Abstract:
An improved storage system, with a mechanism for easily mounting and detaching containers has been developed. The mounting mechanism consists of mounting rods attached to a storage container, which engage in suitably-shaped slots in hangers that can be attached to an overhead structure. The hangers can either be attached to the inside faces of adjacent joists or mounted to an overhead surface. The mounting mechanism is simple in construction and allows easy and rapid mounting and detaching of the storage container. The storage system results in a user-friendly and economical, overhead storage container that can easily be installed with simple hand tools.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional patent application Ser. No. 61/703,810, filed 2012, Sep. 21 by the present inventors. 
     
    
     FEDERALLY SPONSORED RESEARCH 
       [0002]    None 
       SEQUENCE LISTING 
       [0003]    None 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention relates to storage container systems, and more specifically to a storage container system having means that allow users to attach containers to an overhead structure within a building or vehicle. 
         [0006]    It is apparent that currently there is much unused and wasted overhead space, both in structures (homes, businesses, and the like) and vehicles (trucks, buses, aircraft, etc.). Thus, it would be an advantage and convenient to exploit the unused space effectively to store various items. Floor space and shelf space is often overcrowded with items in homes and businesses. Thus, there is a need to provide additional storage space without the added expense of increasing the size of the home or vehicle or the additional expense of an added storage structure outside the home. It is also desirable to use, where possible, the unused space between wooden framing members (rafters, joists, wall studs, and the like) for storage. There are numerous advantages of storing items in an overhead position which include, but are not limited to, the following: stored items are protected from damage (by being kicked or stepped upon), stored items are less likely to be affected by dampness from, for example, a concrete floor, or due to flooding (for example, in a basement), and the stored items are less likely to be accessible to small children or pets. 
         [0007]    2. Prior Art 
         [0008]    The prior art cites overhead storage container systems that hang from the structural members of a building. However, the inadequacies of the prior art are addressed by the set forth present storage system, and the advantages of the new system are presented below versus the cited prior art. 
         [0009]    U.S. Pat. No. 4,446,660 to Miller et al. (1984) shows a drawer-like container, which is supported, between floor joists by a shelf that is suspended between the joists. Compared to U.S. Pat. No. 4,446,660 the present invention provides several advantages. It allows the storage container to be mounted and detached from below, which is more convenient and less awkward for the user. In U.S. Pat. No. 4,446,660 the user must slide the storage container onto the shelf from the end. The present invention allows for storage containers to be mounted essentially adjacent to one another. In U.S. Pat. No. 4,446,660 a space equal to the length of the storage container must be left at one end of the shelf, essentially wasting space. 
         [0010]    U.S. Pat. No. 4,699,437 to Genereaux (1987) shows a container for storing items between joists that has rollers mounted on the sides of the container which engage in tracks that are mounted on the opposing faces of adjacent joists. Compared to U.S. Pat. No. 4,699,437 the present invention provides several advantages. It has a much simpler design, with many fewer and simpler parts, which are easy and inexpensive to manufacture. In the present invention the hangers have the necessary spacing built-in to them so that they can be mounted quickly and easily. In U.S. Pat. No. 4,699,437 the tracks must be separately installed and aligned relative to each other. 
         [0011]    U.S. Pat. No. 5,242,219 to Tomaka (1993) shows a between-rafter storage device, which features a drawer-like container that engages the tracks in a base unit that is attached to the bottom edges of adjacent rafters. Compared to U.S. Pat. No. 5,242,219 the present invention provides several advantages. It allows the storage container to be mounted and detached from below, which is more convenient and less awkward for the user. In U.S. Pat. No. 5,242,219 the user must slide the storage container onto the tracks from the end. The present invention allows for storage containers to be mounted essentially adjacent to one another. In U.S. Pat. No. 5,242,219 a space equal to the length of the storage container must be left at one end of the shelf, in effect wasted space. 
