PATENT ABSTRACT
An overhead storage unit for a modular open office system is provided. The storage unit can be either a freestanding unit or a panel mounted unit. The present invention provides easy to assemble units utilizing a minimum of different components for inexpensive manufacturing and ease of construction. In the freestanding unit, identical end panels are used; whereas in the panel mounted unit complementary right and left end panels are formed. In either unit, the shelves and doors are of identical shape. When assembled, engagement tabs on the panel mounted unit prevent the storage unit from being inadvertently removed.

PATENT DESCRIPTION
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to modular office systems, and more particularly to an overhead storage unit for use with such office systems. 
     2. Description of the Prior Art 
     Modular office systems in which individual panel assemblies are used to configure large work areas are well known in the art. More recently, improvements have been made in both the look and functionality of the panel assemblies. Due to constantly changing work environments, it is desirable to have office systems which allow for ease of redesign and flexibility in the mounting of accessories, for example, to the panel assemblies. 
     In the case of an overhead storage unit, it is often necessary to provide a preconstructed unit which is then secured to a panel such as by bolting or screwing the storage unit to the panel frame. This often necessitates manufacture and/or construction of the storage unit at the factory and shipping the unit in an assembled condition. This can be inconvenient in that the bulk of the assembled unit is much more difficult and costly to ship than is a unit which can be shipped as piece units which are then manufactured in the field at the individual work area location. Moreover, for units which are shipped as individual components which are then assembled in the field, it is desirable to have a storage unit or other accessory which is easy to construct, not requiring detailed instructions. 
     Units mounted on the panel assemblies must also be securable to the panels such that they are not capable of inadvertently falling from the panel, such as would occur if the person accidentally bumped the unit. What is needed, therefore, is an overhead storage unit which can be attached to a panel for an open office system workstation, which can be shipped as individual components which can be then manufactured in the field. The unit must be lightweight for shipping, and have components which are easy to manufacture and thus inexpensive to build. 
     It is therefore an object of the present invention to provide an overhead storage unit for a modular office system wherein the storage unit is made up of easily assembled individual components. 
     It is another object of the present invention to provide a mountable overhead storage unit which is made of components which are as easy to assemble as are the individual panel assemblies which make up the modular office system. 
     It is a further object of the present invention to provide a modular overhead storage unit having a minimum of different individual parts which are capable of simple construction without detailed instructions or tooling. 
     It is a still further object of the present invention to provide an overhead storage unit which is easily mounted on a panel assembly which prevents inadvertent falling of the unit from the panel. 
     SUMMARY OF THE INVENTION 
     The above objects are attained by the present invention, according to which, briefly stated, a modular overhead storage unit is provided for an office system which is made up of a pair of end panels and one or more shelves. In one embodiment of the invention, the end panels are identical pieces, as are each of the shelves. In a second embodiment of the invention, each of the end panels have angled engagement tabs on a back edge thereof for engaging support frames of a panel assembly, in which the engagement tabs prevent inadvertent removal of the storage unit from the panel. A door is provided for the storage unit, which door presents a curved surface which matches the edges of the end panels so as to present a clean, visually pleasing appearance. The individual components of the overhead storage unit can be mass produced such as by stamping or roll forming the metal parts which can be easily assembled on site, without requiring special tooling or detailed instructions to assemble the unit and/or mount it on the panel assembly. 
     A method of manufacturing a storage unit comprises the steps of providing a first piece of sheet metal and forming a first end panel from the first piece of sheet metal, the first end panel having a first outer side, a first inner side, a first bottom edge and a first top edge, wherein the first bottom edge is formed to provide a first shelf attachment area on the first inner side. A second end panel is formed from a second piece of sheet metal, the second end panel having a second outer side, a second inner side, a second bottom edge and a second top edge, wherein the second bottom edge is formed to provide a second shelf attachment area on the second inner side. A third piece of sheet metal is formed into a shelf having a top surface, a bottom surface, a left end and a right end, wherein each of said left and right ends are formed to provide a left end panel attachment area and a right end panel attachment area on the bottom surface. The left end panel attachment area is secured to the first shelf attachment area, and the right end panel attachment area is secured to the second shelf attachment area, whereby the storage unit is assembled. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Various other objects, features, and advantages of the invention will become more apparent by reading the following detailed description in conjunction with the drawings, which are shown by way of example only, wherein: 
     FIG. 1 is an isometric view of a storage unit according to one embodiment of the present invention; 
     FIG. 2 is a side view of the storage unit shown in FIG. 1; 
     FIG. 3 is an exploded view of a storage unit shown in FIG. 1, showing details of the individual components of the unit; 
     FIG. 4 is a perspective view of a hat channel bracket for a slidable door according to one embodiment of the present invention; 
     FIG. 5, consisting of FIGS. 5A and 5B, are detailed views showing the attachment of a top and bottom shelf to an end panel; 
     FIG. 6, consisting of FIGS. 6A and 6B, are detailed views showing the attachment of a top and bottom shelf to an end panel; 
     FIG. 7 is a side view of a storage unit end panel according to a second embodiment of the present invention; and 
     FIG. 8 is a top view of the end panel shown in FIG.  7 . 
