Patent Publication Number: US-8991599-B2

Title: Pop-up tool carrier

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to carriers for hand tools and other small items and more particularly to carriers with multiple storage trays including means to quickly and easily pop up the top tray to a height that provides easy access, e.g., is comfortable for a standing person to access. 
     Tool carriers, portable storage boxes, tackle boxes, and simple open carriers and totes, made of wood and now common in plastic or metal have been around for a very long time. More recent examples of such boxes are shown in the patent literature. See for example, U.S. Pat. Nos. 3,612,635 (Uyeda et al.), 5,611,170 (McGuff et al.), and 6,267,484 (Baker et al.), which disclose tackle or tool boxes having plural trays which are arranged to be moved between a collapse or closed position and an extended or open position and vice versa. While such boxes may be generally suitable for their intended purposes, they nevertheless leave much to be desired from the standpoints of the range of function, compactness and convenience of use. For example, the extendable trays of those boxes are not capable of elevation to heights readily accessible by a standing user (unless the entire box is disposed at an elevated height, e.g., placed on a table or workbench). 
     The use of collapsible/extendable legs on work tables or carts has also been known for a very long period of time. See for example U.S. Applications 2002/0179181A1 and 2006/0037873A1. However, such tables or carts are somewhat limited in their range of extension and compactness. Thus, they are not readily portable to carry hand tools or other small items. 
     The subject invention addresses those needs by providing a device including at least one tray which is readily portable for carrying hand tools or other small items, and which can be placed on the ground or on some other low surface, with the at least one tray being arranged to be elevated to a comfortable and convenient working height for a standing user. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of this invention there is provided a device for holding and carrying various items. The device basically comprises a lower tray, an upper tray, a first strut assembly, a second strut assembly, and a handle that is connected to one of the trays. The strut assemblies are coupled between the lower tray and the upper tray. Each of the strut assemblies has an upper end portion and a lower end portion and comprises a pair of strut or leg sections pivotably connected together. The upper end portion of the first strut assembly is pivotably connected to a first portion of the upper tray, while the upper end portion of the second strut assembly is pivotably connected to a second portion of the upper tray. The second portion of the upper tray is located diagonally to the first portion of the upper tray. The lower end portion of the first strut assembly is pivotably connected to a first portion of the lower tray. In a similar manner the lower end portion of the second strut assembly is pivotably connected to a second portion of the lower tray. The second portion of the lower tray is located diagonally to the first portion of the lower tray. 
     The strut sections of each of the strut assemblies are pivotably connected together at a knee joint and are arranged to pivot with respect to each other in a first rotational direction to an extended or open position. In the open position the upper tray is spaced above the lower tray to provide ready access to items in the lower tray. The strut sections are also arranged to pivot with respect to each other in a second and opposite rotational direction to a retracted or closed position. In the closed position the upper tray is in close proximity to the lower tray to prevent items in the lower tray from accidentally falling out of the lower tray. The handle is arranged to facilitate the carrying of the device when the trays are in the closed position. 
     In accordance with one preferred aspect of this invention each of the leg (strut) sections of the strut assemblies is of identical (i.e., modular) construction in the interests of simplicity of construction and concomitant cost reduction. 
     In accordance with another preferred aspect of this invention the leg (strut) sections are spring loaded in order to assist in deploying the device into the open position and to increase stability in the open position. 
     In accordance with another preferred aspect of the invention the handle is centrally positioned and integral to the bottom tray and extends thru the upper tray to simplify structural demand on the system when transporting loaded trays. 
     In accordance with another preferred aspect of the invention a lid is provided for the upper tray, with the lid having multiple recesses or depressions to retaining and sorting various small articles, e.g., such as screws, nuts, etc., and a flat surface area for enabling one to write thereon. 
     In accordance with another preferred aspect of the invention a latch is provided to ensure and maintain the device in its closed or collapsed position. 
     In accordance with another preferred aspect of the invention the strut sections attached to the upper tray rest against a rim on the lower tray&#39;s rim&#39;s upper surface when the device is in the collapsed position. 
     In accordance with another preferred aspect of the invention the bottom of one device is constructed so that it may readily be stacked on a similar device to achieve a greater working height. Moreover, the bottom surface of the lower tray includes geometry, e.g., feet, to fit or mate with portions of an upper tray of another similar device when the devices are stacked. 
