Abstract:
A system and method of suspending storage containers is described. The system and method comprise, among other things, coupling sets of garage door track to ceiling joists in such a manner that one or more storage containers may be suspended from the garage door tracks. The garage door tracks are configured to allow for easy placement and removal of one or more storage containers. Additionally, the garage door tracks are positioned or coupled in such a way that when the system is loaded with storage containers, the garage door tracks remain stable.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of and claims priority to U.S. Provisional Application Ser. No. 61/617,963, titled “System and Method for suspending storage containers” and filed on Mar. 30, 2012 by Marshall Schoewe. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally concerns storage systems, and more particularly, representative and exemplary embodiments of the present invention generally relate to systems, devices and methods relating to overhead suspension of storage containers and hanger apparatus. 
     2. Description of Related Art 
     Plastic storage containers have become a common household item. Frequently, people use large plastic storage containers to store a variety of items that are used infrequently such as holiday decorations and seasonal sports equipment. While plastic storage containers create a sturdy, reusable, long-lasting improvement to cardboard boxes, some problems still remain. For instance, users of plastic storage containers commonly have difficulty finding an appropriate spot to store the plastic storage containers where they will be “out of the way” and at the same time “easily accessible”. One place where such a spot may be found is overhead area beneath a garage ceiling, and more particularly, the overhead area which exists between a garage ceiling and a raised garage door. Others have attempted to take advantage of such spots. Some examples are found in the following patents, the disclosures of which are hereby incorporated by reference in their entirety. 
     U.S. Pat. No. 7,597,203 describes a wire-frame device, mountable to a ceiling, from which plastic bins may be suspended. Unfortunately, this device is constructed from a complex array of bent wires and rails, each one requiring numerous spot welds. The device suffers from a design which is both difficult and expensive to manufacture. Furthermore, the cross-sectional upside-down ‘U’ shape of the device creates a major structural disadvantage. The rails of the device are essentially free to bend inward, in response to any horizontal force, without any support or structure to counteract that force or bending movement. Furthermore, the weak structural design of the device necessitates the use of specialized storage containers having large, solid lips, making the device unusable with many existing storage containers 
     U.S. Pat. No. 6,725,608 describes suspended overhead shelves designed to fit between a raised garage door and the garage ceiling. Unfortunately, in order for this system to be sturdy, thick boards and support bars must be used. The thickness of these boards and bars wastes substantial space in an already space-limited area. Commonly, the distance between a raised garage door and the garage ceiling may measure only 10 inches. Thus a 1 inch thick bar and 1 inch thick board will take away two full inches from that space, which would mean that at maximum, only storage containers with a height of eight inches could be stored in the shelf space. This limitation makes the device unusable with many existing storage containers. Furthermore, the shelves create a space which is very difficult to access, particularly for items stored in the middle of the shelving. In addition, the cost of using suspended shelves can be substantial. 
     In view of the above, there remains a need for an inexpensive, simple to manufacture, easy to install, inexpensive, sturdy, safe, efficient, space saving device for taking advantage of the overhead space below a ceiling. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides among other things a storage container suspension system comprising a plurality of ceiling joists, a first garage door track coupled to the plurality of ceiling joists, the first garage door track having a first upper horizontal flange, a first vertical side flange integral with the first upper horizontal flange, and a first lower trough integral with the first vertical side flange. A second garage door track may be coupled to the plurality of ceiling joists, the second garage door track having a second upper horizontal flange, a second vertical side flange integral with the second upper horizontal flange, and a second lower trough integral with the second vertical side flange, wherein the first garage door track may be positioned substantially parallel to the second garage door track, and wherein the first garage door track may be positioned such that the first upper horizontal flange extends toward the second garage door track, and wherein the second garage door track may be positioned such that the second upper horizontal flange extends toward the first garage door track. The system may further comprise a storage container having an upper perimeter defining an opening to the storage container, and a circumferential lip extending outward from the upper perimeter of the storage container, and wherein the storage container may be suspended above the ground by the first garage door track and the second garage door track. 
