Patent Publication Number: US-9884699-B1

Title: No tools toy box

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to sturdy boxes for holding various items, including, for example, toys, and more particularly, is directed to a box that can be easily assembled without the use of any tools, while retaining structural integrity. 
     The use of toy boxes, made from wood, plastic, etc., for holding children&#39;s toys are well known. These toy boxes are generally assembled using screws or bolts in order to provide structural integrity. However, such assembly is burdensome and time consuming. Further, over time, the screws and bolts can loosen, thereby reducing the structural integrity and possibly providing a hazard for the child. 
     It is also known to assemble different furniture pieces without the use of tools by using dovetail sliding joints and the like. However, the construction and assembly also tends to be rather difficult. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a toy box that overcomes the aforementioned problems. 
     It is another object of the present invention to provide a toy box that can be easily assembled without the use of any tools, while retaining structural integrity. 
     It is still another object of the present invention to provide a toy box that is easy and economical to use and manufacture. 
     In accordance with an aspect of the present invention, a box includes first and second spaced apart side walls, and first and second ends walls connected to opposite ends of the side walls. Each of the side walls has an elongated slot at a lower end of an inner surface thereof. At least one flooring member is inserted in the elongated slots of the side walls to form a bottom wall of the box. A closure member is inserted into a space adjacent the at least one flooring member to lock the at least one flooring member in the elongated slots of the side walls and the first and second end walls. 
     At least one of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the at least one end wall being coplanar with each other, and wherein the at least one flooring member is locked in the elongated slots of the side walls and the at least one end wall when the closure member is inserted into the space adjacent the at least one flooring member. 
     Preferably, each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, and wherein the at least one flooring member is locked in the elongated slots of the side walls and the end walls when the closure member is inserted into the space adjacent the at least one flooring member. 
     In one embodiment, the at least one flooring member includes first and second flooring members, each inserted in the elongated slots of the side walls to form the bottom wall of the box, and the closure member is inserted between the first and second flooring members. In a modification thereof, the at least one flooring member includes a single flooring member, and the closure member is inserted between an end of the single flooring member and one end wall. 
     The first and second side walls are in parallel, spaced apart relation to each other and the first and second end walls are in parallel, spaced apart relation to each other. 
     Each end wall has a vertically oriented narrow recess at opposite sides thereof, with one end of each recess being open, and each side wall has a connecting plate at opposite sides thereof, with each connecting plate removably locking within one narrow recess. Each narrow recess includes at least one side wall securing rib, and each connecting plate is L-shaped and engages with the at least one side wall securing rib to releasably lock each side wall to a respective end wall. 
     Each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, the elongated slots of the end walls open at opposite ends thereof into the narrow recesses at opposite sides thereof. Further, the elongated slots of the side walls open at opposite ends thereof into the connecting plates at opposite sides thereof. 
     There are also hand openings in upper ends of the end walls, and/or upper ends of the side walls. 
     Each side wall has a capturing recess for holding one end of the closure member in a position adjacent the at least one flooring member. At least one side wall has a ramp positioned below the respective capturing recess for aiding in inserting a respective end of the closure member in the respective capturing recess. 
     The closure member includes a first section that lies against an underside of the at least one flooring member. 
     In accordance with another aspect of the present invention, a method of assembling a box, includes a first step of assembling a first end of a first side wall having an elongated slot at a lower end of an inner surface thereof, with a first end of a first end wall at a lower end of an inner surface thereof; a second step of assembling a first end of a second side wall having an elongated slot at a lower end of an inner surface thereof, with a second end of the first end wall such that the first and second side walls are in spaced apart relation; a third step of sliding at least one flooring member into the elongated slots of the first and second side walls from second, opposite ends of the first and second side walls; a fourth step of assembling the second end of the first side wall with a first end of a second end wall; a fifth step of assembling the second end of the second side wall with a second end of the second end wall; and a sixth step of inserting a closure member into a space adjacent the at least one flooring member to lock the at least one flooring member in the elongated slots of the side walls. 
     At least one of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the at least one end wall being coplanar with each other, and further comprising the step of locking the at least one flooring member in the elongated slots of the side walls and the at least one end wall when the closure member is inserted into the space adjacent the at least one flooring member. 
     Preferably, each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, and further comprising the step of locking the at least one flooring member in the elongated slots of the side walls and the end walls when the closure member is inserted into the space adjacent the at least one flooring member. 
     In one embodiment, the at least one flooring member includes first and second flooring members, each inserted in the elongated slots of the side walls to form the bottom wall of the box, and the sixth step includes the step of inserting the closure member between the first and second flooring members. 
