Abstract:
The present invention relates to kit for a deck storage box utilizing injection molded plastic panels capable of being packaged and shipped in a knocked-down state and constructed into a secure enclosure. The storage device is also constructed to allow interchangeable covers, allowing a number of enclosures to be configured using common components.

Description:
FIELD OF THE INVENTION 
   This invention relates generally to a deck storage device constructed of plastic structural panels. More specifically, the present invention relates to a deck storage box utilizing injection molded plastic panels capable of being packaged and shipped in a knocked-down state and constructed into a secure deck storage enclosure. 
   BACKGROUND INFORMATION 
   Devices for storing household items such as gardening tools, children&#39;s toys, barbeque accessories and the like are well known. Permanent structures such as utility sheds or garages are often utilized for storage of such items. In recent years patios and decks have become a common addition to homes and apartments alike and while patios and decks provide outdoor recreational space for families they often consume a great deal of the lawn space available to the homeowner. Lawn space consumed by decks and patios is no longer available to the homeowner for storage sheds or permanent structures. Requiring the homeowner to find alternative storage space for items normally stored in the utility shed. 
   Devices for storing marine related articles at the water side are also well known. Permanent structures such as boat houses are often used for storage of boats and other equipment. It can be appreciated that on beaches and waterfront property, there are often many types of water toys and recreational equipment such as life-jackets, fishing gear and other articles that may be utilized in the water and which require storage. If there is no storage available at the water side, the equipment must be carried back and forth between storage space remote from the waterfront or placed in a boat which typically does not have adequate storage space and which does not provide adequate security. 
   Although permanent structures such as boathouses or utility sheds may provide adequate storage, such structures have several drawbacks. The permanent structures may be very costly to build and maintain. In addition to the cost, the permanent structure may require a permit to build and occupy space on the property or along the beach. 
   In addition to permanent storage sheds or boat houses, the prior art has proposed a number of different panel systems, or kits comprising blow molded or extruded panels and connector members for forming a wide variety of structures. Due to manufacturing limitations blow molded and extruded plastic components cannot be formed with the integral cross-bracing ribs or the intricate shapes and sharp corners required for integrated connectors that are possible with injection molding. Typically, such systems require extruded metal or plastic connector members having a specific cross-sectional geometry that facilitate an engagement between such members and one or more plastic panels having a complimentary edge configuration. 
   A particularly common structure for the connector members is the I-beam cross section. The I-beam defines free edge portions of the connector member which fit within appropriately dimensioned and located slots in the panel members. U.S. Pat. No. 5,979,352 teaches a storage box that is representative of the state of the art I-beam connector members. The I-beam sides of the connectors engage with the peripheral edge channels of a respective wall panel and thereby serve to join such panels together at right angles. Straight or in-line versions of the connector members are also included in the kits to join panels in a coplanar relationship to create walls of varying length. 
   The prior art has also suggested a number of smaller one piece plastic containers with removable lids for storage use. U.S. Pat. Nos. D308,486, D308,487, D309,106 teach such one piece containers. Typically such containers provide portability for storage but lack capacity to store larger items. Moreover, because these devices do not break down they are difficult to ship from the manufacturer to the consumer. 
   Such prior art systems, while working well, have not met all of the needs of manufacturers to provide a product that can be easily manufactured, packaged and shipped or the needs of consumers requiring structural integrity combined with modularity and aesthetic appearance. 
   Paramount among such needs is a panel system which creates deck storage box walls which resist panel separation, buckling, racking and weather infiltration. Security is a further consideration, the box formed by the panels must tie into the cover and bottom in such a way as to unify the entire enclosure. 
   Also, from a versatility standpoint, a cover should be present which can be easily interchanged after assembly of the side and bottom components and which provides additional seating as well as dependable security and pivoting access to the contents of the deck box. 