     FIG. 9 is a perspective view of a portion of a panel assembly having a slotted vertical support member for the overhead storage cabinet of the present invention thereon. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings in detail, FIGS. 1-3 show one embodiment of an overhead storage unit  10  according to the present invention. The storage unit is comprised of a pair of end panels  13 , and one or more shelves  16  (shown in the figures as comprising a top  16   a  and bottom  16   b  shelf). In the freestanding unit  10  as shown, there is also included a back panel  19 . The unit may also include a door  22  operably connected to the top shelf  16   a  such that when in the closed position (FIGS. 1 and 2) the door is adjacent the front edges  25  of the end panels  13  and when in the open position is adjacent the top shelf  16   a.    
     Each of the end panels includes a shelf attachment area  28  which is formed preferably at both the top  29  and bottom  30  portions of the end panel  13 . In the embodiment shown in FIG. 3, it can-be seen that the end panels are made of identical construction such that an end panel can be either a left or right end panel for the unit. In this way, only a single end panel needs to be manufactured, preferably by progressive die stamping. 
     Also as shown in FIG. 3, each of the shelves comprises an identically formed unit, which is also preferably formed such as by roll forming a piece of sheet metal. On either end of a bottom surface of the shelves  16  is an end panel attachment member  31 . As shown in the figure, the left end panel attachment member  32  of top shelf  16   a  is secured to the top shelf attachment area  28   a  on the left end panel, whereas the right end panel attachment member  33  of the top shelf  16   a  is secured to the top shelf attachment area  28   a  on the right end panel. 
     Both the shelf attachment areas on the end panels, as well as the bottom surfaces of the shelves, are of identical construction such that a shelf can be attached as either a top  16   a  or bottom  16   b  shelf. In this way, one shelf  16  needs to be manufactured for the storage unit, giving rise to ease of manufacturability in that only one shelf form need be stamped out or roll formed from the sheet metal. Preferably, the shelves are secured to the end panels by screws passing through complementary holes  34 ,  37  in each of the shelf attachment areas  28  and the end panel attachment members  31 , respectively. 
     In units where two shelves are provided to form the top and bottom of the cabinet, the door  22  is preferably provided for the front of the cabinet  10 . The door  22  is connected to the top shelf  16   a  by glide hinges  38 . Each of the glide hinges  38  comprises a hinge member  39  and a glide assembly  40 . In this manner, the top of the door is pivotally connected to the top shelf by means of the hinge member  39  such that when the door is swung open it can then be slid back so as to be adjacent to the top shelf  16   a . When in the closed position, the outer surface of the door  22  comprises a curved surface which is complementary to the curvature of the front edge  25  of each of the end panels such that the unit as a whole presents a clean, visually pleasing appearance. The glide assembly portion  40  of the glide hinge is connected to the door  22  by means of a hat channel bracket  41  (shown in FIG.  4 ). The shape of the hat channel bracket  41  as shown in FIG. 4 is such that the channel portion  42  is shaped to abut against the inner surface of the door. The glide hinge  40  is then secured to the hat channel bracket  41  so as to be generally flush with the door  22 . As shown in the side view of FIG. 2, a decorative insert  43  is provided in the roll formed door member. This trim piece, preferably made of plastic, is easily pressed into the sides of the door  22 , so as to provide a finished appearance for the assembled unit. 
     The embodiment shown in FIGS. 1-3 is commonly referred to as a freestanding unit. This unit can also be mounted, such as by threading a screw or bolt through holes  44  in bottom portion  30  of the end panel  13  and secured to vertical stanchions or upmount brackets (not shown). When used as a freestanding unit on a desk, the back panel  19  is preferably secured to the end panels  13  by weld pins or weld screws  46  and provides a closed surface for the storage cabinet. 