     In a modification, the at least one flooring member includes a single flooring member, and the sixth step includes the step of inserting the closure member between an end of the single flooring member and one end wall. 
     The first through fourth assembling steps results in the first and second side walls being in parallel, spaced apart relation to each other and the first and second end walls being in parallel, spaced apart relation to each other. 
     Each end wall has a vertically oriented narrow recess at opposite sides thereof, with one end of each recess being open, and each side wall has a connecting plate at opposite sides thereof, and each of the first through fourth assembling steps includes the step of removably locking each connecting plate within a respective narrow recess. Each narrow recess includes at least one side wall securing rib, and each connecting plate is L-shaped, and the step of removably locking includes the step of engaging each L-shaped connecting plate with a respective side wall securing rib to releasably lock each side wall to a respective end wall. 
     Each of the end walls has an elongated slot at a lower end of an inner surface thereof, with the elongated slots of the side walls and the end walls being coplanar with each other, and the elongated slots of the end walls open at opposite ends thereof into the narrow recesses at opposite sides thereof, and wherein the at least one flooring member also extends outwardly of the elongated slots into the narrow recesses. Also, the elongated slots of the side walls open at opposite ends thereof into the connecting plates at opposite sides thereof. 
     Each side wall has a capturing recess, and wherein the sixth step of inserting a closure member includes the step of inserting opposite ends of the closure member into the capturing recesses for holding the closure member in a position between the at least one flooring member. Further, at least one side wall has a ramp positioned below a respective capturing recess, and the sixth step of inserting a closure member includes the step of sliding one end of the closure member up the ramp for aiding in inserting the respective end of the closure member in the respective capturing recess. Also, the sixth step of inserting a closure member includes the step of inserting the closure member so that a first section thereof lies against an underside of the at least one flooring member. 
     The above and other objects, features and advantages of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view of a toy box according to the present invention; 
         FIG. 2  is a bottom perspective view of the toy box; 
         FIG. 3  is a bottom, outer perspective view of one end panel; 
         FIG. 4  is a top, inner perspective view of the end panel; 
         FIG. 5  is an outer elevational view of the end panel; 
         FIG. 6  is an inner elevational view of the end panel; 
         FIG. 7  is a bottom plan view of the end panel; 
         FIG. 8  is an outer, bottom perspective view of one side panel; 
         FIG. 9  is an inner, bottom perspective view of the side panel; 
         FIG. 10  is an outer elevational view of the side panel; 
         FIG. 11  is an inner elevational view of the side panel; 
         FIG. 12  is an end elevational view of the side panel; 
         FIG. 13  is a bottom plan view of the side panel; 
         FIG. 14  is a perspective view of one bottom board; 
         FIG. 15  is a perspective view of the closure rod; 
         FIG. 16  is an upper perspective view of the removable cover; 
         FIG. 17  is a lower perspective view of the removable cover; 
         FIG. 18  is a side elevational view of the removable cover; 
         FIG. 19  is a perspective view showing a first assembly step of the side walls to one end wall; 
         FIG. 20  is a perspective view showing a second assembly step of the bottom boards to the side walls; 
         FIG. 21  is a perspective view showing a third assembly step of the other end wall to the side walls; 
         FIG. 22  is a perspective view of the assembly of  FIG. 21  rotated so the bottom is facing up and showing a fourth assembly step of the closure rod; 
         FIG. 23  is a perspective view similar to  FIG. 22 , with the closure rod fully inserted; 
         FIG. 24  is a perspective view of the assembly of  FIG. 23 , rotated back so that the bottom is facing down, and showing a fifth assembly step of inserting the cover thereon; 
         FIG. 25  is a perspective view showing a first assembly step of the side walls to one end wall in the modified embodiment; 
         FIG. 26  is a perspective view showing a second assembly step of the bottom board to the side walls in the modified embodiment; 
         FIG. 27  is a perspective view showing completion of the second assembly step of the bottom board to the side walls in the modified embodiment; 
         FIG. 28  is a perspective view showing a third assembly step of the other end wall to the side walls in the modified embodiment; 
         FIG. 29  is a perspective view showing completion of the third assembly step of the other end wall to the side walls in the modified embodiment; 
         FIG. 30  is a perspective view of the assembly of  FIG. 29  rotated so the bottom is facing up in the modified embodiment; 
         FIG. 31  is a perspective view of the assembly of  FIG. 30  rotated so the bottom is facing up and showing a fourth assembly step of the closure rod; 
         FIG. 32  is a perspective view similar to  FIG. 31  but rotated 180 degrees; 
         FIG. 33  is a perspective view similar to  FIG. 31 , with the closure rod fully inserted; 
         FIG. 34  is a perspective view of the assembly of  FIG. 33 , rotated back so that the bottom is facing down, and showing a fifth assembly step of inserting the cover thereon; and 
         FIG. 35  is a perspective view of the assembly of  FIG. 34 , showing completion a fifth assembly step of inserting the cover thereon. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings in detail, a toy box  10  according to a first embodiment of the present invention has a generally rectangular parallelepiped construction, although the present invention is not limited thereby. 