   There are also commercial considerations that must be satisfied by any viable deck box system or kit; considerations which are not entirely satisfied by state of the art products. The deck storage box must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The deck storage box must also be capable of being packaged and shipped in a knocked-down state. In addition, the system must be modular and facilitate the creation of a family of enclosures that vary in appearance and functionality but which share common, interchangeable components. 
   Finally, there are ergonomic needs that an enclosure system must satisfy in order to achieve acceptance by the end user. The system must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the system must not require excessive strength to assemble or include heavy component parts. Moreover, the system must assemble together in such a way so as not to detract from the internal storage volume of the resulting deck storage box or otherwise detract from the internal storage volume of the resulting deck storage box or otherwise negatively affect the utility of the deck storage box. 
   BRIEF DESCRIPTION OF THE INVENTION 
   The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form a deck storage box. The panels are formed of injection molded plastic to interlock with one another without the need for separate fasteners or I-beam connectors. The system incorporates a minimum number of components to construct a deck storage box by integrally forming the connectors into the injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the storage box. The integrated connection of the side wall, cover and bottom panel components also simplifies storage box construction. Injection molding allows the panels to be formed with integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or extruded panels. The same side wall and bottom panel components are used to create a variety of storage boxes and the assembly of the storage boxes require minimal hardware and a minimum number of hand tools. 
   The front and rear wall panels have outwardly projecting locking posts for interlocking cooperative engagement with sockets in the bottom panel. The left and right side wall panels are constructed with outwardly extending contoured locking posts for interlocking cooperative engagement with sockets in the ends of the front and rear panels. The engagement between the locking posts and the sockets serve to rigidly connect the components together. The system further includes a cover which slides into place after the front, rear, side and bottom panels have been fully assembled. The system is constructed to allow various cover panels to be utilized further increasing the utility of the storage box. 
   Accordingly, it is an objective of the present invention to provide a modular deck storage box system having integrated connectors for creating various storage boxes using common components. 
   A further objective is, to provide a modular panel storage box system with integrated connectors which accommodates injection molding plastic formation of the panel components for increased structural integrity. 
   Yet a further objective is to provide a modular panel storage box system in which the side walls, cover, and bottom panel are integrally interlocked without I-beam connectors or fasteners. 
   Another objective is to provide an deck storage box constructed of modular panels having a cover assembly which allows interchangeability after all other parts are assembled. 
   Yet another objective is to provide a kit for a deck storage box that is capable of being packaged and shipped in a knocked-down state and constructed into a secure enclosure. 
   Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  is a perspective view of one embodiment of the instant invention; 
       FIG. 2  is an exploded view of the deck box enclosure shown in  FIG. 1 ; 
       FIG. 3  is a top view of the deck box embodiment shown in  FIG. 1 ; 
       FIG. 4  is a section view along lines  1 — 1  of the deck box embodiment shown in  FIG. 3  illustrating the structural ribs integrally formed into the panels; 
       FIG. 5  is a section view along lines  2 — 2  of the deck box embodiment shown in  FIG. 3  illustrating the cooperative engagement of the panels; 
       FIG. 6  is a partial section view along lines  3 — 3  of the deck box embodiment shown in  FIG. 5  illustrating the cooperative engagement of the locking posts and the bottom panel; 
       FIG. 7  is partial perspective view illustrating the cooperative engagement between the hinge pin receiver and the hinge pin; 
       FIG. 8  is a partial section view along lines  4 — 4  of the deck box embodiment shown in  FIG. 5  illustrating the cooperative engagement of the cover hinge pins and the rear panel; 
       FIG. 9  is a partial section view along lines  5 — 5  of the deck box embodiment shown in  FIG. 5  illustrating the cover latch of the instant invention; 
       FIG. 10  is a partial perspective view illustrating the support strap of the instant invention; 
       FIG. 11  is a partial perspective view illustrating the cooperative engagement between the side panel and the support strap of the instant invention; 