     Referring to FIGS. 5 and 6, it can be seen that the shelf attachment areas  28  formed on the end panels  13  are of a complementary shape such that with the freestanding unit  10  the end panels are substantially identical. Both the top  29  and bottom  30  portions edge of the end panels are formed with the shelf attachment areas therein, the shelf attachment areas each comprising a right angled member  58 . The shelf attachment area is on the inner side of the end panel  13  such that on the top portion  29  a horizontal portion  61   a  of the right angle member projects inward and the vertical member  64   a  projects downward therefrom. Similarly, on the bottom portion  30  the horizontal member  61   b  projects inward and the vertical member  64   b  projects upward therefrom. The bottom shelf  16   b  is attachable to the bottom, or first and second, shelf attachment areas  28   b  by resting the end panel attachment members  31  on the edges  65  of the vertical members  64   b  on the bottom portions  30  of each of the end panels  13 . The top shelf  16   a  is secured to the top, or third and fourth, shelf attachment areas  28   a  by the complementary formed horizontal shelf portion  66  on the bottom surface of the top shelf which is supported on the horizontal portion  61   a . A vertical member  67  of the shelf abuts against the vertical members  64  of the end panel. The shelves are then held in place by screws passing through holes  34  and  37 . 
     In this manner, identical shelves having substantially similar cross sections can be formed and can be attached as either a top or bottom shelf. In order to attach the hinge member  39  of the glide hinges  38  to the top shelf  16   a , holes  70  may be provided on one edge of the shelves  16  to accommodate the mounting screws for the glide hinges. The glide hinges allow the top of the door to pivot on the top shelf, and then slide back over the top shelf by means of the glide assembly  40  in a manner well known in the art. 
     Referring now to FIGS. 7 and 8, end panels  113  for a second embodiment of the present invention will be described in detail. In this embodiment, engagement tabs  115  are provided on the back edge  117  of each of the end panels. These engagement tabs engage slots in a pair of supports for the panel assemblies as will be described in detail below. As shown in particular in FIG. 8, the engagement tabs have an angled portion which is angled inward with respect to the inner surface of the end panel  113 . Preferably, the angled portions  119  are angled inward from about 33 to 46 degrees, and most preferably at about 40 to 46 degrees. That is, the angled portions project inward towards the storage unit when in the assembled condition. A downwardly projecting hook portion  121  engages slots  123  in each of the vertical support members  125  (only one of which is shown in the Figure). In this embodiment, separate right and left end panels are provided for the assembled storage unit. 
     In order to manufacture this panel mounted storage unit so as to be mounted such as in an overhead manner above a work desk, each of the end panels  113  are first attached to the support frame for the panel. As shown in FIG. 9 this is done by inserting the engagement tabs into slots  123  of each of the vertical support members  125  provided in the panel frame support, such that the hook portion is secured to the panel frame. The use of engagement tabs on supporting accessories for modular office components is well known, however, the engagement tabs of the present invention provide a unique advantage. After the end panels have been attached to the supports  125  for the panel assembly  127 , a bottom shelf can be secured to the shelf attachment area  128  on the bottom portion  130  of the end panels in a similar manner to that of the first embodiment previously discussed. If desired, only one shelf can be provided for the unit so as to provide an open shelf storage area, and the right and left end panels would not include the top shelf attachment area and door. In either case, with either one or two shelves, after the bottom shelf is secured to each of the end panels by inserting screws through the holes in the shelves which then are threadingly engaged with holes  134  in the end panel  113 , the storage unit cannot be removed from the panel support frame. This is due to the fact that the angled portions of the end panel are both angled inward with respect to the storage unit. Thus, with the shelf in place, it is relatively difficult, if not impossible, to remove the end panels from the slots in that they cannot be angled with respect to the panel support frame so as to remove the engagement tabs from the vertical slots. With the panel mounted unit, a back panel is not included since the back edges of the end panels abut against the panel frame assembly. 
     The storage unit of the present invention can be utilized with the Panel Frame Assembly which is the subject of U.S. patent application Ser. No. 08/868,083 filed on Jun. 3, 1997, which application is assigned to the present assignee and incorporated herein by reference. 
     In this manner, the modular overhead storage unit of the present invention provides an easy to ship unit which can be shipped in an unassembled condition and can be easily constructed in the field at the work station location. In the case of the first embodiment, identical shelves and end panels are provided so as to provide ease of manufacturability. In the second embodiment (FIGS.  7  and  8 ), although two separate end panels are provided, the end panels are of a complementary or mirror image shape. In either embodiment, both the shelves and the door for the storage unit can be identical. Thus, the storage unit of the present invention provides an inexpensive to manufacture and ship storage unit which can be easily assembled into a modular office system. 
     While specific embodiments of the invention have been described in detail, it would be appreciated by those skilled in the art that various modifications and alterations would be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.