Abstract:
A storage box for a cargo bay of a vehicle including a conveyor on which items, e.g., tools and materials, are stored. The conveyor is actuatable to move the items in a pre-selected direction, preferably toward the side or rear of the vehicle cargo bay to provide easy access to the items. In another aspect, the storage box includes fold-out shelving. The shelving includes multiple panels hinged together. A first panel is hingedly connected to an intermediate panel, which is hingedly connected to a second panel, which is pivotally connected to the storage box. The panels are operable in (a) a collapsed mode, where the panels fold substantially vertically against one another, and (b) an extended mode, where the first panel moves outwardly to a substantially vertical position and the intermediate and pivot panel pivot downward to a substantially horizontal position.

Description:
This application is a division of U.S. application Ser. No. 10/361,339 filed Feb. 10, 2003 (now U.S. Pat. No. 7,036,861), which is hereby incorporated by reference. 

   BACKGROUND 
   The present invention relates to toolboxes, and more particularly to toolboxes mounted in the cargo bay of a vehicle. 
   Pick-up trucks and vehicles having open cargo bays are used extensively for transporting purposes. To protect tools and materials transported in a pick-up bed or an open cargo bay from both theft and the elements, it is common to use a toolbox, also referred to as a “utility box,” that includes an enclosed storage space within which items may be stored. Most toolboxes include a door that provides access to the storage space. 
   Typically, the toolboxes mount across the pick-up bed between the pick-up bed side panels, or along the side panels. These configurations enable a user to access the toolbox door, by standing along side the side panels, rather than having to enter the pick-up bed. 
   Often, a toolbox includes one or more storage bins that subdivide the storage space and improve organization within the box. Most storage bins are slidably mounted on ledges or rails in the toolbox to facilitate access to items stored under the bins. 
   Although conventional pick-up bed toolboxes provide a way to protect, access and organize items stored therein, they suffer several shortcomings. First, it is common for items stored in a toolbox to shift in transit, particularly if the vehicle traverses a rugged construction site. In some cases, an item that was placed in the toolbox on one side, or the front, of the pick-up bed may shift in the toolbox to the other side or rear of the pick-up bed. Accordingly, the user must go to the other side of the vehicle or enter the pick-up bed to retrieve the item. This can be frustrating, and usually wastes valuable work time. Second, a user may place an item in a toolbox on one side of a pick-up bed, and later desire to retrieve the item from the other side of the pick-up bed. With a conventional toolbox, the user has no choice but to go to the side that the item was originally placed in the toolbox to retrieve it. Third, where toolboxes are mounted in pick-ups or vehicles having tall ride heights, a user frequently accesses and uses only the storage space immediately adjacent the pick-up side panels because it is difficult to reach over the side panels and access the center of the toolbox. Thus, many times the storage capacity of the toolbox is underutilized. 
   Furthermore, conventional toolbox storage bins frequently make it difficult to store large items, e.g., large power tools, in the toolbox. Typically, the boxes must be removed from the toolbox to accommodate large items. Often, the bins are lost or forgotten after removal and therefore no longer useful. Additionally, debris, such as dirt or nails, collects on the ledges or rails that support the bins, inhibits the movablility of the bins, and damages the interior of the toolbox. 
   SUMMARY OF THE INVENTION 
   The aforementioned problems are overcome in the present invention wherein a utility or toolbox is provided that includes a conveyor. The conveyor is mounted between opposite sides of the toolbox. An actuator enables a user to convey items disposed in the toolbox and on the conveyor in a pre-selected direction, for example, toward the user at either opposing ends of the toolbox. 
   In one embodiment, the conveyor is driven by a motor that is activated by controls mounted near opposing sides of the toolbox. Accordingly, a user may engage the conveyor regardless of the side of the box at which he or she is located. 
   In another embodiment, the conveyor includes a belt having a continuous tensioner to keep the belt taut. With the tension, the belt is driven with sufficient traction to withstand slippage on drive rollers or drums when heavy items are disposed on the conveyor. 