     Particular implementations of the invention may further comprise one or more of the following features. The storage container suspension system may further comprise a ceiling coupled to the plurality ceiling joists, and positioned between the first and second garage tracks and the ceiling joists. The ceiling may comprise drywall. The first horizontal flange and the second horizontal flange may comprise a plurality of holes. The first and second garage tracks may be coupled to the plurality of ceiling joists by one of a nail, a screw, and a bolt. The first lower trough may comprise a first edge rail and the second lower trough may comprise a second edge rail. The first and second edge rails may comprise open-section rolled rails. The first and second edge rails may comprise rounded solid rails. The first and second edge rails may be less than 2 inches away from a lower surface of a ceiling. A portion of the circumferential lip of the storage container may be in contact with an edge of the first lower trough, and a portion of the circumferential lip of the storage container may be in contact with an edge of the second lower trough. The first and second garage tracks may be comprised of a metal. The thickness of the first and second horizontal upper flange and the thickness of the first and second vertical side flange and the thickness of the first and second lower trough may greater than ⅛ th  inches. The first and second vertical side flanges may comprise one or more holes. A stopper may be coupled to at least one of the one or more holes. 
     The present invention provides among other things a method for installing a storage container suspension system comprising coupling a first garage door track to a plurality of ceiling joists, wherein the first garage door track comprises a first upper horizontal flange, a first vertical side flange integral with the first upper horizontal flange, and a first lower trough integral with the first vertical side flange. The method may further comprise coupling a second garage door track to the plurality of ceiling joists, wherein the second garage track comprises a second upper horizontal flange, a second vertical side flange integral with the second upper horizontal flange, and a second lower trough integral with the second vertical side flange, and wherein the second garage door track is positioned such that it is substantially parallel with the first garage door track, and where the second garage door track is positioned such that the first and second upper horizontal flange extend toward each other The method may further comprise suspending a storage container above the ground by the first garage door track and the second garage door track. The method may further comprise adjusting a spacer tool to measure the distance between opposing inner vertical surfaces of the storage container. The step of coupling the second garage door track to the plurality of ceiling joists may further comprise using the spacer tool to position the second garage track a distance from the first garage door track suitable for suspending the storage container above the ground. The spacer tool of method may further comprise a the spacer tool comprises a threaded rod, a first and second nut coupled to the threaded rod, a first and second spacer nut coupled to the threaded rod, a first and second wing-nut coupled to the threaded rod. The method step of adjusting a spacer tool to measure the distance between opposing inner vertical surfaces of the storage container may further comprise adjusting the position of the first and second nut along the threaded rod such that the distance between an outer edge of the first nut and an outer edge of the second nut is substantially the sane as distance between opposing inner vertical surfaces of the storage container. 
     Aspects and applications of the invention presented here are described below in the drawings and detailed description of the invention. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventor is fully aware that he can be his own lexicographers if desired. The inventor expressly elects, as his own lexicographer, to use only the plain and ordinary meaning of terms in the specification and claims unless he clearly states otherwise and then further, expressly sets forth the “special” definition of that term and explains how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventor&#39;s intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims. 
     The inventor is also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above. 
     Further, the inventor is fully informed of the standards and application of the special provisions of 35 U.S.C. §112, ¶6. Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. §112, ¶6, to define the invention. To the contrary, if the provisions of 35 U.S.C. §112, ¶6 are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. §112, ¶6. Moreover, even if the provisions of 35 U.S.C. §112, ¶6 are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures. 
         FIG. 1  depicts a perspective view of the system according to an embodiment of the invention. 
         FIG. 2  depicts a cross-sectional view of the system according to an embodiment of the invention. 
         FIG. 3  depicts perspective view of a portion of the garage door track according to an embodiment of the invention. 
         FIG. 4  depicts a front view of a spacer tool according to an embodiment of the invention. 
         FIG. 5  depicts a perspective view of a hanger cart according to an embodiment of the invention. 
     
    
    
     Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment. 
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. The full scope of the inventions is not limited to the examples that are described below. 
