Abstract:
A storage container having a unique hinge arrangement is provided. The container includes a cover and base portion having hinge portions extending therefrom. The hinge portions are molded from a die configuration that creates adjacent cavities formed vertically and laterally. The hinge portions are arranged such that the cover and base interfit to reveal a continuous passage. A pin is inserted through the continuous passage completing a workable hinge. The storage container includes internal lateral wall sections on the cover and base having tabs extending therefrom. The tabs are configured to accept removable spacers. The spacers include side walls that are contoured such that an object may be easily removed without becoming caught in an angled corner. Transparent lids are releasably latched to the inside of the cover and base. The latches for the lids are located in a position that requires each lid to be locked prior to closing the case.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional of U.S. patent application Ser. No. 09/840,278, filed on Apr. 23, 2001, now U.S. Pat. No. 7,048,133, the disclosure of which is incorporated herein by reference. 

   FIELD 
   The present invention relates generally to storage containers, and more particularly to a storage container having a unique divider system and hinge configuration. 
   BACKGROUND 
   Storage containers exist in many varieties and may be used to store, organize and transport various items such as fasteners, tool bits and other accessories. 
   The storage container of the present invention is designed such that it may simplify the manufacturing of a storage container. Plastic storage containers can be typically manufactured fairly inexpensively, but often at the expense of being less rigid and providing less flexibility in adapting the storage container to store items of various sizes and shapes. When used to store tool bits, fasteners or accessories on a job site, a storage case must be built to be strong and durable so that if it is dropped, it does not break open and spill its contents. Storage containers often include a base portion and a cover portion hingedly connected to the base portion. 
   Conventionally, molding a plastic cover with an integrated hinge portion would involve a first step of positioning a metal rod in the section of the die to consist of the hinge portion and a second step of removing the metal rod after the cover is molded to reveal the resultant continuous passage for the pin of the hinge. The base portion of the case would be molded in a similar fashion with the resultant hinge portion able to interfit with the hinge portion of the cover such that a pin may be inserted therethrough creating a hinged container. It would be desirable to mold the cover and base including the hinge side of a storage container each in a single step. 
   SUMMARY 
   The storage container in accordance with this invention provides an improved storage container and method to mold the same. The molding process incorporates strategically placed bores and apertures in a die. The bores and apertures are formed at right angles such that they cooperate to form a continuous passage able to accept a pin to form a hinge. A base, cover and two internal transparent lids are each constructed with the unique hinge configuration. 
   The container includes internal lateral wall sections on the cover and base having tabs extending therefrom. Removable spacers slidably interfit with the tabs to allow the user to customize the interior of the container. 
   The transparent lids of the internal compartment have slidable latches for engagement with inner slots of the cover and base. The latches are aligned such that both lids must be secured in the locked position prior to properly closing the storage container. 
   Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 

   
     DRAWINGS 
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
       FIG. 1  is a perspective view of an assembled storage container shown in an open position; 
       FIG. 2A  is a plan view of the outer surface of the cover constructed in accordance to the teachings of the preferred embodiment; 
       FIG. 2B  is a plan view of the inner surface of the cover; 
       FIG. 2C  is a top view of the cover; 
       FIG. 2D  is a side view of the cover; 
       FIG. 2E  is a bottom view of the cover; 
       FIG. 3A  is a plan view of the outer surface of the base of the storage container constructed in accordance to the teachings of the preferred embodiment; 
       FIG. 3B  is a plan view of the inner surface of the base; 
       FIG. 3C  is a top view of the base; 
       FIG. 3D  is a side view of the base; 
       FIG. 3E  is a bottom view of the base; 
       FIG. 4A  is a plan view of the first side of a cover plate according to the principles of the present invention; 
       FIG. 4B  is a plan view of the second side of the cover plate; 
       FIG. 4C  is a rear view of the cover plate; 
       FIG. 4D  is a side view of the cover plate; 
       FIG. 5  is a perspective view of a spacer according to the principles of the present invention; 
       FIG. 6  is a perspective view of a cover plate latch according to the principles of the present invention; 
       FIG. 7  is a perspective view of the storage case latch member according to the principles of the present invention; 
       FIG. 8A  is a plan view of the inner surfaces of the cover and base to illustrate the alignment of the tab portions; 
       FIG. 8B  is a plan view of the first and second cover plates, the second cover plate identical to the first but rotated and flipped 180 degrees from the first cover plate; 
       FIG. 9  is a plan view of an assembled storage container shown in an open position to illustrate the outer surface of the cover and base; 
       FIG. 10A  is an exploded perspective view of a mold used to construct a cover portion of the storage container according to the preferred method of the present invention; 
       FIG. 10B  is an exploded perspective view of the bottom and side mold members used to construct the cover portion according to the preferred method of the present invention; and 
       FIG. 11  is an enlarged perspective view of the area  11  of  FIG. 10  illustrating the alignment of the hinge forming pegs. 
