other. For example, as shown in FIG. 21, panel 202b
includes apertures 212b adjacent the bottom of the panel and
aperture 214b adjacent the top of the panel. When cubby panel 202d
is stacked on panel 202b, the panels may be releasably connected
via, for example, a fastener, through apertures 214b of panel 202b
and corresponding apertures 212d (not visible) of panel 202d.
[0098] Similar to the support panels, the cubby panels may include
apertures through which a shelf may be releasably secured to a
cubby panel. For example, cubby panels 202b and 202d include
apertures 216b and 216d, respectively, disposed between the shelf
supports of the cubby panels.
[0099] Cubby panels may include generally vertical channels. For
example, cubby panels 202b and 202d include vertical channels 218b
and 218d, respectively. When a cubby unit is formed by stacking
cubby panels, a channel may be formed by channels 218b and 218d
that is substantially similar to channel 90 previously described
herein and dimensioned for receiving a vertical member. That is, in
one embodiment, when stacked, channels 218b and 218d may be taken
as a single channel similar to channel 90 of the support panels. A
vertical member may be disposed within the channels 218b and 218d
and, similar to that of a vertical member disposed within a
vertical channel of a support member, provide a metal-to-metal
contact point between a cubby unit and a connecting member that
connects a cubby unit to a portion of a vehicle. In another
embodiment, a vertical member disposed within the vertical channels
of stacked cubby units may be releasably connected to the cubby
panels to prevent the stacked panels from sliding forward or
backward relative to one another.
[0100] As previously mentioned, using stackable cubby panels to
create a cubby unit wall or a cubby unit allows for creating taller
units. This feature may be beneficial to create cubby units in
different sized vehicles. For example, a system or kit may include
a cubby panel or panels that have a height of about 50% of the
upright panels used for the other storage units. In another
embodiment, a cubby panel may have a height greater than about 50%
of the height of a support panel. In one embodiment, a cubby panel
may have a height that is about 75% the height of the support
panels. The height of a cubby panel is not critical and may be
selected as desired for a particular purpose or intended use. A
first vehicle, however, may have a height in the cargo area that
could not accommodate a cubby unit formed from stacking the cubby
panels. A second vehicle may have a cargo area height that could
accommodate a cubby unit formed from the stacked cubby panels. Thus
the same panels in one vehicle may be used to create a different
(sized) unit in another vehicle.
[0101] In another embodiment, cubby panels may be configured such
that opposing panels may be stacked to form a single, taller cubby
panel (or storage panel). With reference to FIG. 22, a cubby unit
300 is shown comprising cubby panels 302 and 304. Cubby panels 302
and 304 comprise first and second surfaces, the first (outer)
surface of each panel being generally planar, and the second
(inner) surface of each panel comprising shelf support channels 306
and drawer slide channels 308. Panels 302 and 304 are essentially
mirror images of each other, with the second (inner) surfaces of
the opposing panels facing each other. The cubby panels 302 and 304
are connected along a bottom, front edge of the panels by connector
member 310. The cubby unit 300 could comprise one or more shelves
or drawers, but is shown in FIG. 22 without such storage features.
A taller cubby panel 320 (FIG. 22A) may be formed by disconnecting
connector member 310 and flipping or inverting panel 302 and
placing top edge 303 of panel 302 on top edge 305 of panel 304.
Panels 302 and 304 may be connected in any suitable manner to
prevent the panels from slipping in either a front-to-back or
side-to-side manner. For example, a connector member could be
releasably fastened to any of the inner surface, outer surface,
front edge, and/or back edge of the panels. The new panel 320 may
then be positioned adjacent another cubby panel or support panel as
desired to provide a new storage space for a vehicle. It will be
appreciated that a new panel could also be created by inverting or
flipping panel 304 onto panel 302.