       FIG. 1  shows a perspective view of the storage system according to one embodiment of the invention. Ceiling joists  10  are shown as substantially parallel to each other. Generally, ceiling joists  10  are coupled to and supported by walls, frames, or other structures of a building (not shown). In the embodiment shown, ceiling joists  10  form part of a garage ceiling. Generally, in the United States, ceiling joists are spaced about 24 inches apart. The present invention is not limited to this spacing and can be easily adjusted to accommodate various configurations of ceiling joist spacing and ceiling joist orientation. In one embodiment,  FIG. 1  may represent a single cell of the storage system which can be extended in any direction or repeated in any direction across a ceiling. In the embodiment shown, a ceiling  12  is attached to the bottom side of ceiling joists  10 . Ceiling  12  may be comprised of a variety of materials, for example, ceiling  12  may comprise drywall, sheetrock, wood, plywood, particle board, sheet metal, or any other material commonly used to construct ceilings. In the embodiment shown, ceiling  12  is comprised of drywall. While this embodiment is probably the most common ceiling configuration found, it is not a limitation of the invention that ceiling  12  be present as a part of the storage system. 
     In the embodiment shown, garage door tracks  22  are coupled to ceiling joists  10  through ceiling  12 . In an alternative embodiment, garage door tracks  22  may be directly attached to ceiling joists  10 . Garage door tracks  22  may be coupled to ceiling joists  10  using a variety of different methods or fasteners. For example, garage door tracks may be coupled to ceiling joists  10  with nails, screws, bolts, adhesives, or other general construction fasteners. In the embodiment shown, garage door tracks  22  are coupled to ceiling joists  10  using screws (not shown). In one embodiment, construction fasteners (not shown) may pass through pre-existing holes in garage door tracks  22 . In another embodiment, the construction fasteners are drilled or punched through garage door tracks  22 . In the embodiment shown, garage door tracks are placed back-to-back in pairs. In an alternative embodiment, each of garage tracks  22  may be placed separate from one another. Garage tracks  22  are comprised of upper horizontal flanges  16 , vertical side flanges  20 , which are integral with upper horizontal flanges  16 , and lower troughs  14 , which are integral with vertical side flanges  20 . In one embodiment, lower troughs  14  may further comprise edge rails or edge lips  18 . In the embodiment shown edge rails or edge lips  18  are formed by the curled edges of lower troughs  14  forming an open-section rolled rail. Alternatively, edge rails or edge lips  18  could be formed by round, solid rails that are integral with the edges of lower troughs  14 . 
     In the embodiment shown, garage door tracks  22  are shown to be substantially parallel to each other. Garage door tracks  22  are shown in pairs in a back-to back configuration with horizontal flanges  16 , and lower troughs  14 , extending outwardly in opposite directions. It is not a limitation of the current invention that garage door tracks  22  always be assembled in pairs, indeed, when installing a plurality of garage tracks  22  across a ceiling, the outermost garage door tracks of the plurality of garage door tracks may be installed solitarily. 
       FIG. 2  depicts a cross-sectional view of the system according to an embodiment of the invention. This embodiment is similar to the embodiment shown in  FIG. 1  and further depicts construction fasteners  24 , which are used to couple garage door tracks  22  to ceiling joists  10 . Construction fasteners  24  may be drilled or punched into and through upper horizontal flanges  16  of garage door tracks  22 , or alternatively, construction fasteners  24  may pass through optional upper horizontal flange holes  25  in the upper horizontal flanges  16  of garage door tracks  22 . In one embodiment, upper horizontal flange holes occur at 24 inch intervals along the entire length of garage door tracks  22 . 
       FIG. 2  also depicts a storage container  30 . Storage containers come in many different shapes, sizes, materials and dimensions. For example, storage container  30  could have an opening that is rectangular, circular, or some other geometric shape. Generally, storage container  30  has an inner container width  33  and an outer container width  35 . The inner container width  33  may be described as the distance between opposing inner vertical surfaces of the storage container. The outer container width  35  may be described as the distance between the outer edges of container lips  32 . As shown, storage container  30  can be suspended by garage door tracks  22 . As shown, edge rails  18  provide a surface upon which container lips  32  can rest and glide along for loading and unloading. A unique method for appropriately positioning garage door tracks  22  such that storage container  30  can be easily placed in and out of a suspended position will be discussed later in  FIG. 4 . 
     As described earlier in  FIG. 1 , the embodiment shown may be cellular and can be extended in planar directions across ceiling  12 , thus accommodating one or multiple rows of storage container  30 , wherein each row may comprise one or multiple storage containers  30 . 