     In accordance with another preferred aspect of the invention the connection of a strut section to a tray is accomplished by means of an axle which is of sufficient length and integrated or securely attached to the strut section to mate with portion of the tray. 
    
    
     
       DESCRIPTION OF THE DRAWING 
         FIG. 1  is an isometric view from the top showing one exemplary embodiment of a device (e.g., a device having an upper tray and a lower tray) constructed in accordance with the subject invention in its collapsed or closed position or state; 
         FIG. 2A  is an isometric view, similar to  FIG. 1 , but showing the device of  FIG. 1  in its open extended or open position or state; 
         FIG. 2B  is an isometric view, similar to  FIG. 2A , but showing two devices of  FIG. 2A  stacked on each other in their open position or state; 
         FIG. 3  is an isometric view, taken from the top, of a cover forming a portion of the device shown in  FIG. 1  for closing off the upper tray of that device; 
         FIG. 4  is an isometric view, taken from the bottom, of the cover shown in  FIG. 3 ; 
         FIG. 5  is a partially exploded isometric view, taken from the top, showing the embodiment of the device shown in  FIG. 2A ; 
         FIG. 6  is an enlarged isometric view of a portion, i.e., a knee joint of a typical strut assembly (to be described later), shown within the circular area  6  in  FIG. 2A ; 
         FIG. 7  is an exploded isometric view of the knee joint shown in  FIG. 6 ; 
         FIG. 8  is a partially exploded isometric view of the device of  FIG. 2A , but without the cover on its upper tray; 
         FIG. 9  is an enlarged exploded isometric view showing the connection between the lower end of one strut assembly to the lower tray of the device of  FIGS. 1 ,  2 A and  2 B; 
         FIG. 10  is an enlarged isometric view taken from a different direction showing the connection between the lower end of one strut assembly to the lower tray of the device of  FIGS. 1 ,  2 A and  2 B; 
         FIG. 11  is an enlarged isometric view showing a portion, e.g., the interconnection between a latch (e.g., a security clip) and the cover of the device of  FIG. 1 ; and 
         FIG. 12  is an isometric view of the underside of the lower tray of the device shown in  FIG. 2A . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the various figures of the drawing wherein like reference characters refer to like parts, there is shown at  20  in  FIG. 1  an exemplary embodiment of a carrier or tote device constructed in accordance with this invention. The device  20  basically comprises a pair of trays, i.e., an upper tray  22  and a lower tray  24 , each of which is arranged to portably hold hand tools or other small items (not shown) therein. Each tray is of a general rectangular shape, but other shaped trays can be used as well. The trays can be formed of any suitable material, e.g., plastic, metal, wood or any combination thereof. The details of the trays  22  and  24  will be described later. Suffice it for now to state that each includes a bottom wall  60  and peripheral sidewall  52  (both to be described later) defining and bounding a hollow interior which is divided into sections to facilitate the holding of various hand tools or small items, e.g., hardware, etc., in sorted regions. In the exemplary embodiment shown, the lower or primary tray  24 , serves as the base for the device to support the device on any horizontal surface, e.g., the ground. 
     The trays  22  and  24  are connected together by a pair of extendable/retractable leg or strut assemblies  26  and  28  to enable the trays of the device  20  to be extended from a compact or closed state, like shown in  FIG. 1 , wherein the tools or items are enclosed within the trays of the device so that they cannot accidentally fall out, to an extended or open state like shown in  FIG. 2A . The strut assemblies  26  and  28  are of identical construction to each other as will be described in detail later. 
     In accordance with one preferred aspect of the invention, the strut assemblies are constructed and sized so that when the upper tray  22  is in the extended or open position/state it is disposed and held sufficiently above the lower tray  24  so that if the lower tray is placed on the ground or some other low surface the upper tray will be at a height which can be conveniently and comfortably reached by a standing or sitting user. As should be apparent, the extension of the upper tray to its open position also enables ready access to the contents of the lower tray, since the upper tray will no longer be juxtaposed immediately above the lower tray. 