         [0012]    U.S. Pat. No. 5,628,153 to Fontanez (1997) shows a between-joist storage device which features a container with wheels on opposite sides that engages tracks mounted to opposing joists. Compared to U.S. Pat. No. 5,628,153 the present invention provides several advantages. The invention herein has a much simpler design, with fewer and simpler parts, which are easy and inexpensive to manufacture. The storage containers can be easily mounted and detached. In U.S. Pat. No. 5,628,153 the storage containers are supported using a complex system of mounting tracks and engaging wheels. In U.S. Pat. No. 5,628,153 no method for mounting and detaching the storage containers is shown. 
         [0013]    U.S. Pat. No. 5,649,751 to Longhurst (1997) shows a between-joist storage device which features a box with rods affixed to the ends that is supported by hooks mounted to the faces of opposing joists. Compared to U.S. Pat. No. 5,649,751 the present invention provides several advantages. It allows the storage container to be mounted and detached without substantial pivoting. In the preferred embodiment of U.S. Pat. No. 5,649,751 the storage container is mounted first on one end, filled with items, and then rotated and mounted on the other end. This may disturb the items that are placed in the storage container, which is undesirable. 
         [0014]    U.S. Pat. No. 5,845,979 to Longhurst (1998) shows a between-joist storage device, which features a storage case that is supported between the joists by pairs of interacting hooks. Compared to U.S. Pat. No. 5,845,979 the present invention provides several advantages. It allows the storage container to be mounted and detached without substantial pivoting. 
         [0015]    U.S. Pat. No. 7,597,203 to Jasniy (2009) shows a storage system that uses support rails, which attach to a ceiling that hold storage containers with projecting lips along opposing sides. Compared to U.S. Pat. No. 7,597,203 the present invention provides several advantages. It allows the storage container to be mounted within the space between the joists. In U.S. Pat. No. 7,597,203 the storage system is mounted below the joists, which wastes the space between the joists. The present invention allows the storage container to be mounted and detached from below, which is more convenient and less awkward for the user. In U.S. Pat. No. 7,597,203 the user must slide the storage container onto the rails from the end. The present invention allows for storage containers to be mounted essentially adjacent to one another, in a virtually unlimited number (only limited by the total allowable space in the structure). In U.S. Pat. No. 7,597,203 a space equal to the length of the storage container must be left at one end of the support rails. 
         [0016]    It is evident from the aforementioned prior art that the previous efforts to produce an overhead storage system have not resulted in a system that is versatile, easy to use, and assemble. Herein, we have discovered a system that is flexible to use, simple to assemble, and relatively inexpensive due to few components: an economical overhead storage container that can quickly and easily be installed with simple hand tools. 
       SUMMARY 
       [0017]    An improved storage system, with a mechanism for easily mounting containers has been developed. The mounting mechanism consists of mounting rods attached to a storage container, which engage in suitably-shaped slots in hangers that can be attached to an overhead structure. The hangers can either be attached to the inside faces of adjacent joists or mounted to an overhead surface. The mounting mechanism is simple in construction and allows easy and rapid mounting and detaching of the storage container. 
         [0018]    The storage system herein provides several advantages. An embodiment is an improved overhead storage container system with means for easy mounting and detaching a storage container. The system provides a simple and inexpensive way to manufacture overhead storage containers, and provides an overhead storage container that can quickly and easily be installed with simple hand tools. The storage system results in a more user-friendly, yet economical, overhead storage container. Still further advantages will become apparent from the following detailed description and the accompanying drawings. 
     