   In another aspect of the present invention, a pick-up bed toolbox is provided that includes a fold-out shelving unit. The shelving unit includes multiple panels hingably connected to one another. One end panel, a “slider panel,” may be slidably mounted to the toolbox. An opposite end panel, a “pivot panel,” is pivotally mounted to the toolbox. An intermediate panel is mounted between the end panels. The panels are operable in a collapsed mode, where the panels fold-up and out of the way in the toolbox, and an extended mode, where the slider panel slides to a vertical position, and the intermediate panel and pivot panel fold-out to horizontal positions forming a shelf. Optionally, the slider panel includes a storage tray oriented relative to the intermediate and pivot panels so that it does not interfere with the folding of the panels in the collapsed mode. 
   The present invention provides a utility or toolbox with increased functionality and accessibility. With the conveyor, a user may easily access contents of the toolbox from any side or end of the pick-up bed or cargo bay, regardless of whether the contents shifted in transit or where the contents were placed after the last use. In turn, this reduces the time spent accessing items in the toolbox. Furthermore, the improved shelving of the present invention provides on-demand subdivision of toolbox storage space. It also easily folds out of the way, enabling a user to take full advantage of the storage space without removing the shelving unit altogether from the toolbox. 
   These and other objects, advantages and features of the invention will be more readily understood and appreciated by reference to the detailed description of the invention and the drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the toolbox of the present invention shown in conjunction with a pick-up bed and a foldable bed cover; 
       FIG. 2  is an exploded view of the conveyor; 
       FIG. 3  is a perspective view of the drive assembly of the conveyor; 
       FIG. 4  is an exploded view of an alternative embodiment of the conveyor; 
       FIG. 5  is a cut away view of the toolbox including a fold-out shelving unit in an extended configuration shown in full lines and a collapsed configuration shown in broken lines; 
       FIG. 6  is a side elevational view of the fold-out shelving unit in an extended configuration in full lines and a collapsed configuration shown in broken lines; and 
       FIG. 7  is a perspective view of an alternative embodiment of the fold-out shelving unit. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   I. Overview 
   A toolbox constructed in accordance with a first embodiment of the invention is illustrated in the drawings and generally designated  10 . With reference to  FIG. 1 , the toolbox  10  is shown in conjunction with a conventional folding cargo cover  120 , having a panel  122  that opens to provide access to the interior of the toolbox. The toolbox generally includes a frame  20  including multiple vertical support members  22  and horizontal members  24 . Sides  30  and ends  32  are secured to the frame to define storage space. A conveyor  40  is mounted to the frame  20 , preferably near the bottom of the frame, to form a floor of the toolbox  10 . 
   With reference to  FIGS. 5 and 6 , the toolbox includes a fold-out shelving unit  70  mounted in the frame  20  of the toolbox  10 . The fold-out shelving  70  includes multiple panels  72 ,  74 ,  76 , hinged to one another and extendable from a collapsed mode to an extended mode, in which the intermediate panel  72  and pivot panel  76  form a support surface on which items may be stored. The fold-out shelving unit  70  may installed in a toolbox with the conveyor of the present invention as desired. 
   In the drawings, the toolbox shown is a crossover design that extends between the side panels  102 ,  104  of the pick-up bed  100 . However, the present invention also is suitable for other pick-up bed toolbox designs, including a side mount toolbox design, where the toolbox is mounted along and parallel to one or more of the side panels, and a bed design, where the toolbox is mounted between the side panels on the bottom of the pick-up bed  106 . Furthermore, although shown in connection with a folding cargo cover  120 , the present invention is well suited for stand-alone toolboxes including one or more doors or covers that provide access to the interior of the toolbox. Finally, although the toolbox  10  is shown mounted in a pick-up bed, it is also well suited for a variety of other cargo bays, for example, cargo bays in or on hybrid sport utility vehicles, vans, trailers, tractors and other vehicles. 
