Abstract:
A tool box having a reinforced door that withstands prying and resists flexing during use. The door comprises a reinforced region including a first flange, a second flange and a third flange extending from the first edge of the door. At least one additional flap extends from an edge of the door adjacent to the reinforced region and is welded to the reinforced region to provide additional strength. In another embodiment, a second and a third additional flap is included on the door, and each additional flap may be welded to an adjacent flap or welded to the reinforced region. Multiple reinforced regions, each including at least one flange, may also extend from the door body to provide increased strength.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a Non-Provisional Utility application which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/210,732 filed Mar. 23, 2009 entitled “ROLLED TOOLBOX DOOR” which is hereby incorporated by reference in its entirety. 
    
    
     A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
     BACKGROUND 
     The present invention relates generally to an enclosure for storing items. More particularly, the present invention relates to a metal box for storing tools or other hardware, especially a rectangular sheet metal box with a hinged door having a reinforced region for improving the structural rigidity of the door. 
     Tools, hardware and other items are commonly stored in metal enclosures, generically referred to as tool boxes, for safe-keeping during periods of non-use. Tool boxes of this type are frequently placed in garages, mounted on vehicles, or kept at outdoor work sites. In these situations, public accessibility increases the likelihood of attempts by unauthorized individuals to gain access to the items stored in the tool box. Typically, to prevent theft of stored items, a tool box includes a hinged door having a locking latch for selectively restricting access to the contents of the tool box. Unauthorized individuals aimed at gaining access to the stored contents of a tool box may attempt to forcefully disengage the lock and pry the tool box open using an instrument, such as a crowbar or hammer, inserted between the edge of the tool box door and the body of the tool box. Generally, the edge of the door nearest the latch is a common target of these attempts. Such attempts may permanently deform both the tool box door and the tool box body, thereby leaving gaps between the door and tool box body, allowing theft of the stored items or permitting rain and debris to enter the enclosure, causing further damage to any remaining items. 
     A tool box may also be used as a work space for performing tasks, such as hammering, sanding, sawing, cutting or bending, on a work piece. Generally, these tasks involve the repeated application of force to a work piece. Such tasks are commonly performed using the edge of the tool box adjacent to the door to support the work piece. For example, at a construction site a worker may open a tool box door, remove a tool, close the tool box door and then begin hammering or cutting a work piece using the closed toolbox as a work space to support the work piece. Typically, such use takes place on the side of the tool box nearest the door because the user is naturally positioned on that side upon retrieval of a tool from inside the tool box. Further, where the tool box is mounted on a bench or vehicle, the side of the tool box including the door may be the only region accessible for use as a work space. This type of activity may be repeated multiple times, causing tool box doors to experience accelerated wear. Repeated high-impact use can cause injury to the user if the tool box door bends or flexes during such use, causing the work piece to unexpectedly move. 
     The ability of a tool box to withstand prying and deformation depends greatly on the mechanical strength and rigidity of the door. Others have attempted to produce tool box doors with improved strength by increasing the thickness of the door material. Although thicker material is more resistant to prying and bending, the use of thicker material increases the cost of production and adds weight to the tool box. Prior art tool boxes also include a rectangular sheet metal door bent at the edges to form a rim extending from the door. Conventional tool box doors often flex and deform when used as a work space for high-impact activities. Similarly, a single perpendicular rim does not effectively withstand attempts to pry the door open. 
     Thus, there is a need for a tool box with a reinforced door having increased rigidity for withstanding prying and resisting flexing during use. 
     BRIEF SUMMARY 
     The present invention provides a tool box for storing items. The tool box includes a reinforced door. In one embodiment, the tool box and the reinforced door are made of sheet metal. The door includes a reinforced region extending from at least one edge of the door wherein the reinforced region can include a first flange extending from the door, a second flange extending from the first flange and a third flange extending from the second flange. Additionally, the door includes a first flap extending from an edge of the door adjacent to the reinforced region. The first flap extends in the same direction as the first flange and the first flap can be welded to the reinforced region. Additional flaps or reinforced regions may also extend from the remaining edges of the door. 
     The reinforced region provides resistance to prying, preventing unauthorized individuals from gaining access to the contents of the tool box. The added strength of the door gives users a greater peace of mind that the stored articles are safe. The reinforced door also provides a safe region of the tool box for use as a work space. The present invention reduces damage resulting from use of the tool box exterior as a work space because the reinforced region provides rigid support to the door, allowing it to withstand greater forces and preventing flexing during use. Similarly, because the reinforced region and the flap provide rigid support to the entire door, the cost of production of the door can be reduced by using thinner material for the door body. 
     It is therefore a general object of the present invention to provide a tool box having a door with a reinforced edge that is resistant to damage from prying. 
     Another object of the present invention is to provide a tool box door having a rigid structure that prevents bending during use. 