[0102] The ability to invert a panel may be desirable in the field
where a vehicle may not have additional pieces necessary to form a
different panel structure. For example, a vehicle may not have the
capacity to store extra cubby panels to form a taller section. Or,
cubby panels, such as: for example, 302 and 304, could be removed
from one vehicle in which they are used to form a cubby unit, such
as 300, and then inserted into a separate vehicle as a taller panel
simply by inverting the cubby panels to form the taller
structure.
[0103] The shape, size, and general configuration of a cubby panel
may be selected as desired for a particular purpose or intended
use. The cubby panels may include features similar to those of the
upright vertical panels of the storage units, including, for
example, shelf support means, drawer support means, cut-out
portions, vertical channels for receiving a vertical member, and
the like. Similar to the upright or support panels of a storage
unit, a cubby panel may include such features only on one side of
the cubby panel or may include such features on both sides, such
that a storage system may be expanded by adding additional
upright/support panels or cubby panels. It will also be appreciated
that a cubby panel may have a generally planar upper surface and
does not have to have a ledge configuration as shown in FIGS. 1,
20, and 21.
[0104] The primary components of an individual storage unit, e.g.,
support panels, cubby panels, shelves, drawers, doors, dividers, of
a shelving unit/system in accordance with the present disclosure
are formed from a material other than metal. The components are
formed from a polymer material such as plastic materials. Suitable
plastic polymers include, but are not limited to, polyethylenes,
polypropylenes, polystyrene, acrylonitrile-butadiene-styrene
resins, phenolic resins, polyurethanes, polyolefins,
polyisocyanurates, and the like. The polymer materials may also be
composite materials, i.e., a polymer matrix reinforced with a fiber
or other reinforcing material having a sufficient length to
thickness ratio to provide a desirable reinforcing function in one
or more directions. In one embodiment, the polymer material is a
foamed polymer. Foamed polymers are also known as cellular
polymers, polymeric foams, and expanded polymers. Examples of
suitable foamed polymers include, but are not limited to, cellular
polystyrene, polyurethane foams, polyisocyanurate foams, phenolic
foams, cellulose acetate, and polyolefin foams.
[0105] The components of a storage unit/system in accordance with
the present disclosure may be formed by any suitable molding method
including, but not limited to, injection molding, blow molding,
vacuum forming, and the like. Foamed polymers may be formed by
injection molding, blow molding, extrusion, casting, vacuum
forming, and the like.
[0106] A storage system in accordance with the disclosure is
modular in a number of difference aspects. In one aspect, an
individual storage unit is modular in that shelves, drawers, doors,
dividers, and the like may be removed and/or repositioned to
provide different size spaces to meet a particular storage need.
Additionally, the length of an individual storage unit is
changeable by changing the distance between support panels.
[0107] In another aspect, a storage system comprising at least two
storage units may be reconfigured by adding or removing storage
units. In some embodiments, the storage units of a storage system
may be separate storage units positioned adjacent one another. In
other embodiments, such as, for example, storage system 33 in FIG.
1, adjacent storage units share a support panel (e.g., panel 50 is
shared by storage units 34 and 36). Additional storage units could
be added by simply adding support panels. Additionally, the size of
one storage unit maybe changed without the need to change the size
of another unit in the system.
[0108] A storage unit or storage system may be reconfigured in any
way desired for a particular purpose or intended use. The above
combinations, embodiments, and examples of how a storage unit or
system may be reconfigured are merely exemplary embodiments and
examples of a few of the numerous combinations or
configurations.
[0109] A kit may also be provided that includes one or more of at
least one of the components to form a storage unit or system in
accordance with the disclosure. For example, a kit may include two
or more support panels, one or more shelves, one or more drawers,
doors, dividers, etc. A kit that includes shelves may include
shelves of different lengths to form storage units, including cubby
units, of different sizes.
[0110] The exemplary embodiment has been described with reference
to the specific embodiments disclosed herein. Modifications and
alterations may occur to others upon reading and understanding the
preceding detailed description. It is intended that the exemplary
embodiment be construed as including all such modifications and
alterations insofar as they come within the scope of the appended
claims or the equivalents thereof.
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