   II. Toolbox Construction and Conveyor Assembly 
   The toolbox and conveyor assembly of the present invention will now be described in more detail with reference to  FIGS. 1–4 . The toolbox as shown includes a frame having multiple vertical members  22  forming the corners of the frame  20 . The vertical members  22  are connected to one another with the horizontal members  24 . The vertical and horizontal members may be of an extruded construction including slots or holes. These slots or holes are optionally modular to enable a user to adjust the position of the horizontal elements  24  relative to the vertical elements or vice versa or include additional shelving or accessories within the toolbox  10 . As shown in  FIG. 1 , side panels  30  and end panels  32  may be joined with the vertical and/or horizontal members  22 ,  24 , as desired, to form an enclosed storage space within the frame. 
   The vertical members  22  may include feet  28  that extend from the vertical members  22 . The feet  28  optionally are selectively extended and retracted from the vertical members  22  to adjust and level the frame relative to the pick-up bed bottom  106  against which the feet are positioned. For example, the feet may include a bolt portion that is threadably received and fixedly disposed in the vertical member  22 . 
   The frame further includes brackets  60  that secure the frame  20  to the pick-up bed  100  and prevent it from tipping or moving relative to the pick-up bed. The brackets  60  may be secured to the frame  20  with any conventional fasteners including bolts, screws, welds, clamps and the like. 
   As shown in particular detail in  FIG. 1 , the frame  20  is shown mounted in a pick-up bed with the panel  122  of the folding cover  120  adapted to close over the top of the frame  10  and enclose the storage space defined within the frame. The folding cover including this panel is generally well known, and, therefore, will not be described in detail. For example, the folding cover may be constructed in accordance with U.S. Pat. No. 6,422,635 to Steffens et al, issued Jul. 23, 2002 and entitled “Folding Cargo Bay Cover for Pickup Truck,” the disclosure of which is incorporated by reference. 
   As will be appreciated, although shown in conjunction with a folding cover, the toolbox of the present invention may be of other conventional pick-up bed toolbox designs. For example, the toolbox may be a frameless, stand-alone toolbox, including extending members, or “wings,” that rest directly on the side panels  102  and/or  104  and one or more doors that provide access to the interior of the toolbox. Additionally, the toolbox may be suspended entirely above the pick-up bed floor  106 . 
   As shown in  FIGS. 1–3 , a conveyor assembly  40  is mounted within the frame. In general, the conveyor assembly  40  is mounted in the lower most portion of the frame or toolbox  10  to form the floor thereof. The positioning of the conveyor assembly  40  relative to the bed  106  may be adjusted by adjusting the position of the horizontal members  24  relative to the vertical members. As shown in  FIG. 2 , the conveyor assembly includes a belt  43  that is driven by the drive assembly  42 . The belt  43  and drive assembly  42  are mounted to the side rails  60  or the members  22  or  24 . 
   The belt  43  extends between opposing ends of the frame  20 , and, for example, between opposite side panels  102  and  104  of the pick-up bed  100 . Optionally, in other toolbox designs, for example the side mount and bed designs, the conveyor may run parallel to the side panels  102 ,  104  and/or along the bed  106 , respectively. As shown in  FIG. 2 , the belt is a continuous belt that wraps around end drums  66 ,  67  and serpentines through the drive assembly  42 . 
   The end drums  66  and  67  are rotatably mounted to the side rails  60 . Adjacent the end drums  66  and  67 , optional shields  68  are disposed. The shields prevent debris from passing below the belt and into the drive assembly  42 . 
   Referring to  FIGS. 2 and 3 , the belt  43  is supported between the end drums by the side rails  60  and/or the support plate  74 . The side rails  60  may mount directly to the vertical members  22  of the frame  20  or, alternatively, may mount to the horizontal members  24 . The side rails  60  include a side rail plate  61  that extends inwardly from the side rails toward the belt. The side rail plate  61  defines a recess  62  within which the support plate  74  rests and is supported. The support plate  74  may be joined to the side rail  61  in the recess  62  with any conventional means, e.g., adhesives, tape, welding, screwing and the like. 
   The conveyor assembly  40  may further include belt guides  65  that are disposed under the lower-most portion of the belt and hold that portion up to prevent it from drooping below the side rails  60  or any other portion of the toolbox or conveyor assembly as desired. As desired, additional motor rollers and guides may be used in connection with the toolbox conveyor assembly. 