    
     
       DETAILED DESCRIPTION OF DRAWINGS 
         [0019]      FIG. 1  is a perspective right-side view of a storage container constructed in accordance with the invention, showing the mounting rods on one side of the container (mounting rods on the opposite side are hidden from view). 
           [0020]      FIG. 2  is a perspective right-side view of a storage container constructed in accordance with the invention, showing a preferred way of adding mounting rods to a storage container by providing holes in the sides of the storage container through which the rods are inserted.  FIG. 2  shows the rods through the holes. 
           [0021]      FIG. 3  is a perspective below-view of a hanger. 
           [0022]      FIG. 4  is a perspective left-hand view from below of two hangers attached to two joists. 
           [0023]      FIG. 5  is a perspective left-hand view from below of a storage container mounted to two hangers, which are attached to two joists. 
           [0024]      FIG. 6  shows one preferred shape of the slots in a hanger. 
           [0025]      FIG. 7  shows a second type of hanger slot arrangement. 
           [0026]      FIG. 8  shows a third type of hanger slot arrangement. 
           [0027]      FIG. 9  shows a fourth type of hanger slot arrangement. 
           [0028]      FIG. 10  shows a hanger slot arrangement that can accommodate storage containers of different sizes due to the size and shape of the slots. 
           [0029]      FIG. 11  shows a second type of hanger slot arrangement that can accommodate storage containers of different sizes. 
           [0030]      FIG. 12  shows a third type of hanger slot arrangement that can accommodate storage containers of different sizes. 
           [0031]      FIG. 13  shows a hanger slot arrangement that has provisions for mounting two storage containers. 
           [0032]      FIG. 14  is a perspective view from below of a hanger that is designed to attach to a flat horizontal surface. 
           [0033]      FIG. 15  shows the design and dimensions for the hangers used in the example herein. 
       
    
    
     DRAWINGS 
     Reference Numerals 
       [0000]    
       
         
           
               1  Storage Container 
               1 A Fore-Aft Distance between Mounting Rods 
               2  Storage Container Side 
               3  Mounting Rod 
               4  Hanger 
               4 A Front Slot to Rear Slot Dimension 
               4 B Minimum Fore-Aft Distance between Mounting Rods for Slots which Accommodate Containers of Different Sizes 
               4 C Maximum Fore-Aft Distance between Mounting Rods for Slots which Accommodate Containers of Different Sizes 
               5 A Front Slot 
               5 B Rear Slot 
               5 C Front Slot with Alternate Design 
               5 D Rear Slot with Alternate Design 
               5 E Front Slot with Alternate Design 
               5 F Rear Slot for Containers of Different Sizes 
               5 G Rear Slot for Containers of Different Sizes 
               5 H Front Slot for Containers of Different Sizes 
               6  Mounting Hole 
               7  Alignment Pin 
               8  Joist 
               9  Integral Flange 
           
         
       