       FIG. 12  is a partial perspective view illustrating the cooperative engagement between the cover panel and the support strap of the instant invention; 
       FIG. 13  is a perspective view illustrating an alternative embodiment of the instant invention; 
       FIG. 14  is an exploded view of the deck box enclosure shown in  FIG. 10 ; 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
     FIGS. 1–5  which are now referenced illustrate perspective, exploded and sectioned views of the deck box enclosure, generally referenced as  10 , according to a preferred embodiment of the present invention. The enclosure is made up of a floor panel  100 , left side wall panel  200 , right side wall panel  300 , rear wall panel  400 , front wall panel  500  and cover panel  600 . In the preferred embodiment, the panels comprising the assembly are formed of but not limited to a suitable plastic such as polystyrene or polyethylene, through the process of injection molding. The result is that the panels comprising the deck box enclosure  10  are formed as single-walled panels with integral connectors, and cross bracing. Strengthening ribs  202  and gussets  204  are formed within the inner surfaces of the wall panels  200 – 300  in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown in  FIG. 1 . The floor panel  100  has a top surface  104 , bottom surface  106 , like-constructed front and rear edges  108  and  110 , and like-constructed left and right edges  112  and  114 . Adjacent to each of the front and rear edges  108 ,  110  is a means of attaching the floor panel to the front and rear wall panels  400 ,  500  illustrated as a plurality of formed sockets  116  extending downwardly from the top surface  104 . The formed sockets  116  are constructed and arranged to cooperate with locking posts  210  extending outwardly along the bottom edges  402 ,  502  of the front and rear wall panels  400 ,  500 . The locking posts  210  and sockets  116  are constructed and arranged so that the locking posts  210  enter and mateably engage the sockets  116  securing the panels together in an inter-fitting engagement with their respective top surfaces in a perpendicular arrangement. The top surface of the bottom panel is also constructed with a plurality of grooves  102  extending around the perimeter of the top surface  104 . The grooves  102  are constructed and arranged to cooperate with tongues  214  ( FIG. 4 ) extending downward from the bottom surfaces of the front, back, and side panels. The tongue  214  and groove  102  arrangement increases the structural integrity of the deck box  10  by preventing the panels  200 ,  300 ,  400 ,  500  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the deck box  10 . 
   The left and right side wall panels  200  and  300  are each configured having a first end  208  and a second end  212 . Both ends  208 ,  212  include an integrally formed attachment means illustrated as an elongated contoured attachment post  210 . The attachment posts  210  are generally constructed and arranged to cooperate with the contoured sockets  408  provided in either end of the front  400  and rear panels  500 . 
   The outer surface of the panels  200 ,  300 ,  400 ,  500  are constructed generally smooth having a plurality of inwardly bowed grooves  230  for added strength and aesthetic appearance. The inside of the panels  200 ,  300 ,  400 ,  500  are constructed with a plurality of strengthening ribs  204  extending across the panels with a portion of the ribs  204  ( FIG. 4 ) being provided with a plurality of gussets  206  to further strengthen the panels. The ribs  204  and gussets  206  increase the structural integrity of the deck box  10  by preventing the panels  200 ,  300 ,  400 ,  500  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the deck box  10 . The integrally formed ribs  204  and gussets  206  are facilitated by injection molding. Injection molding offers significant strength and stability advantages over blow-molding or extrusion as utilized in the prior art. In this manner the enclosure of the instant invention is capable of handling a significant amount of weight as compared to blow molded or extruded deck boxes. 
   The left and right side panels  200 ,  300  are attached to the front and rear panels  400 ,  500  by inserting the contoured locking posts  210  into contoured sockets  408  until the spring tabs  126  integrally formed into the contoured locking posts  210  engage the apertures  234  in the sockets  408  of the front and rear panels  400 ,  500 . It will be appreciated that the purpose of the contoured elongated locking posts  210  are to align two panels in a perpendicular relationship and to facilitate their mechanical connection. The perpendicular panels are brought into an overlapping relationship wherein the contoured locking posts  210  enter the corresponding cavity  408  in the front and rear panels  400 ,  500 . The result is a mechanically secure connection between the two panels. The overlapping edges between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for separate connectors. Second, the design creates a positive lock that prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another. The resultant deck box created by the combination of the interlocking panels benefits from high structural integrity and reliable operation. 