     As will be seen from the discussion to follow, the strut assemblies  26  and  28  are constructed so that when the device is in its open or extended position it is very stable, e.g., resistant to accidental collapse. However, even in the stable open state, the device is still capable of being manually collapsed by the user to the compact state shown in  FIG. 1 , such as when it is desired to carry the device to some other working or storage location. 
     In the interest of minimizing complexity, manufacturing costs, and to enhance ease of use, the preferred embodiment of the device  20  utilizes only two leg assemblies (instead of the typical four). Those assemblies are situated at corners of the device diagonally opposite each other. Each assembly comprises two sections, e.g., legs  30  and  32  of assembly  26 , and legs  34  and  36  of assembly  28 . Each section is an elongated member that has one end connected respectively with either the top or bottom tray, and one end connected to the adjoining section at what is hereforth referred to as the knee or pivotable joint (to be described later) to enable those sections to fold with respect to each other. 
     Preferably the folding leg sections are spring loaded in order to assist in deploying the invention into the open or extended position and to increase stability in the extended position. To that end, each knee joint includes a torsion spring (to be described later). Moreover, rotational stops (also to be described later) are provided in the knee joint and on the lower tray so that when the device in the fully deployed or extended/open position the leg sections encounter those stops to maintain the device in that position. The springs serve to bias the associated leg sections into an extended over-center position that ultimately helps lock them against the rotational stops. Assuming a somewhat vertical orientation of the device  20 , the springs help with deployment and work in conjunction with gravity help maintain the device in the extended position and ultimately reasonably stable position of the upper tray. 
     In operation (to be described later) the collapsing of the upper tray to the compact or closed position involves the operator holding the upper tray while biasing the two leg assemblies towards each other inwardly against the springs. Once the legs are folded to a small degree inwardly one simple lowers the upper tray while the legs continue folding and retracting into a compact orientation alongside the trays. 
     Referring now to  FIGS. 1 ,  2 A and  5 , it can be seen that each of the sections of each strut assembly is preferably modular (i.e., identical in construction), in the interest of simplicity and reduced component costs. Like the trays, the leg sections can be formed of any suitable materials. It should be pointed out at this juncture that the leg sections of the strut assemblies can differ in construction, size and material, if desired, e.g., the length of the leg sections  30  and  34  may be different than the length of the leg sections  32  and  36 . In any case, the leg sections  30  and  32  of the strut assembly  26  are pivotably connected to each other by a pivotable joint  38  (to be described later), while the leg sections  34  and  36  of the strut assembly  28  are pivotably connected to each other by a pivotable joint  40  (also to be described later). 
     In order to minimize the number of components required to connect the two trays together so that they can be extended/retraced with respect to each other, the strut assemblies  26  and  28  are preferably located at opposite diagonal corners of the trays as mentioned above. This diagonal arrangement also aids in providing stability for the trays and facilitates the collapsing of the trays to the closed position shown in  FIG. 1 . To that end, as best seen in  FIGS. 2A and 8 , the upper end of the leg section  30  is pivotably connected to the upper tray  22  at one corner  42 , while the upper end of the leg section  34  is pivotably connected to the upper tray at another corner  44 . The corner  44  is disposed diagonally to the corner  42 . In a similar manner, the lower end of the leg section  32  is pivotably connected to the lower tray  24  at one corner  46 , while the lower end of the leg section  36  is pivotably connected to the lower tray  24  at another corner  48 . The corner  48  is disposed diagonally to the corner  46 . The corner  48  is located below and slightly laterally of the corner  44 , while the corner  46  is located below and slightly laterally of the corner  42 . 