   

   DETAILED DESCRIPTION 
   The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
   With reference to  FIG. 1 , the storage container  10  of the present invention is shown. The storage container  10  includes a base  12  and a cover  14  hingedly attached to the base  12 . A pair of transparent cover plates  16 ,  18  are provided for selectively enclosing the storage area defined by the base  12  and cover  14 , respectively. 
   As shown in  FIGS. 2A–2E , the cover  14  includes a cover surface  20 , an inner surface  22 , a top wall  24 , side walls  26 ,  28  and a bottom wall  30 . Similarly, referencing now  FIGS. 3A–3E , the base  12  includes a bottom surface  32 , an inner surface  34 , a top wall  36 , side walls  38 ,  40  and bottom wall  42 . The storage container  10  includes removable spacers  52  ( FIG. 1  and  FIG. 5 ) that may be selectably positioned within the storage container to customize the interior space. Slidable latches  70 ,  70 ′ releasably secure cover plates  16  and  18  to the base  12  and cover  14 , respectively. Latch  80  releasably secures cover  14  to the base  12 . 
   With continued reference to  FIGS. 2A–2E , the cover  14  will now be described in greater detail. Cover surface  20  is contoured to include upwardly extending portions  44 . The inner surface  22  includes parallel dividers  46 ,  56  extending between side walls  26 ,  28 . Parallel dividers  46 ,  56  and bottom wall  30  include tabs  48  extending therefrom. Tabs  48  are configured to engage fingers  50  of removable spacers  52  (best shown in  FIG. 5 ). Opposing tabs  48   a ,  48   b  ( FIG. 2B ), are laterally offset a predetermined distance such that a readily available piece of material may be substituted for a spacer  52 , in the event a spacer is misplaced. The predetermined distance is configured to be a distance common to readily available scrap pieces of material such as, but not limited to, ⅛ inch plywood. Bottom surface  30  includes integrated hinge member  76 . A slot  58  is configured to accept a finger  98  on latch  70 ′ (best shown in  FIGS. 1 and 6 ) of cover plate  18 . 
   Turning now to  FIGS. 3A–3E , the base  12  will now be described in greater detail. The inner surface  34  of the base  12  is configured much the same as the cover  14 . Base surface  32  includes recessed portions  54 . The recessed portions  54  are coordinated to interfit with the upwardly extending portions  44  of cover  14  such that a series of cases  10  may be securely stacked. The inner surface  34  includes parallel dividers  64 ,  66  extending between side walls  38 ,  40 . Parallel dividers  64 ,  66  and bottom wall  42  include tabs  68  extending therefrom. Tabs  68  are configured to engage tabs  50  of removable spacers  52  (best shown in  FIGS. 1 and 5 ). Opposing tabs  68   a ,  68   b  are laterally offset a predetermined distance such that a scrap piece of material may be substituted for a spacer  52  as described above. Base  12  includes integrated hinge member  86 . A slot  120  is configured to accept finger  98  on latch  70  (best shown in  FIGS. 1 and 6 ) of cover plate  16 . 
   The storage container  10  of the present invention allows the apertures of the hinge portion to be formed without the need of a metal rod for forming the apertures. The configuration of the cover  14  and the base  12  illustrated in  FIGS. 2A–3E  include hinge portions  76  and  86 , respectively. The hinge member  76  of cover  14  including tab portions  78  which are formed from a die configuration that creates cavity sections  82  ( FIG. 2B ) in a direction perpendicular to the plane of cover  14 . Additionally, the die allows cavity sections  84  (viewed from  FIG. 2E ) to be formed in a direction parallel to the plane of cover  14  and in a location between cavity sections  82 . The insert portions of the die are strategically located such that cavity sections  82  and  84  cooperate to form a continuous passage  88  ( FIGS. 2B and 2D ) which is created without the need for additional steps involving a metal rod die insert as is required with conventional hinge molding techniques. 
   The base  12  is molded in a similar fashion to create a continuous passage for a hinge pin. Tab portions  90  of hinge member  86  include cavity sections  92  ( FIG. 3B ) perpendicular from the plane of base  12 . Accordingly, cavities  94  ( FIG. 3E ) are also incorporated in a direction parallel to the plane of base  12 . Cavities  92  and  94  cooperate to form a continuous passage  96  ( FIG. 3B  and  FIG. 3D ). 
   Turning now to  FIGS. 4A through 4D , the interior of case  10  includes two symmetric transparent cover plates  16 ,  18 . The cover plates  16 ,  18  are molded with the same hinge strategy as mentioned for the cover  14  and base  12 . The tab portions  102  of hinge sections  100  include cavities  104  formed perpendicular to face  106  of cover plate  16 ,  18  on a first side of the cover plates  16 ,  18 . Cavities  108  are also formed from the geometry of the die and are perpendicular to face  106  on a second side of the cover plates  16 ,  18 . Cavities  104  and  108  are parallel to each other and offset which cooperate to form a continuous passage  110  ( FIG. 4D ). The tab portions  102  of the cover plates are laterally offset such that a first cover plate  16  may be turned 180 degrees from a second cover plate  18  allowing the tab portions  102  to interfit. This feature allows both cover plates  16 ,  18  to be molded from the same die. Cover plates  16 ,  18  include a slot  112  integrated thereon to accept slidable latches  70 ,  70 ′ ( FIGS. 1 and 6 ). 