     One advantage of the embodiment shown is that when storage containers  30  are properly set into place and suspended by garage door tracks  22 , vertically directed forces on one track are substantially counterbalanced by vertically directed forces in the opposite direction from an adjacent or back-to-back garage door track. This advantage is especially apparent when there is at least one storage container  30  suspended from each row of garage door track  22 . This advantage creates a more ridged and stable suspension system wherein horizontal flanges  20  are not subject to bending inwardly or outwardly under normal operating circumstances. Additionally, this advantage allows for the use of storage containers with smaller container lips 
       FIG. 3  depicts a perspective view of a portion of the garage door track  23  according to an embodiment of the invention. This embodiment of garage door track  23  is similar to the garage door track in earlier figures, but additionally comprises optional vertical side flange holes  41  and  42  and optional upper horizontal flange holes (not shown). Vertical side flange holes  41  and  42 , and upper horizontal flange holes are useful for installation purposes. As discussed earlier, optional upper horizontal flange holes may provide a passage for a construction fastener, such as a nail, screw, bolt or other general construction fastener, to pass through and thereby couple the garage door track  23  to a ceiling joist. 
     Optional vertical side flange holes  41  and  42  are useful for coupling a spacer tool (shown in  FIG. 4 ) to garage door track  23  for the purpose of distancing, positioning and aligning two garage door tracks during installation. Additionally, a stopper (not shown), such as a bolt, screw, rod, rubber stopper, lock, padlock, or other conventional stopper, may be coupled to one or both of side flange holes  41  and  42 . The stopper may provide the function of stopping a storage container from sliding or passing over the edge of the end of the garage door track. Other embodiments of the invention may simply have a stopper which is integral with the garage door track or coupled in a different manner to the garage door track. 
       FIG. 3  also depicts an upper horizontal flange rail  19 . Similar to edge rails or edge lips  18  upper horizontal flange rail  19  may be formed by a curled edge of the upper horizontal flange  16  forming an open-section rolled rail as depicted in  FIG. 3 . Alternatively, edge rail  19  could be a round, solid rail integral with the upper horizontal flange  16 . 
       FIG. 4  depicts a front-view of the spacer tool  90  according to an embodiment of the invention. Spacer tool  90  may be helpful for installation of garage door tracks and specifically for distancing, positioning and aligning garage door tracks. 
     Spacer tool  90  comprises threaded rod  50 , which may be made of metal plastic or any other material suitable for adjusting inner nuts  60  and  65 , spacer nuts  70  and  75 , and outer nuts  80  and  85 , along its length. The length and diameter of threaded rod  50  may be any reasonable size considering the threaded rod&#39;s application. In one embodiment, threaded rod  50  is a metal threaded ¼ inch rod that is 24 inches long. A length of 24 inches corresponds to a standard distance of separation of the centers of two adjacent ceiling joists, and thus enables use of the rod for convenience and ease of determining the location of ceiling joists above a ceiling. 
     Coupled to the threaded rod may be inner nuts  60  and  65 , spacer nuts  70  and  75 , and outer nuts  80  and  85 . Each of inner nuts  60  and  65  has an inner surface,  61  and  66  respectively, and an outer surface,  62  and  67  respectively. Spacer nuts  70  and  75  have inner surfaces  71  and  76  respectively and outer surfaces  72  and  77  respectively. And outer nuts  80  and  85  have inner surfaces  81  and  86  respectively. The lengths of spacer nuts  70  and  75  are chosen so as to correspond substantially to the horizontal distance between a vertical side flange of a garage door track and an edge or edge rail of a lower trough of the same garage door track. In one embodiment, spacer nuts are approximately ⅞ inches long each. It may be noted that there exist many different types and sizes of nuts and consequently inner nuts  60  and  65 , spacer nuts  70  and  75 , and outer nuts  80  and  85 , could be interchanged with other types and sizes of similar nuts. For example, outer nuts  80  and  85  may be wing nuts as shown in  FIG. 4 , or, outer nuts  80  and  85  could alternatively be hex nuts similar to inner nuts  60  and  65 . Furthermore, as an example, the spacer nuts  70  and  75  may be chosen to have a length substantially equal to the distance between the inner wall of a vertical side flange  20  of a garage door track  22  and an edge  18  of a lower trough of the garage door track  22 . 