     Turning now to  FIGS. 5 ,  8 ,  9  and  10  the details of the pivotable connection of the leg sections to the trays will now be described. Each of those connections is accomplished in the same manner. Thus, in the interest of brevity only the connection of the leg section  32  of leg assembly  26  to the tray  24  will be described. In particular, as can be seen the lower end of the lower leg section  32  of the leg assembly  26  includes an axle  50  projecting therefrom. The sidewall  52  of the lower tray  24  includes a semicircular recess or depression  54 . A hole  56  is located at the center of the recess  54 . A rim or flange  57  forms the top peripheral edge of the sidewall  54 . An ear  58  projects up from the bottom wall  60  of the tray  24  immediately behind the depression  54  in the sidewall  52 . The ear includes a pair of axially aligned holes, only one of which,  62  can be seen in  FIG. 9 . The holes in the ear are axially aligned with the hole  56  in the sidewall. The lower end of leg section  32  is in the form of a circular ring-like structure  64 , with the axle  50  projecting perpendicularly from the center thereof. The outside diameter of the axle  50  is slightly less than the inside diameter of the axially aligned holes so that it may be received therein and able to rotate about the axis of the aligned holes. The free end of the axle includes plural resilient barbed fingers  66  for holding the axle in place in the aligned holes, thereby completing the pivotable connection. As should be recognized by those skilled in the art the stability of the axle  50  within the aligned holes in the multiple support walls, i.e., the sidewall  52  and the walls of the ear  58 , far exceeds that which would be achieved with the axle passing through a single wall, e.g., the sidewall  52 , alone. This arrangement helps considerably in managing the elevated height of the device with the use of just two leg assemblies. 
     In order to restrict the leg sections to a predetermined range of pivotable movement and thus insure stability of the trays when the device is in the open or extended position/state, the device  20  includes the heretofore mentioned stops. For example, as best seen in  FIG. 10 , a stop  68  projects outward from the sidewall  52  of the tray  24  at corner  46 . The stop  68  is arranged to be engaged by a portion  70  of the leg section  32  when that leg section rotate in the counterclockwise direction to extend the device  20  to its open position. Thus, continuous counterclockwise rotation (over-rotation) of the leg section  32  is prevented. The lower leg section  36  of leg assembly  28  is similarly connected to the lower tray  24  adjacent the corner  48 . The rotational stops  68  of the lower tray  24  in combination with stops (to be described shortly) at the knee joints  38  and  40  create a vertically oriented stability of the leg assemblies in the extended position such that additional means or stops is eliminated (e.g., stops for the upper tray  22  are unnecessary). 
     Referring now to  FIGS. 1 ,  5 ,  6  and  7 , the details of the knee joints  38  and  40  will be described. Each of those joints is of identical construction. Thus, in the interest of brevity only the details of knee joint  38  of the leg assembly  26  will be described. As best seen in  FIGS. 6 and 7  the upper end of the leg section  32  is in the form of a circular ring-like structure having a central hub  72  from which plural spokes  74  project to an outer circular surface  76 . The lower end of the leg section  30  is of identical construction. Thus, the lower end of the leg section  30  is in the form of a circular ring-like structure having a central hub  72  from which plural spokes  74  project to an outer circular surface  76 . A hole  78  is located at the center of each of the hubs  72  for receipt of a pin or rivet  80  ( FIGS. 5-7 ) to pivotably connect the two leg sections together and thereby form the knee joint  38 . The outer circular surface  76  of leg section  32  includes a pair of spaced apart projections or stops  82  and  84 , as does the outer surface  76  of leg section  30 . The stop  82  of the leg section  30  is arranged to abut the stop  82  of the leg section  32 , while the stop  84  of the leg section  30  is arranged to abut the stop  84  of the leg section  32  to prevent/restrict the pivoting or folding action of the leg sections to a desired angular range. In particular, when the leg sections are in the extended or open position, such as shown in  FIG. 6 , the surfaces of the stops  82  contact each other. 
     As mentioned earlier each knee joint includes a torsion spring. That spring is designated by the reference number  86  and is best seen in  FIG. 7 . The spring basically comprises a helix of coils having a central passageway  88 . The ends of the spring are in the form of linear projections  90  and  92  extending in opposite directions parallel to the central axis of the spring to key the spring to the leg sections  30  and  32 . To that end, the linear end portion  90  of the spring is received within a through hole  94  in one of the spokes  74  of the leg section  30 , while the linear end portion  92  is received within a through hole  96  in one of the spokes  74  of the leg section  32 . The pin or rivet  80  extends through the spring&#39;s passageway  88  and through the aligned holes  78  of the leg sections  30  and  32  to complete the knee joint. 
     As will be appreciated by those skilled in the art when the device  20  is in the extended or open position the effect of gravity and the bias provided by the torsion springs  86  cooperate to rotate the leg sections  30  and  32  of assembly  26  and the leg sections  34  and  36  of assembly  28 , so that their respective stop surfaces  82  abut and apply pressure to each other, thereby tending to maintain those leg sections in the extended position ensuring stability of the device. It should be noted that the use of the over-center knee joints with the rotation limiting stops enables the device to be held in its open position by gravity alone. Thus, while the use of the torsion springs is preferred since it provides additional bias to hold the device in the open position, such springs are not mandatory. 