   Referring now to  FIGS. 8A and 8B , tab portions  90  of hinge  86  of the base  12  are offset from hinge portions  78  of cover  14  so as to interfit when mated. Furthermore, the tab portions  102  of the cover plates  16 ,  18  are positioned between hinge members  86 ,  76  of the base  12  and cover  14 , respectively (placing  FIG. 8B  onto  FIG. 8A  to create  FIG. 1 ). The respective hinge portions  90  of base  12 ,  78  of cover  14  and  102  of cover plates  16 ,  18  interfit to define one continuous passage  114  aligned to accept a hinge pin  130  ( FIG. 1 ). 
   Turning now to  FIG. 5 , the spacer  52  will now be described. A series of spacers  52  will be included for the user to customize the size of the inner compartments. Spacer  52  includes flared arms  116  having fingers  50  extending therefrom. Central block portions  51  extend generally parallel to a longitudinal axis of the spacer  52 . The fingers  50  are adapted to slidably engage tabs  48  of cover  14  or tabs  68  of base  12 . More specifically the fingers  50  define outer walls  50   a  that cooperate with inner walls  51   a  defined on the central block portions  51  to form slots  53 . In an installed position, the tabs  48  and  68  rest within the slots  53 . The spacers  52  are made from a flexible material such as soft rubber or other elastomeric material. The spacers  52  are configured to maintain a constant slope in the uninstalled position ( FIG. 5 ) and the installed position ( FIG. 7 ). The flared arms  116  of spacers  52  are contoured such that an object may be easily removed from the box without becoming caught in a 90 degree corner of an inner compartment. The internal configuration also provides shock resistance in the event of a drop or sudden impact. 
   Referencing now  FIGS. 4A ,  4 B and  6  with continued reference to  FIG. 1 , the cover plates  16  will now be described. Cover plate  16  includes a latch  70  slidably engaged with slot  112 . The latch  70  (best shown in  FIG. 6 ), includes body  74 , having an arm  98  and outwardly extending fingers  72  and tang  99 . Wing section  60  has a contoured surface to enhance grip while sliding latch  70 . Latch  70  is slidably engaged to slot  112  of cover plate  16 . When a cover plate  16  is in its closed position, latch  70  may be laterally moved such that fingers  72  of arm  98  engage the rear surface of slot  120  securing the cover plate  16  to base  12  in a locked position. 
   The second cover plate  18  (identical to the first cover plate but flipped 180 degrees) also includes a slot  112 ′ and latch  70 ′. The latch  70 ′ slidably engages slot  58  of cover  14  when in a locked position. The relationship of latches  70 ,  70 ′ to cover plates  16  and  18  are such that the latches  70 ,  70 ′ of the cover plates  16 ,  18  must be in a locked position in order for the carrying case  5  to properly close. Explained further, if the latches  70 ,  70 ′ are not in a locked position, the wing  60  of latches  70 ,  70 ′ will abut against one another preventing the case  10  from properly closing. 
   Turning now to  FIG. 7  with continued reference to  FIGS. 2A and 2B , the cover  14  includes a slidable latch  80 . The slidable latch  80  includes outer circumferential wall  128  including fingers  122  for engagement with track  124  of base  12  and track  105  on cover  14 . Ribs  118  laterally extend from face  126  of latch  80  to improve grip. 
   Referencing  FIGS. 10 and 11 , the mold used to construct the cover  14  of the storage container  10  will now be described. The tool  140  includes a first and second die member  136  and  144 . Die  136  includes vertical pegs  142  extending therefrom and tab sections  150 . The base  12  is molded from a similar tool having a corresponding peg and tab arrangement which are offset from those of the cover tool  140  such that the molded parts cooperate to form a hinge. As such, a similar die arrangement is used to mold the cover plates  16 ,  18 . 
   The method of constructing the cover  14  and base  12  of storage container  10 , will now be described. In a first general step the preferred method of the present invention provides a first tool  140  having a first die member  136  including a series of pegs  142  extending in a first direction and a second die member  144  including a series of pegs  146  extending in a perpendicular direction. 
   In a second general step, the preferred method of the present invention introduces the molten plastic material to the first tool  140 . 
   In a third general step, the first and second die members  136  and  144  are removed to reveal a cover  14  having a first continuous passage  88 . 
   The base  12  is formed similar to the cover  14 . 
   The first continuous passage  88  of cover  14  is then aligned with the second continuous passage  96  of base  12  and the passage  110  through cover plates  16 ,  18 . A pin  130  is inserted through the passages  88 ,  96  and  110 . 
   The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.