   As shown in  FIGS. 2 and 3 , the drive assembly  42  includes a motor  46  that is mounted to the side rail  60  and/or the horizontal member  24  with a mounting bracket  47  using conventional fastening means. The motor  46  rotates the drive gear  48 , which transfers rotation to the drive belt  49 , the driven gear  50  and subsequently the drive roller  52 . The drive roller  52  is rotatably mounted to the side rails in a conventional manner and rotates when driven by the motor. Upon rotation, the roller  52  urges the belt  43  to scroll in a desired direction conveying articles (not shown) disposed on the belt  43  toward one of the ends of the frame  20 . If the motor continues to scroll the belt, one or more articles on the belt may accumulate at the end of the frame. Optionally, the motor is reversible so that it can operate in forward and reverse modes thereby motivating the belt  43  to scroll toward either side of the pick-up bed side panels  102  or  104  or the ends of the toolbox  10 , as desired. The drive gear  48 , driven gear  50  and drive belt  49  may be covered with a cover (not shown) to prevent debris from affecting these components. 
   The drive assembly  42  optionally includes a tension roller  54  to maintain the belt  42  in continuous tension. The tension roller  54  includes an axle  53  that mounts within slots  55  defined by the side rails  60 . Tension roller springs  56  are mounted to the side rails  60  with a tension roller spring screw  57 . The springs  56  may be pre-biased to pull the conveyor belt  43  wrapped around the tension roller  54  taut. The axles  53  are mounted in the slots  55  to provide slack in the belt  43 . 
   The motor  46  is preferably actuated by one or more controls  59  that are mounted to the frame  20  or other components of the toolbox  10  in desired locations. In one embodiment, two controls  59  are provided, with one adjacent each of the side panels  102  and  104 . Optionally, the controls  59  may be substituted with a remote control that operates the motor via wireless communication. 
   An alternative construction for the toolbox conveyor assembly of the present invention is illustrated in  FIG. 4 , which shows the alternate conveyor from its underside. This alternative conveyor system  140  mounts to the frame as described in the embodiment above, and includes a continuous belt  143  mounted around drums  148 . The drums are rotatably mounted on axles  148  that mount within a support pan  142 . This support pan  142  is further mounted to the frame  20  as in the embodiment described above. A motor  44  drives drive gear  145 , which in turn rotates the belt  141  and drives the driven drum gear  147  to rotate the drum  148 . The motor operates under the same principles and is controlled by the controls  59  as in the embodiment described above to carry items on the conveyor belt  143  toward a user. 
   The construction of the conveyor assembly of the present invention may be further modified as desired. For example, the continuous belt may be replaced with a scrolling belt design where the belt coils up on rotatable end drums disposed at opposite sides of the frame. Alternatively, the continuous belt may replace with multiple rollers. 
   III. Toolbox Fold-Out Shelving 
   The toolbox fold-out shelving of the present invention will now be described in more detail with reference to  FIGS. 5–6 . The fold-out shelving unit  70  includes a slider panel  74 , intermediate panel  72  and a pivot panel  76 . The slider panel  74  and pivot panel  76  are connected to the intermediate panel  72  with hinges  73 . The panels preferably are constructed of extruded aluminum, however, they may be constructed of any metal, plastic or other material as desired. 
   The pivot panel  76  is hingedly connected to intermediate panel  72  with hinge  73 , and pivotally mounted to vertical members  22 , with mounting brackets  78 . Preferably, the pivot panel  76  is mounted to an axle  79  that is mounted to brackets  78 . The panel  76  rotates relative to the axle  79 , brackets  78  or both. Optionally, the pivot panel  76  includes an initiator spring  96  that biases against an initiator spring rod  97 . As shown in  FIG. 6 , the initiator spring is biased when the pivoting panel  76  is in a horizontal position. This bias urges the pivot panel  76  to pivot upward. In effect, this bias initially assists a user in folding the shelving unit to a collapsed or closed configuration. 
