Abstract:
A rack for providing a lower cost solution for manufacturing and shipping is disclosed. The rack, suitable for use in freezer or cooling components comprises a top element, a bottom element and side elements between said top and bottom elements, linearly arranged, wherein three of said elements are joined together at corresponding edges with a flexible hinge mechanism, a joining mechanism including a catching mechanism and a connecting mechanism, said joining mechanism retaining adjacent ones of said elements in a substantially perpendicular arrangement, each of said elements including at least one of said catching mechanism and said connecting mechanism and adjacent ones of said elements contain alternate ones of said catching mechanism and said connecting mechanism; and a back element linearly attached with a flexible hinge mechanism along an edge of each of said side elements, wherein said back element includes a snap fit retaining mechanism along a top end and a bottom end of each edge.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Storage of biological samples often requires the use of a refrigerator and/or freezer unit. Such samples are commonly sealed in plastic micro-tubes (such as Cryovial brand from Simport Plastiques Ltee, Beloeil, Quebec, Canada), which are small vessels, each of which typically holds a total volume of 1 to 3 milliliters, and has a separate sealing screw cap. These tubes are commonly organized in standard 81-place (9×9 configuration) or 100-place (10×10 configuration) storage boxes or trays. The boxes and the tube holder frame can be made from cardboard (inexpensive, but not very durable), or plastic (such as polypropylene, or polycarbonate, typically with drain holes for liquid nitrogen storage). These boxes are available in different heights (typically 2 inches high or 3 inches high) to accommodate the most popular sized sample tubes. Another popular method stores samples in 96-well or 384-well microtiter plates with sealing lids, or small tubes that are configured into a 96-place pattern and have the same standard footprint dimensions of microtiter plates. 
         [0002]    Microtube storage boxes (i.e., trays) and storage microplates are typically organized in a laboratory refrigerator or freezer using a stainless steel rack having properly sized openings (shelf spaces) to hold the boxes (or plates). Current freezer racks are typically made of a stainless steel material having a number of shelves for holding specimen trays. The freezer racks are typically sized to accommodate known freezer compartment sizes such that one or more freezer racks may be placed within freezer compartment. The racks are sized such that a maximum amount of space within the freezer compartment is occupied, and a maximum number of storage boxes, trays or plates can be accommodated. 
         [0003]    However, conventional freezer racks are bulky items as their construction requires that the racks be manufactured according to the desired size. This bulkiness further complicates the shipping of the racks as the shipping materials must accommodate the fully constructed freezer rack. In addition, the racks are constructed with the knowledge that the rack is suitable for a slide-in up-right freezer unit or a drop-in (chest style) freezer unit, and are constructed with shelf spaces for specific height boxes. Hence, there is currently a need for a lightweight and modular freezer rack that may be shipped in a disassembled, flat packaged form, assembled on-site and suitable for different sizes and types of freezer units, and can be used for various height boxes (such as common 2 inch and 3 inch high boxes). 
       SUMMARY OF THE INVENTION 
       [0004]    A rack for providing a lower cost solution for manufacturing and shipping is disclosed. The rack, suitable for use in freezer or cooling components comprises a top element, a bottom element and side elements between said top and bottom elements, linearly arranged, wherein four of said elements are joined together at three shared edges with a flexible hinge mechanism, a joining mechanism including a catching mechanism and a connecting mechanism, said joining mechanism retaining adjacent ones of said elements in a substantially perpendicular arrangement, each of said elements including at least one of said catching mechanism and said connecting mechanism and adjacent ones of said elements contain alternate ones of said catching mechanism and said connecting mechanism; and a back element linearly attached with a flexible hinge mechanism along an edge of each of said side elements, wherein said back element includes a snap fit retaining mechanism along a top end and a bottom end of each edge. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0005]      FIG. 1  illustrates a prospective view of an embodiment of the present invention in a first, unfolded, state; 
           [0006]      FIG. 2  illustrates a prospective view of a locking mechanism of the present invention in a first state; 
           [0007]      FIG. 3  illustrates a prospective view of a locking mechanism of the present invention in a second, folded, state; 
           [0008]      FIG. 4  illustrates a prospective view of an embodiment of the present invention in a second, folded, state; 
           [0009]      FIG. 5  illustrates a prospective view of an exemplary shelve unit in accordance with the principles of the invention; 
           [0010]      FIGS. 6 and 7  illustrate prospective views of different configurations of an embodiment of the invention in accordance the principles of the invention; 
           [0011]      FIGS. 8A and 8B  illustrate a first and second prospective view of a strap connector in accordance with the principles of the invention; 
           [0012]      FIG. 9  illustrates an exemplary retaining ring in accordance with the principles of the invention; 
           [0013]      FIGS. 10A and 10B  illustrate prospective views of a plurality of racks in accordance with the principles of the invention; and 
           [0014]      FIG. 11  illustrates an expanded view of the retaining ring shown in  FIG. 10B  in accordance with the principles of the invention. 