     Specifically, as shown generally in  FIGS. 1 and 2 , toy box  10  includes first and second side walls  12  and  14 , which are connected together at ends thereof by first and second end walls  16  and  18 . A bottom wall  20  is formed by first and second generally square shaped bottom boards  22  and  24  ( FIG. 14 ), although any flooring member can be used in place of boards  22  and  24 . For example, the flooring member need not be planar as with boards  22  and  24 , but can have different contours. A closure rod  26  is provided to secure and lock first and second bottom boards  22  and  24  with first and second side walls  12  and  14  and with first and second end walls  16  and  18 . Finally, a removable cover  28  is provided to cover the upper open end of toy box  10 . Preferably, first and second side walls  12  and  14 , first and second end walls  16  and  18  and removable cover  28  are made from a rigid plastic material, and first and second bottom boards  22  and  24  and closure rod  26  are made from a medium density fiberboard (MDF), although the present invention is not limited thereto. 
     As shown best in  FIGS. 3-7 , each end wall  16 ,  18  includes a solid generally square parallelepiped shaped end panel  29 , with a generally square outer surface  30 , a generally square inner surface  32 , a top surface  34 , a bottom surface  36 , and rounded side surfaces  37 . A vertically oriented, generally rectangular, narrow recess  38  is provided at each end of each end wall  16 ,  18 , extending through inner surface  32  from a position through bottom surface  36  and up to a position slightly spaced from top surface  34 , that is, closed by a closure wall  40  at its upper end and having an inlet opening  42  at bottom surface  36 . Each recess  38  is thereby defined by an inner vertical wall  44 , a parallel, spaced apart outer vertical wall  46 , upper closure wall  40  which connects together vertical walls  44  and  46 , and a bottom wall  48  which contains outer surface  30  on the opposite side thereof. 
     Reinforcing and guiding ribs  50  extend partially into recess  38  from inner vertical wall  44  in parallel, spaced apart relation to each other. Each reinforcing and guiding rib  50  extends the full height of inner vertical wall  44  and is also connected with bottom wall  48 . Although four reinforcing and guiding ribs  50  are shown, the present invention is not limited thereby. Preferably, a lowermost reinforcing and guiding rib  50   a  extends in line with bottom surface  36 . Furthermore, guiding ribs  50  can be eliminated, and need not be provided to define each recess  38 . 
     In addition, side wall securing ribs  52  extend from outer vertical wall  46  in spaced apart relation to each other, preferably at positions between reinforcing and guiding ribs  50 . However, unlike reinforcing and guiding ribs  50 , side wall securing ribs  52  are spaced from bottom wall  48  of recess  38  to provide a capturing space  53  therebetween, as best shown in  FIG. 7 , the purpose for which will be understood from the discussion which follows. In addition, side wall securing ribs  52  can also be eliminated. 
     An elongated board capturing slot  54  extends horizontally through inner surface  32  and exits at opposite ends thereof through inner vertical walls  44  of opposite recesses  38 . Further, a hand opening  56  extends entirely through ends walls  16 ,  18  centrally at an upper end thereof. It will be appreciated, however, that hand openings can alternatively extend entirely through side walls  12 ,  14  centrally at upper ends thereof. 
     In order to increase the strength and rigidity of end walls  16 ,  18 , a plurality of horizontally oriented recesses  58  are provided in inner surface  32  and extend partially through end walls  16 ,  18 , at positions between elongated board capturing slot  54  and hand opening  56 . In order to increase the strength and rigidity, a rectangular shallow recess  60  is provided in outer surface  30 . 
     As shown best in  FIGS. 8-13 , each side wall  12 ,  14  includes a solid generally rectangular parallelepiped shaped side panel  62 , with a generally rectangular outer surface  64 , a generally rectangular inner surface  66 , a top surface  68 , a bottom surface  70 , and opposite side surfaces  72 . 