   The slider panel  74  is hingedly connected to intermediate panel  72  with hinge  73 , and slidably mounted to the shelving guide rails  88  via slide guide  80 . Although referred to herein as a slider panel, the panel  74  may be free from sliding or other engagement with other components of the toolbox  10 , and simply fold with respect to the intermediate panel  72 . With reference to  FIGS. 5 and 6 , the slide guide  80  includes a guide member  81  that interfits within the shelving guide rails  88 , which are joined with or defined by a horizontal member  24 . The guide member  81  slides between the rails  88  to allow the fold-out shelf unit to operate as described below. 
   The guide member  81  of the sliding member  80  also may include a mechanism to hold the shelving unit in a collapsed configuration. Specifically, as shown in  FIGS. 5 and 6 , the slide guide  80  includes a post  84  on which a detent spring  82  is mounted. A pin  86  biases the detent spring upward against the lower most guide rail ( FIG. 5 ) when the fold-out shelf unit is in an extended position. The slide guide may include a pin  86 ′ and a post  84 ′ opposite the pin  86  and post  84  so that the spring  82  may be mounted in reverse and the same slide guide used on the opposite side of the shelf. When the fold-out shelf unit is collapsed or folded into the vertical orientation (shown in broken lines in  FIG. 5 ), the detent spring  82  biases upward to secure over the end of the lower most guide rail  88  and hold the unit  70  in a collapsed configuration. 
   Optionally, a stop member  90  is disposed within the guide rails  88  to stop the fold-out shelving unit from extending beyond a pre-selected position. Further optionally, the slide guide is modified to mount a holding tray  92  to the sliding panel  74 . As desired, the tray  92  may be deleted from the fold-out shelf unit and the slide guide  80  modified accordingly. Additionally, multiple shelving units  70  may be installed on opposite sides of the toolbox  10  as desired to subdivide the general storage space of the toolbox and allow a user to organize his or her tools or materials within the toolbox  10 . 
   In operation, the fold-out shelving unit shown in  FIGS. 5 and 6  is held in a collapsed configuration (shown in broken lines) by the detent spring  82 . The pivot panel  76 , slider panel  74  and intermediate panel  72  are substantially vertical in this collapsed configuration and held out of the way to provide access to the interior of the toolbox  10 . To extend the fold-out shelf unit and subdivide the toolbox  10 , a user pushes the slider panel  74  away from the side  32  of the toolbox. Initially, the user must push with sufficient force to coil the detent spring downward, thereby disengaging it from the lower most guide rail  88 .  FIG. 4  shows the fold-out shelving unit  70  as it begins to unfold in an accordion-like manner. As the shelving unit is extended, the guide member  81  of the slide guide  80  slides within the guide rails  88 . The slide guide  80  continues to slide in the guide rails  88  until the sliding panel  74  is disposed in a substantially vertical position and the intermediate panel and pivot panel  76  are disposed in substantially horizontal positions; the guide stop  90  preferably defines the point at which the slide guide  80  can no longer slide and the panels attain these positions. 
     FIG. 5  shows the fold-out shelving unit in a fully extended configuration. Items may be stored on the intermediate and/or pivot panels in this configuration. Preferably, the orientation of the hinges  73  prevents the intermediate and pivot panels from folding downward and collapsing. 
   Other configurations of hinges and panels of the shelving unit may be substituted as desired. For example  FIG. 7  illustrates an alternative embodiment of the fold-out shelving unit  170  that includes many of the same elements of the embodiment described above, including the pivot panel  176 , the intermediate panel  172  and the slider panel  174 . In this embodiment, however, the slide guide  180  mounts to a tab  190  extending from the slider panel  174 . A slide rod  196  is secured to the horizontal members  24  of the frame  20  with brackets  192  and  194 . The slide rod  196  interfits within a slide rod hole  182  defined by the slide guide  180 . The slide guide  180  slides on the slide rod  196  allowing the fold-out shelf unit to extend and collapse as described above. 
   The above descriptions are those of the preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any references to claim elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.