     Yet another object of the present invention is to provide a tool box with a reinforced door that can be manufactured at a reduced cost using thinner door material without sacrificing structural rigidity of the door. 
     Still yet another object of the present invention is to provide a tool box door with a reinforced region that provides a rigid work space for performing tasks on a work piece. 
     Still yet another object of the present invention is to provide a reinforced tool box door with a reinforced edge that will provide a safe work space for a user. 
     Still yet another object of the present invention is to provide a tool box having a reinforced door that prevents unauthorized access to the tool box cavity. 
     Numerous other objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the following disclosure when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of a tool box consistent with the present invention. 
         FIG. 2  is a perspective view of an embodiment of a tool box consistent with the present invention. 
         FIG. 3  is a perspective view of a tool box door consistent with the present invention. 
         FIG. 4  is a perspective view of a portion of a tool box door consistent with the present invention. 
         FIG. 5  is a perspective view of a portion of a tool box door consistent with the present invention. 
         FIG. 6  is a schematic view of a tool box door consistent with the present invention. 
         FIG. 7  is an exploded view of a tool box door consistent with the present invention. 
         FIG. 8  is a sectional view showing a cross-section of Section A-A of  FIG. 7 . 
         FIG. 9  is a sectional perspective view of an embodiment of a tool box door consistent with the present invention. 
         FIG. 10  is a perspective view of one embodiment of a tool box door consistent with the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIG. 1 , there is shown generally an embodiment of a tool box  10  consistent with the present invention. The tool box  10  has a box body  16  and a door  12 . The box body  16  includes a cavity  20  for storing items and an opening  18  for accessing the cavity  20 . The door  12  is connected to the box body  16  by a hinge  106 . The door  12  includes mounting holes  104  for connecting the door  12  to the hinge  106 . In one embodiment, the mounting holes  104  are positioned on the second flange  44 .  FIG. 1  illustrates a tool box  10  with the door  12  in an open position. When the door  12  is in the open position, the cavity  20  of the tool box body  16  may be accessed through the opening  18  for retrieving or storing items. To prevent the door  12  from over-swinging on the hinge  106 , one embodiment of the tool box  10  may include one or more cables  96  fastened at one end to a first connection point  94  on the tool box door  12  and at the other end to a second connection point  98  on the tool box body  16 . 
     Referring now to  FIG. 2 , an embodiment of a tool box  10  is illustrated with the door  12  in a closed position. The door  12  includes a latch  92  for securing the door  12  to the tool box body  16  in the closed position. The latch  92  may also be used to restrict access to the cavity  20  by selectively engaging the tool box body  16  to prevent the door  12  from being opened when the door  12  is in the closed position. 
     As shown in  FIG. 3 , the door  12  includes a door body  22 . The door body  22  includes an interior surface  26 . The interior surface  26  of the door body  22  is defined as the surface of the door body  22  facing the cavity  20  when the door  12  is in the closed position. The interior surface  26  of the door body  22  is surrounded by the first edge  30 , the second edge  34 , the third edge  38  and the fourth edge  42 . The door  12  includes at least one reinforced region  24 . The reinforced region  24  includes a first flange  40 , a second flange  50 , and a third flange  60 , shown in  FIG. 5 . The first flange  40  extends from the first edge  30  of the door body  22 . In one embodiment, the first flange  40  extends from the door body  22  at an angle about 90-degrees. In one embodiment, the first flange  40  is planar. The first flange  40  extends in the direction of the cavity  20  when the door  12  is in the closed position. The first flange  40  defines a first flange interior surface  100 , shown in  FIG. 9 . The first flange interior surface  100  is defined as the surface of the first flange  40  adjacent to the interior surface  26  of the door body  22 . The second flange  50  extends from the first flange interior surface  100 . In one embodiment, the second flange  50  extends at an angle about 90-degrees relative to the first flange interior surface  100 , and the second flange is planar. The second flange  50  defines a second flange interior surface  104  positioned adjacent to the first flange interior surface  100 , shown in  FIGS. 8 and 9 . The third flange  60  extends from the second flange interior surface  104 . The third flange  60  includes a fixed edge  140  connected to the second flange  50 . The third flange  60  also includes a free edge  138  extending toward the interior surface  26  of the door body  22 . In one embodiment, the third flange  60  is planar. The free edge  138  of the third flange  60  defines a gap  58  between the door body  22  and the third flange  60 , shown in  FIG. 8 . 
     Referring again to  FIG. 3 , the door  12  includes a first flap  36  connected to the second edge  34  of the door body  22 , a second flap  44  connected to the third edge  38  of the door body  22 , and a third flap  46  connected to the fourth edge  42  of the door body  22 . In other embodiments, the door  12  may include fewer flaps. Each flap  36 ,  44 ,  46  may be welded onto the door body  22 , or may alternatively be formed by bending the door body  22 . 