       
    
    
       [0015]    It is to be understood that these drawings are solely for purposes of illustrating the concepts of the invention and are not intended as a definition of the limits of the invention. It will be appreciated that the same reference numerals, possibly supplemented with reference characters, where appropriate, have been used throughout to identify corresponding parts. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0016]      FIG. 1  illustrates an exemplary freezer rack  100  in accordance with a first, unfolded, state, including top member  110 , first side member  120 , bottom member  130  and second side member  140 , which are linearly joined together. First side member  120  and second side member  140  each includes a back surface  150 . 1 ,  150 . 2  linearly joined at back edge of the first and second side members. Back surface  150 . 1 ,  150 . 2 , preferably, are limited is size to create a back surface that is not fully closed. However, it would be appreciated that back surface  150 . 1 ,  150 . 2  may be sized to provide a fully closed back surface when the freezer rack  100  is in a second, folded, state. In the embodiment shown in  FIG. 1 , the bottom element  130  is positioned between and adjacent to the side elements  120 ,  140 . However, it would be recognized that it may be possible to provide an embodiment of the invention wherein a top member  110  may be positioned between and adjacent to side members  140  and  120  or a side member may be positioned between and adjacent to top member  110  and bottom member  130 . 
         [0017]    Each of top member (or element)  110 , first side member  120 , bottom member  130  and second side member  140  is a known material thickness. Between each member  110 ,  120 ,  130 , and  140  the material thickness is substantially reduced so as to produce a region in which the member may be brought into substantially vertical orientation. Areas  145  are referred to in the art as a flexible hinge or “living hinge.” The use of a continuous, foldable, hinged material is advantageous as it allows for the flat shipment of the freezer rack in accordance with the principles of the invention. A hinge member  145  is also incorporated along a back edge of each of side members  120  and  140  to attach back surface  150 . 1 ,  150 . 2 . 
         [0018]    Along an edge adjacent to the living hinge of each of top member  110 , first side member  120 , bottom member  130  and second side member  140  is a plurality of locking or joining mechanisms  160  that lock respective ones of the members in substantially vertical orientation when the members are folded along the corresponding hinge. Also shown are catching mechanisms  172 . 1  on top member  110  and matching mechanism  172 . 2  on a top portion of back surface  150 . 1 . Similar locking mechanisms  176 . 1  are shown on bottom member  130  and matching mechanism  176 . 2  on a bottom portion of back surface  150 . 1 . Locking or catching mechanism  172 . 1 ,  172 . 2  and  176 . 1 ,  176 . 2  retain back surface  150 . 1  in substantially vertical orientation with top and bottom members  110 ,  130 , respectively. Similar locking mechanisms  170 . 1 ,  170 . 2  and  174 . 1 ,  174 . 2  are shown on back surface  150 . 2 . In one aspect of the invention, catching mechanism  172 . 2 , 176 . 2 ,  170 . 2  and  174 . 2 , may represent protrusions that engage corresponding catching mechanism  172 . 1 ,  176 . 1 ,  170 . 1 , and  174 . 2 , that are formed on back edges of top and bottom elements  110 ,  130  respectively. Catching mechanism  172 . 1 , for example, may represent a pincer mechanism that engages corresponding protrusion  172 . 2  to create a snap-fit engagement or joining means. It would be recognized that catching mechanism  172 . 2  may represent a pincer mechanism and catching mechanism  172 . 1  may represent a protrusion that engages pincer mechanism  172 . 2 . 
         [0019]    Indentures or indents  190  are positioned along a front, first, edge of each of first side member  120  and second side member  140 . Indentures  190  provide regions for joining together a plurality of freezer racks  100  when in a folded state, as will be explained with regard to  FIGS. 11A and 11B . Along a back, second, edge of each of first side member  120  and second side member  140  is indentures  195 . Indentures  195 , in conjunction with indentures  190 , provide regions for joining together a plurality freezer racks  100  when in a folded, second, state. Also shown are raised areas  197  on each of back surfaces  150 . 1 ,  150 . 2 , corresponding to each of indentures  195 . In an alternate embodiment, a groove (not shown) may extend from indenture  190  to indenture  195 . 