     
       DETAILED DESCRIPTION OF INVENTION 
       [0054]      FIG. 1  is a perspective view taken from the right side of the storage container  1 , constructed in accordance with one embodiment. In this embodiment the storage container is rectangular in shape and has a bottom and four sides. Two mounting rods  3  are firmly attached, as shown in  FIG. 1  by gluing or the like, to the storage container side  2 . Two mounting rods  3  are also attached, in a similar position, to the opposite container side (not shown). 
         [0055]    The storage container  1  can be of many structural designs. While most typically box-shaped, other shapes could be adapted to the system. The storage container can be constructed of any suitable material: for example, cardboard corrugated board, wood, plastic, metal, and fiberglass. The storage container can either have a perforated structure (for example a perforated plastic, wood, or metal crate) or be made from a translucent or transparent material (in whole or part), for example a transparent or translucent plastic resin or plastic composite, in order to allow the user to see what it contains without necessitating removal from its mounted position. Alternatively, one can affix a label to the bottom of the container for easy reading of contents. The storage container can be designed to nest with similar storage containers. The storage container can be provided with a lid in order to protect the contents from dust, dirt, insects, water, humidity, mold, or other harmful environments. The storage container can be an off-the-shelf item, provided it has suitable shape and size. 
         [0056]    Two mounting rods  3 , which are approximately perpendicular to the side of the storage container, extend from each of two opposing sides. The mounting rods can be circular, square, or some other shape in cross section. The mounting rods may be either solid or tubular. The mounting rods do not have to be the same in cross sectional shape or size, nor constant in cross sectional shape or size. The rods can be constructed of wood, metal, plastic, fiberglass or other suitable materials. 
         [0057]    Four mounting rods, two on each of two opposing sides are used at a minimum. Additional mounting rods may be utilized (for example three per side) for increased load capacity or other benefits. 
         [0058]    One preferred way of adding mounting rods to a storage container is by providing holes in the sides of the storage container, for example by drilling, and then by inserting rods which are longer than the width of the storage container through the holes.  FIG. 2  is a perspective view taken from the right side of the storage container  1 , showing this method of adding mounting rods to a storage container. Alternatively, mounting rods may be attached to a storage container by using an adhesive, mechanical fasteners, welding or brazing, or molding them as part of the container itself, for example in the case of injection molded plastic containers. 
         [0059]    The mounting rods  3  are typically positioned near the corners of storage container  1  because this maximizes the usable internal space of the storage container and provides the most secure position when the container is mounted in the hangers  4 . The fore-aft distance between the mounting rods  3  is important because it determines the position of the slots  5 A and  5 B in the hangers  4 . Dimension  1 A in  FIG. 1  is the fore-aft distance between the mounting rods  3 . 
         [0060]    The vertical position of the mounting rods on the container can be varied in order to control the height of the container compared to the overhead structure. For example, if it is desired that the container be lower relative to the overhead structure the mounting rods can be attached to the storage container at a higher point on its sides. In the case where mounting rods are attached to the storage container by using holes in the sides of the storage container, multiple sets of holes can be provided in order to provide the user with a means of height adjustment for the storage container. 
         [0061]      FIG. 3  is a perspective view from below of a hanger  4  constructed in accordance with one embodiment. The mounting mechanism utilizes two hangers, a right-hand hanger and a left-hand hanger, which are attached to the overhead structure (as illustrated herein as the overhead joists). The mounting rods  3  on the storage container  1 , in  FIG. 2 , engage in suitably-shaped slots  5 A and  5 B on the hangers forming an interconnection. In general, the slots in the hangers are inverted “J” shapes. The “J” shape allows the mounting rods to drop somewhat as the storage container is mounted in the hangers. This provides a secure mounting position, as the storage container must be lifted somewhat to be detached from the hangers, which prevents accidental detachment of the storage container from the hangers. 
         [0062]    The hangers can be constructed from any suitable material, for example, wood (including plywood, tempered hardboard, and fiberboard), plastic, metal or fiberglass. The hanger  4  can have mounting holes  6 , which allow the hanger to be attached to the overhead structure with mechanical fasteners (screws, bolts, nails, or staples and the like). Alternatively, the hangers can be mounted to the overhead structure using other attachment means such as expandable mechanical devices, adhesives, hook and loop fasteners, mounting brackets, and the like. For mounting to joists or similar structural members, alignment pins  7  can be utilized to make installation of the hangers simpler. The hangers are positioned so that the alignment pins  7  are in contact with the bottom edge of the joists  8 . 