     Referring now to  FIG. 4  and  FIG. 5 , a first welded region  28  connects the first flap  36  to the reinforced region  24 . In one embodiment, shown in  FIG. 4 , the first welded region  28  connects the first flap primary edge  66  to the first flange  40 . The welded region  28  may also connect the first flap  36  to the second flange  50 , as shown in  FIG. 5 . Alternatively, the welded region  28  may connect the first flap  36  to both the first flange  40  and the second flange  50 . 
     Referring now to  FIG. 6 , one embodiment including a single piece of material for forming into a door  12  consistent with the present invention is shown. Each dotted line corresponds to a region where the door  12  is bent to form a flange or a flap. Referring simultaneously to  FIG. 3  and  FIG. 6 , in one embodiment a second welded region  52  connects the first flap secondary edge  68  to the second flap primary edge  74 . The second welded region  52  is positioned to join the first flap secondary edge  68  and the second flap primary edge  74 . A third welded region  54 , connecting the second flap  44  to the third flap  46 , is positioned to join the second flap secondary edge  76  and the third flap secondary edge  84 . A fourth welded region  56  connects the third flap primary edge  82  to the reinforced region  24 . In one embodiment, the fourth welded region  56  connects the third flap  46  to the first flange  40 . In another embodiment the fourth welded region  56  connects the third flap  46  to the second flange  50 . In yet another embodiment, the fourth welded region  56  connects the third flap  46  to both the first flap  40  and the second flap  50 . 
     Referring further to  FIG. 6 , in one embodiment the door  12  is formed from a continuous piece of material, including a door body  22 . The door body  22  has a height  122  and a width  120 . The door body  22  includes a center point  32  positioned substantially at the center of the interior surface  26  of the door body  22 . This embodiment includes a first flange  40  having a width  108  and a length  110 . The second flange  50  includes a width  112  and a length  114 . The third flange  60  includes a width  116  and a length  118 . In one embodiment, the length  118  of the third flange  60  is less than the length  114  of the second flange  50  and less than the length  110  of the first flange  40 . In another embodiment, the ratio of the length  118  of the third flange  60  to the length  114  of the second flange  50  is about 0.5. In other embodiments, the ratio may vary from greater than zero to less than one. In one embodiment, the length  114  of the second flange  50  is less than the length  110  of the first flange  40 . The width  108  of the first flange  40  is about equal to the width  120  of the door body  22 . The width  112  of the second flange  50  is about equal to the width  108  of the first flange  40 , and the width  116  of the third flange  60  is about equal to the width  114  of the second flange  50 . In other embodiments, the widths and lengths of the first flange  40 , second flange  50  and third flange  60  may vary relative to each other or relative to the width  120  and height  122  of the door body  22 . 
     Referring now to  FIG. 7 , one embodiment of a door is illustrated in an exploded view, showing the exterior surface  142  of the door body  22 . Consistent with the present invention, the first planar flange  40  includes a proximal edge  160  connected to the first edge  30  of the door body  22 , and a distal edge  162 . The second planar flange  50  includes a proximal edge  164  connected to the distal edge  162  of the first planar flange  40 , and a distal edge  166 . The third planar flange  60  includes a fixed edge  140  connected to the distal edge  166  of the second planar flange  50 , and a free edge  138 . The first flap  36  is connected to the second edge  34  of the door body  22 . The second flap  44  is connected to the third edge  38  of the door body  22 , and the third flap  46  is connected to the fourth edge  42  of the door body  22 . As shown in  FIG. 8  and  FIG. 9 , the free edge  140  of the third flange  60  defines a gap  58  between the third flange  60  and the inner surface  26  of the door body  22 . 
     Referring now to  FIG. 10 , further consistent with the present invention, the door  12  may include a second reinforced region  144 . The second reinforced region may include a fourth flange  150  extending from the first flap  36 . The first welded region  28  connects the first reinforced region  24  to the second reinforced region  144 . In another embodiment, a third reinforced region  146  is connected to the second flap  44 . The third reinforced region  146  includes a fifth flange  152 . The second welded region  52  connects the second reinforced region  144  to the third reinforced region  146 . In another embodiment, referring further to  FIG. 10 , a fourth reinforced region  148  is connected to the third flap  46 . The fourth reinforced region  148  includes a sixth flange  154  extending from the third flap  46 . The third welded region  54  connects the third reinforced region  146  to the fourth reinforced region  148 . The fourth welded region  56  connects the first reinforced region  24  to the fourth reinforced region  148 . Other embodiments include a seventh flange  156  connected to the third reinforced region  146  and an eighth flange  158  connected to the fourth reinforced region  148 . 
     Thus, it is seen that the Tool Box with Reinforced Door readily achieves the ends and advantages mentioned as well as those inherent herein. While certain preferred embodiments of the invention have been illustrated and described for the purposes of the present disclosure, numerous changes and arrangement in construction of the parts may be made by those skilled in the art, which changes are accomplished within the scope and spirit of the invention as defined by the appended claims.