         [0020]      FIG. 2  illustrates a prospective detailed view of locking or joining mechanism  160  when freeze rack  100  is in a first, unfolded, configuration.  FIG. 2  illustrates a first latching element  160 . 1  extending substantially vertically from one of the members. In this illustrated example, latching or catching element  160 . 1  extends substantially vertically from a surface of first side element  120 . Also shown is second latching or connecting element  160 . 2  comprising columns  210 . 1 ,  210 . 2  extending substantially vertically from surface  110 , for example. Connection element  220  connects columns  210 . 1 ,  210 . 2  and forms a space  220 . 1  therebetween. Also incorporated into second latching or connection element  160 . 2  is leg  230  that extends substantially vertically from the surface of top member  110 . A front surface  220 . 2  of connection element  220  is shown sloped away from latching mechanism  160 . 1 . The slope surface  220 . 2  is advantageous as it allows connection member  220  to slide over first latch element  160 . 1 . 
         [0021]      FIG. 3  illustrates a prospective detailed view of locking mechanism  160  when freezer rack  100  is in a second, folded, configuration.  FIG. 2  illustrates in this folded configuration, first latching element  160 . 1  extending through the opening  220 . 1  (not shown) to so that first latch element  160 . 1  engages a rear surface  220 . 3  of connection member  220 . Also illustrated is an end of leg  230  being in contact with surface  120 . The purpose of the leg  230 , and specifically its angled shape, is to guide sample boxes into the created shelf spaces so the sample boxes do not get stopped by the locking mechanism. 
         [0022]      FIG. 4  illustrates a prospective view of freezer rack  100  in a second, folded, configuration. As illustrated, engagement mechanisms  160  retain each member in a substantially perpendicular orientation. Also engaging element  176  (i.e.,  176 . 1 ,  176 . 2 ) and not shown elements  170  ( 170 . 1 ,  170 . 2 ),  172  ( 172 . 1 ,  172 . 2 ), and  174  ( 174 . 1 ,  174 . 2 ) retain back surface  150 . 1  (and not shown  150 . 2 ) substantially vertical orientation to top and bottom members  110 ,  130 , respectively. Also shown are protrusions  410  extending from an outer surface to an inner surface of first and second side members  120 ,  140 . Protrusions  410  provide means for attaching shelving within the cavity formed by freezer rack  100  in this second configuration. Within raised areas  197  are openings  420 . Openings  420  are substantially parallel to protrusions  420 . 
         [0023]      FIG. 5  illustrates a prospective view of a shelf  500  in accordance with principles of the invention. Shelve  500  is substantially flat are sized to fit within the freezer rack shown in  FIG. 4 . Protrusions  510 , extending from the side edges of shelf  500  engage corresponding protrusions  410  in sides  120 ,  140  to lock shelf  500  in place with a snap fit connection. Also shown are pincers  520  along a back edge of shelf  500 . Pincers  520  engage openings  420  to retain the back edge of shelf  500  in a fixed relationship. 
         [0024]      FIG. 6  illustrates a first exemplary embodiment of the invention wherein two shelf elements  500  are positioned within the cavity formed by rack  100 . In this configuration, rack  100  is capable of holding three (3) trays or boxes, which are typically sized at three inches in height.  FIG. 7  illustrates a second exemplary embodiment of the invention wherein three shelf elements  500  are positioned within the cavity formed by rack  100 . In this configuration, rack  100  is capable of holding four (4) boxes, sized at 2 inches in height. 
         [0025]    Although the present invention has been illustrated with respect to a two shelf and a three shelf configuration, it would be recognized that more shelves may be incorporated into the freezer rack  100  by the proper placement of the protrusions  410 . 
         [0026]      FIG. 8  illustrates a prospective view of an exemplary strap connection for attaching freezer racks in accordance with the principles of the invention. In this exemplary embodiment, strap connection  800  is an extended length U-shaped device having a first end having a substantially U shape that connects two extended length arms  810 . 1 ,  810 . 2 . At the end of each arm  810 . 1 ,  810 . 2  is a latching or capturing mechanism  820 . 1 ,  820 . 2 , comprising a narrower arm  822 . 1 ,  822 . 2  extending from the arms  820 . 1 ,  820 . 2 , respectively. Extending from arms  822 . 1 ,  822 . 2  are lip members  824 . 1 ,  824 . 2 , respectively, that retain a nut or cap that may be placed on arms  822 . 1 ,  822 . 2 . The flexibility of arms  810 . 1 ,  810 . 2  allow retaining rings sized to fit over lips  824 . 1 ,  824 . 2  to engage arms  822 . 1 ,  822 . 2 . 