     Spacer tool  90  is useful for positioning garage door tracks relative to the width of storage containers. For example, spacer tool  90  may be used in conjunction with a storage container by adjusting the position of inner nuts  60  and  65  along the threaded rod  90  so that the distance between outer surfaces  62  and  67  is substantially equal to the distance between opposing inner vertical surfaces of the storage container. It may be noted that the walls of some storage containers have a tendency to “bow” outwardly at the midsection of the storage container. In this instance, it may be preferable to adjust the outer surfaces  62  and  67  of inner nuts  60  and  65  so that the distance between outer surfaces  62  and  67  is substantially equal to the distance between opposing inner vertical surfaces of the storage container at or near the edge of the storage container. This will help to ensure a more even load dispersion along a vertical edge of a storage container when the storage container is suspended from garage door tracks. 
     Once inner nuts  60  and  65  are in position, the inner surfaces  71  and  76  of spacer nuts  70  and  75  may be adjusted so as to abut the outer surfaces  62  and  67  of inner nuts  60  and  65  so as to lock inner nuts  60  and  65  in their places. 
     At this point, spacer tool  90  can be used in conjunction with a first pre-mounted garage door track. If the first pre-mounted garage door track has vertical side flange holes, then one end of the spacer tool may be placed through the vertical side flange hole so as to bring into contact the inner surface of the vertical side flange and the outer surface  72  of spacer nut  70 . Next, outer nut  80  may be used to secure spacer tool  90  to the vertical side flange of the pre-mounted garage door track. Next, a second, un-mounted garage door track can be appropriately positioned with respect to the pre-mounted garage door track by bringing the second end of the spacer tool through a vertical side flange hole of the un-mounted garage door track so as to bring into contact the inner surface of the vertical side flange of the un-mounted garage door track with the outer surface  77  of spacer nut  75 . It may be noted that throughout the installation process, it may be desirable to use one or more spacer tools simultaneously according to the above described method. Next, with the second un-mounted garage door track positioned the correct distance away from the pre-mounted garage door track, outer nut  85  may be used to secure spacer tool  90  to the vertical side flange of the un-mounted garage door track. At this point, the un-mounted garage door track can be mounted to the above ceiling joists at the appropriate locations. 
     Using the above mentioned mounting method results in two mounted garage door tracks which are positioned so as to allow the suspension of the originally measured storage container. This method of installation allows for rapid, custom fit, tight tolerances and accurate installation of the storage container suspension system. The tight tolerances and accurate installation achieved by the use of spacer tool  90  allows for the use of storage containers which have minimally protruding container lips. 
     In alternative embodiments, inner nuts  60  and  65 , spacer nuts  70  and  75  and outer nuts  80  and  85  may be chosen from a variety of different hardware parts that are accomplish the abovementioned purposes of spacer tool  90 . 
       FIG. 5  depicts a hanger cart  100  according to one embodiment of the invention. Hanger cart  100  may be used in conjunction with the garage door track to provide the ability to suspend an almost endless variety of different things. Hanger cart  100  is comprised of round rails  102  and cross members  104 . Round rails may be solid or tubular. The diameter of round rails  102  is chosen so as to allow round rails  102  to rest within the lower troughs of garage door tracks. When hanger cart  100  is positioned with round rails  102  resting in the lower troughs of mounted garage door tracks, cross members  104  can be used to suspend an almost endless variety of objects. In an alternative embodiment, hanger cart  100  may be rotated such that round rails  102  are positioned perpendicular to the garage door tracks. In this configuration round rails  102  only come into contact with the edge or rail of the lower trough. This configuration allows for less sliding resistance of hanger cart  100 , and allows hanger cart  100  to be moved easily along the garage door track. It is contemplated that an endless variety of additional options may be added to hanger cart  100  that would allow for greater configurability of the suspension system. For example, wheels could be added to the ends of round rails  102  and could be configured to set in the lower troughs of the garage door track which would allow hanger cart  100  to slide very easily up and down the garage door tracks. As another example, hooks could be attached to cross members  104  and would allow for suspension of more custom or specific objects.