   Referring to  FIG. 6 , the front and rear panels  400 ,  500  are attached to the floor panel  100  by sliding the locking posts  210  along the bottom edges  402 ,  502  into the corresponding sockets  116 . The sockets  116  in the bottom panel  100  correspond in shape and size to that of the locking posts  210  and spring tabs  126  integrally formed into the sockets  116  align with apertures  234  in the locking posts  210  to engage the front and rear panels  400  and  500 . The result is a positive mechanical connection between the front and rear panels  400 ,  500 , and the floor panel  100 . 
   Referring to  FIGS. 7–9 , partial perspsective and section views of the deck box illustrating one of the hinge means illustrated herein as a separable hinge assembly. The hinge assemblies generally include a plurality of hinge pins  602  and a plurality of cooperating hinge pin receivers  404 . The hinge pin receivers  404  are integrally formed into the top outer portion of the rear panel  400  and are constructed and arranged to cooperate with a cover hinge pin  602  to allow rotational movement of the cover  600 . The hinge pins  602  are each supported by a pair of downwardly depending supports  604  located adjacent to the rear edge  110  of the cover  600 . The hinge pins  602  cooperate with their respective hinge pin receivers  404  to allow rotational movement of the cover  600  and also allow the cover  600  to be removed when in the open position by lifting the cover upward and sliding the pins  602  outward from the hinge pin receiver  404 . 
   Referring to  FIGS. 10–12 , the removable and replaceable support strap is illustrated in cooperation with a side panel and the cover. The support strap(s)  216  are constructed from a flexible material, e.g. nylon, and arranged to provide support for the cover  600 ,  610  while it is in the open position. The flexibility of the support strap allows the cover to be easily closed without the need to disconnect the strap. The support strap  216  is constructed with a first end  216 A which is removably attachable to one of the side panels  200  via integral spring tabs  220  and a second end  216 B which is removably attachable to the cover  600 ,  610  via snap groove  222 . The side panels  200  and  300  are constructed with an integrally formed U-shaped strap mount  226  having an aperture  218  for receiving the first end  216 A of the support strap. The cover  600 ,  610  is constructed with an integrally formed tab  616  having an aperture  618  for receiving the second end  216 B of the strap  216 . The support strap  216  is easily attached to the side panel strap mount  226  and the cover  600 ,  610  by sliding the second end  216 B of the support strap  216  through apertures  218  and  618  and thereafter snapping spring tabs  220  into place and sliding the snap groove  222  into place using the stem  224 . The snap in and snap out arrangement allows the support strap to be easily attached or unattached from the cover and/or side panel without the need for tools. 
   It should be appreciated that the hinge and cover strap assemblies allow the cover to be installed and/or removed when the cover  600  or  610  is in the open position and yet the cover is secure and non-removable when in the closed position. 
   Referring to  FIGS. 13–14 , an alternative embodiment of the present invention is shown wherein the deck box can be utilized as a bench seat by changing the cover  610 . In this manner the same construction can be utilized to build different deck boxes utilizing substantially the same components. Reinstallation or changing the cover to a bench seat cover  610  merely requires the hinge pins  602  to be lined up with the corresponding hinge pin receivers  404  in the rear panel  400  and slid in and downward into the receivers  404 . The cover  610  is secured in place by pivoting the cover downward until the spring latch  510  ( FIG. 9 ) integrally formed into the front panel  500  engage corresponding catches  612  formed in the depending front portion of the cover  610 . The result is a positive mechanical connection between the side panels  200 , front and rear panels  300  and the cover. The cover can be further secured by inserting a lock through the apertures  614  and  514  provided in the cover  600 , 610  and the front panel  500 . 
   All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. 
   It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification. 
   One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.