         [0027]      FIG. 8B  illustrates a second prospective view of strap connector  800  illustrating lips  820 . 1 ,  820 . 2 , in further detail. Lips  824 . 1 ,  824 . 2  are shown in a preferable circular configuration, which may be used to retain a circular retaining ring. Although strap connector  800  is shown utilizing a snap-fit connection, it would be recognized that the lips  824 . 1 ,  824 . 2  may be removed and threads incorporated onto arms  822 . 1 ,  822 . 2  and a threaded nut may be screwed on to arms  822 . 1 ,  822 . 2  to retain the ends of strap connector  800 . 
         [0028]      FIG. 9  illustrates an exemplary retainer ring  900  in accordance with a preferred embodiment of the invention. Retainer ring  900  is sized to have an inner diameter dimension to fit over arms  822 . 1 ,  822 . 3  while to retaining arms  810 . 1 ,  810 . 2  in a substantially parallel arrangement. An outer diameter dimension of retainer ring  900  is sized to enable lips  824 . 1 ,  824 . 2  to engage flat surface  910 . Alternatively, ring  900  may include a threaded section on the inner circumference to enable retaining ring  900  to be screwed-onto a threaded end of arms  822 . 1 ,  822 . 2 . 
         [0029]      FIG. 10A  illustrates a prospective view of the construction of an exemplary modular freezer rack system  1000  incorporating racks  100 A,  100 B, and  100 C in a frontal view. Although three racks are shown in this exemplary system, it would be recognized that a greater or a lesser number of racks  100  may be joined together dependent upon a desired size and/or configuration. 
         [0030]      FIG. 10A  illustrates joining racks  100 A,  100 B,  100 C together with strap connectors  800  placed to engage first side member  120  of a first rack, e.g.,  100 B and a second side member  140  of an adjacent second rack, e.g.,  100 A. Strap connectors are placed along the first and second side member of adjacent racks (e.g.,  100 A,  100 B) in corresponding ones of the indents or notch element  190 . Indents  190  are sized so that the outer surface of “U” shaped section of strap  800  is flush with the outer edges of joined racks  100 A,  100 B. 
         [0031]      FIG. 10A  further illustrates the placement of boxes  1010  on bottom member  130  and shelves  500 . 
         [0032]      FIG. 10B  illustrates a prospective view of the modular rack system  1000  shown in  FIG. 10A  with regard to a back view. In this illustrated embodiment of the invention, retainer rings  900  engage the arms of strap connector  800  that have been inserted into indentures  190  (not shown) and extended along first and second side member  120 ,  140 , respectively of adjacent racks (e.g.,  100 A,  100 B). Retaining rings  900  are positioned on arms  822 . 1 ,  822 . 2  (not shown) after being placed over lips  824 . 1 ,  824 . 2  (not shown). Retaining rings  900  are positioned within the raised area  197  on back portion  150 . 1 ,  150 . 2  of adjacent racks (e.g.,  100 A,  100 B). The use of raised areas  197  on back portion  150 . 1 ,  150 . 2 , which create a recess in one side of back portion  150 . 1 ,  150 . 2 , is advantages as it provides a recessed area wherein ring  900  may be placed without extended past an outer edge of rack  100 . 
         [0033]      FIG. 11  illustrates an expanded view of retainer ring  900  engage strap connector  800  within raised area  197 . Strap connector, as noted previously, extends along side walls of adjacent racks  100 A,  100 B, for example, to a rear edge within raised area  197 . Retaining ring  900  may then be placed over lips  824 . 1 ,  824 . 2 , in a snap fit connection, to retain strap connector  800  in place. Also shown are openings  420  and pincers  520  along the back edge of shelf  500  engaging openings  420 . 
         [0034]    Alternatively, an inner circumference of retaining ring  900  may include a screw thread that may be screwed-onto a screw thread that may be incorporated onto arms  822 . 1 ,  822 . 2 , in the absence of lips  824 . 1 ,  824 .  2 . In another embodiment, a cotter pin attachment may be used to retain strap connector  800  in place. In this embodiment, arms  822 . 1 ,  822 . 2 , may include a hole that allows for the insertion of a cotter pin. In another embodiment, a spring washer may be used to retain strap connector  800  in place. The-spring washer may be placed over arms  822 . 1 ,  822 . 2  to retain the arms of strap connector  800  tightly against the sides of adjacent freezer racks. 
         [0035]    While there has been shown, described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.