     In order to facilitate the carrying of the device when it is in its closed or compact condition, a handle  100  ( FIGS. 1 ,  5  and  8 ) is provided. The handle is centrally positioned and integral to the bottom tray and extends through the upper tray to simplify structural demand on the system when transporting loaded trays. In particular, the handle basically comprises a walled pedestal-like structure projecting upward from the center of the bottom wall  60  of the lower tray. The pedestal-like structure includes four walls which taper upward from the bottom wall  60  of the tray to the top of the pedestal-like structure. The pedestal-like structure is arranged to be received within a complementary walled window  102  in the center of the upper tray  22 , when the device is in the closed position. In that position portions of the walls of the pedestal-like structure confront portions of the walls of the window, with the top end of the pedestal-like structure extending above the upper tray  22  as best seen in  FIG. 1 . A pair of hand-holes  104  are located in opposite walls of the pedestal-like structure adjacent its top. The hand-holes are arranged to receive the fingers of a person carrying the device. 
     The upper tray  22  preferably includes a removable cover  106  to ensure that the contents of the upper tray don&#39;t fall out. That cover is best seen in  FIGS. 3 and 4 . The cover  106  includes a top wall  108  of generally rectangular shape corresponding to the profile of the top edge or rim of the sidewall  52  of the upper tray  22 . A lip  110  projects downward from the periphery of the top wall  108 . The undersurface of the top wall  108  is arranged to be disposed on the top edge of the sidewall  52  of the upper tray to close off the interior of that tray. The top wall  108  includes several depressions or recesses  112 , each of which is arranged to receive and hold small items, e.g., hardware (such as screws, nuts, washers, etc.), therein. A portion  114  of the top wall is planar to serve as a writing surface upon which a piece of paper can be placed. In addition, the top wall  108  includes a central opening  116  having a peripheral wall  118 , for receipt of the upper portion of the handle  100  when the device is in its closed condition. 
     In order to hold the device in the closed condition, the device includes a latch or clip  120 , which is best seen in  FIG. 11 . The clip is in the form of a resilient finger  122  that projects out from a wall of the pedestal-like structure  100  adjacent its top. The clip includes a flared free end  124  having a bottom edge or surface  126  which is arranged to overlie a portion of the top wall  108  contiguous with the opening  116  in the cover  106  when the cover is in place and the device  20  is in its closed or compact state. With the clip in place, the device  20  cannot be extended to its open position. When the upper tray is in the closed position, such as shown in  FIG. 1 , it covers the lower tray to prevent the contents of the lower tray from falling out. Moreover, in this position the upper strut sections  30  and  34  rest against the rim  57  of the lower tray  24 . 
     To deploy or extend the upper tray  22  to its open position, all that the user has to do is to release the clip  120  by simply pressing against the flared outer surface of the clip so that the bottom edge  126  clears the periphery of the opening  116 , whereupon the upper tray  22  is released and can be extended to its open position. Conversely, to engage the clip  120  all that the user has to do is to press the upper tray  22  and cover  106  downward, so that the edge of the central opening  116  of the cover rides over the flared outer surface of the free end of the clip, thereby displacing the resilient clip until the lower surface of the peripheral wall  118  of the cover is below the clip&#39;s edge  126 . At this time the resilient finger forming the clip springs back to its neutral condition, with its bottom edge  126  obstructing upward movement of cover and tray. While not shown, the clip  120  is constructed so that in the event that the cover  106  is not in place, the clip will engage a portion of the upper tray in order to again prevent inadvertent extension of the upper tray without the cover needing to be in place. 
     Since the top wall  108  of the cover is planar (except for the depressions or recesses  112 ), it can serve as a base to enable a similarly constructed device  20  to be stacked on it. This arrangement provides more trays for a user to access, with the upper tray being at an even greater height when both are in the open position as shown in  FIG. 2B . With such an arrangement the height of the uppermost tray would be readily accessible to someone working on a ladder adjacent the stacked devices. 