         [0063]      FIG. 4  is a perspective left-hand view from below of two hangers  4  attached to the inside faces of two adjacent joists  8  in accordance with one embodiment. The alignment pins  7  enable the user to fasten the hangers to the joists in the proper position with a minimum of measuring and aligning. The hangers are fastened to the joists using mechanical fasteners (such as screws) inserted through mounting holes  6  in this embodiment. The hangers can also be attached to the outside faces of the two adjacent joists or, alternatively, to one inside face and one outside face of adjacent joists. 
         [0064]      FIG. 5  is a perspective left-hand view from below of one storage container  1  supported by two hangers  4  attached to two joists  8  in accordance with one embodiment. The mounting rods  3  engage in the slots  5 A and  5 B allowing the storage container  1  to be supported between the joists  8 . The hangers are positioned at essentially the same fore-aft position on the joists  8  so that the mounting rods  3  on the storage container can engage the slots  5 A and  5 B on both hangers simultaneously. 
         [0065]    A range of hanger slot designs can be used in the context of the present invention.  FIG. 6  shows one preferred shape of the slots  5 A and  5 B in a hanger. The relative position of the front slot  5 A and the rear slot  5 B is determined by the fore-aft distance  1 A between the mounting rods  3  on storage container  1 . Dimension  4 A in  FIG. 6  is approximately the same as the fore-aft distance  1 A between the mounting rods  3 . 
         [0066]      FIG. 7 ,  FIG. 8 , and  FIG. 9  show alternate hanger slot designs. 
         [0067]      FIG. 10 ,  FIG. 11 , and  FIG. 12  show hanger slot arrangements that can accommodate storage containers of different sizes (i.e. with different distances between mounting rods). In these designs, one slot is provided in each hanger, which has an extended horizontal region. For example, the hanger slot design shown in  FIG. 10  can accommodate storage containers with fore-aft distances  1 A between the mounting rods  3  ranging from dimension  4 B to dimension  4 C. 
         [0068]      FIG. 13  shows a hanger slot arrangement that has provisions for mounting two storage containers. In this case, two pairs of slots are provided in each hanger. The distance between the front slot and rear slot for each pair of slots is determined by the fore-aft distance between the mounting rods  3  for the corresponding storage container  1 . The relative position of the slots for the first container compared to those for the second container is determined by providing sufficient clearance between the two containers so that they can be easily mounted and demounted from the hangers. 
         [0069]    It is not a limitation that the present invention (incorporating the hangers, rods and storage containers) be used only for attaching to joists. A variety of attachment means may be used for securing the hangers to an overhead structure. An example of attachment means is the use of flanges, angle (“L” shaped) brackets, and the like. Another example is the use of integral flanges, where the flanges are part of the hangers themselves, or flanges which are fastened to the hangers using suitable attachment means (mechanical fasteners, adhesives, hook and loop fasteners, and the like). In one embodiment,  FIG. 14  shows a hanger with an integral flange that would be suitable for mounting to a horizontal surface, for example to a ceiling, to the bottom side of a shelf, inside a closet or cabinet, or to the inside of the roof of a vehicle. 
         [0070]    The following example is presented to illustrate further various aspects of the present invention, but is not intended to limit the scope of the invention in any respect. 
       EXAMPLE 
       [0071]    This is an example of one embodiment of an Overhead Crate Storage System. 
         [0072]    A collapsible plastic storage crate (Taskett™ from Schiffmayer Plastics Corporation, 1201 Armstrong St., Algonquin, Ill. 60102) with a height of 11 inches, a width of 14 inches, and a length of 20¾ inches was used as storage container  1 . The collapsible crate was drilled in four locations with a ⅜-inch diameter drill bit on both long sides  2  of the crate. The holes were drilled 1 inch from the ends of the crate and 4½ inches from the bottom of the crate. Two ⅜-inch diameter wooden dowels, each with a length of 15½ inches, were used as mounting rods  3  and were inserted in the aforementioned holes in the crate so that ¾ inch of each dowel projected beyond the sides of the crate. The fore-aft distance  1 A between the dowels was 18¾ inches. Two hangers  4 , a right hand hanger and a left-hand hanger, were made from ⅛ inch thick tempered hardboard according to the dimensions in  FIG. 15 . The slots  5 A and  5 B were cut into the hangers in the shape shown in  FIG. 15  with a slot width of ¾ inch. The slots were positioned as shown in  FIG. 15  so that they accommodated the 18¾ inches fore-aft distance between the dowels. Two nylon cup washers with an outside diameter of ½ inch and a depth of ¼ inch were riveted to each hanger to act as alignment pins  7  and were positioned as shown in  FIG. 15 . The hangers were attached to two adjacent 2 inches×8 inches (nominal) joists  8  (1.5 inches×7.5 inches actual size) on a center-to-center spacing of 16 inches with the alignment pins against the bottom edges of the joists. The hangers were positioned at approximately the same fore-aft position on the joists. Each hanger was securely fastened to its respective joist by installing two 1½ inches long deck screws through mounting holes  6  into the joist. The crate was lifted into position so that the dowels on both sides of the crate engaged the slots in both hangers simultaneously, mounting the crate to the joists overhead.