     In order to facilitate the stacking of two or more devices and prevent the upper one from sliding off of the underlying device, the bottom wall of the lower tray  24  is contoured to include plural projections or feet. In particular, as best seen in  FIG. 12  the bottom wall includes four feet  128 ,  130 ,  132 , and  134  situated at respective corners of bottom surface of tray  24 . These feet are shaped to engage respective corners of the cover of an underlying device  20  to align and position the tray on top of the upper tray  22  of the underlying device. Thus, two or more devices can be stacked on top of each other. Moreover, the bottom surfaces of each of the feet are flat and coplanar so that those feet can be disposed directly on the ground or some other support surface, if desired. 
     As should be appreciated from the foregoing, the preferred embodiment of each leg segment, where connected to the lower or upper tray, has a rigid axle securely integrated or mounted to the respective leg portion and runs through a series of support holes in the bottom or upper tray for purposes of spreading out the forces. This allows for thinner less structural side walls in the trays with strong readily-moldable consistent thickness walls, while increasing their interaction with the leg segments and thus enhancing stability. In the preferred embodiment the axles of the legs are secured in place with a molded-in barbed tip. It should be recognized there are a number of other ways this can be accomplished. Also in the preferred embodiment a rivet is used to join the two adjacent leg segments where they join at the knee joint. Likewise other alternative means can be used to fasten this joint. 
     It will be recognized that the torsion springs mentioned above will always attempt to influence the upper tray away from the lower tray toward the extended or open position unless some means is offered to counter such bias. In the preferred embodiment a single latch or clip is configured in one side of the handle where it is easily accessed for release of the top tray. As designed the function of the latch is fully automatic in securing the upper tray in the collapsed position. All the user need do to secure the device in its closed state is to ensure that the upper tray, with or without the cover, is collapsed sufficiently to allow engagement of the latch. The configuration of the disclosed preferred embodiment that places the carrying handle integral to the bottom tray not only facilitates a simple means to securing the device in a closed (collapsed and compact) position, but also places the burden of load bearing advantageously on the lower tray, where all the weight of the upper tray and its various contents are easily supported. 
     In order to elevate the upper tray two folding spring loaded leg assemblies which are simple in construction and efficient in operation are provided. This arrangement is easily manipulated and intuitive to deploy or collapse with minimal effort. The legs, being configured to collapse and fold up alongside the trays, provide an unobtrusive and compact position for more convenient transport and storage. Furthermore this configuration is highly reliable and designed to enhance appearance. While it will be recognized that there are any number of ways to extend and separate the trays from each other (telescoping tubes being one possible arrangement) or to lock the legs in position, such as with knobs, latches, and the like, such structures bring with them extra complexity, cost and operational demands of the user. Thus, the preferred embodiment is constructed as described above. However, this does not rule out the inclusion of additional locking members, such as knobs, etc., where some sacrifice regarding convenience is accepted for the sake of achieving a more robust device. 
     It should also be noted that wheels or casters may be added to the bottom tray or to an independent structure that supports the lower tray in order to add another level of movement flexibility. Further still, multiple trays of three or more could be employed while adhering to the essence of the current invention furthering the range of storage and height available. 
     As should be appreciated from the foregoing, the device of this invention is constructed to set it apart from all other previous tool boxes and totes. In particular its extendable top tray feature eliminates the all too common hassle and discomfort of bending and stooping associated with retrieving tools and articles from prior art tool boxes, etc., that rest on the floor or at a height that is well below what is convenient to the user. Further enhancing this unique feature is a design and construction that facilitates quick and easy extension of the top tray and then equally simple and quick collapsing for compact storage and transport. 
     While devices constructed in accordance with this invention are highly effective in situations not offering suitable or conveniently located tables to rest a tool box or tote tray on, they also have the advantage in other situations. For example they can be used when a user is working on a step ladder. In such an application they can be stacked thereby providing an upper tray that is elevated to twice the height of a single device, thereby reducing the need to climb up and down a ladder to retrieve items to complete the specified task. In such cases additional stability is easily managed, for example, with a clamp securing the devices to a leg of the ladder. 
     Without further elaboration the foregoing will so fully illustrate my invention that others may, by applying current or future knowledge, adopt the same for use under various conditions of service.