     An L-shaped connecting plate  74  extends outwardly from each side surface  72 , and specifically, includes a first elongated plate  76  thereof that extends outwardly from each side surface  72  and a second elongated plate  78  that extends at a right angle from the free edge of first elongated plate  76  in a direction toward the outside of each side panel  62 . First elongated plate  72  is spaced slightly from top surface  68  and bottom surface  70 . In addition, the opposite ends of second elongated plate  78  include beveled edges  80 . 
     An elongated board capturing slot  82  extends horizontally entirely through inner surface  66  and exits at opposite ends, continuing through first elongated plates  76  on opposite sides thereof. 
     A rod capturing recess  84  is formed centrally in inner surface  66  just below elongated board capturing slot  82  and in open communication therewith. A rod entry recess  86  is formed in inner surface  66 , open at bottom surface  70  and extending toward rod capturing recess  84  but spaced therefrom by a land  88 . Rod entry recess  86  includes a ramp surface  90  that decreases in depth from bottom surface  70  toward the opposite end thereof. 
     In order to increase the strength and rigidity of side walls  12 ,  14 , a plurality of horizontally oriented recesses  92  are provided in inner surface  66  and extend partially through side walls  12 ,  14 , at positions between rod capturing recess  84  and top surface  68 . In order to increase the strength and rigidity, a rectangular shallow recess  94  is provided in outer surface  64 . 
     As shown in  FIG. 15 , closure rod  26  is formed by a generally elongated, rectangular parallelepiped bar  96  having an upper surface  98  with an insertion bar  100  extending upwardly therealong. Further, opposite ends of elongated bar  96  and insertion bar  100  have beveled ends  102 . 
     Lastly, as shown in  FIGS. 16-20 , removable cover  28  includes a generally rectangular panel  104  having rounded corners  106 . A rectangular raised portion  108  of lesser outer dimensions than panel  104 , extends downwardly from the lower surface  110  of panel  104 , thereby defining a shoulder  112  at the lower surface  110  in surrounding relation to raised portion  108 . A hand opening  114  extends entirely through panel  104  and raised portion  108  at a center position of cover  28  adjacent an elongated side edge thereof. A plurality of horizontally oriented recesses  116  are provided in raised portion  108  and extend partially into panel  104 , and a rectangular shallow recess  118  is provided in an outer surface  120  of panel  104 , in order to increase the strength and rigidity thereof. 
     Referring now to  FIGS. 19-24 , a description of the assembly of toy box  10  will now be described. 
     As shown in  FIG. 19 , in a first assembly step, side walls  12 ,  14  are connected to first end wall  16 . In doing so, L-shaped connecting plates  74  at one end of side walls  12 ,  14  are inserted through inlet openings  42  into vertically oriented narrow recesses  38  of first end wall  16 . During this insertion, second elongated plates  78  thereof are inserted in capturing spaces  53  between bottom wall  48  of recesses  38  and side wall securing ribs  52 , until the upper ends of L-shaped connecting plates  74  abut against closure walls  40 . In such position, elongated board capturing slots  54  and  82  are in alignment in a common plane. 
     As shown in  FIG. 20 , in a second assembly step, bottom boards  22  and  24  are then slid into elongated board capturing slots  82  of side walls  12 ,  14 , and bottom board  22  can even be slid into elongated board capturing slot  54  of first end wall  16  at this time. 
     Thereafter, as shown in  FIG. 21 , in a third assembly step, second end wall  18  is connected to the opposite ends of side walls  12 ,  14  in the same manner as in the first step of  FIG. 19 . Specifically, L-shaped connecting plates  74  at the opposite ends of side walls  12 ,  14  are inserted through inlet openings  42  into vertically oriented narrow recesses  38  of second end wall  18 . During this insertion, second elongated plates  78  thereof are inserted in capturing spaces  53  between bottom wall  48  of recesses  38  and side wall securing ribs  52 , until the upper ends of L-shaped connecting plates  74  abut against closure walls  40 . In such position, elongated board capturing slots  54  and  82  at the opposite side of box  10  are also in alignment in a common plane. 
     As shown in  FIGS. 22 and 23 , in a fourth assembly step, the assembly of  FIG. 21  is rotated so that the bottom is facing up. Then, insertion bar  100  of closure rod  26  is force fit in the space  25  between bottom boards  22  and  24 . For this purpose as shown in  FIG. 22 , one end of closure rod  26  is inserted into one rod capturing recess  84 , and the opposite end of closure rod  26  rides up ramp surface  90  at the opposite side of toy box  10 , and is then force fit over land  88  until it snaps into place into the other rod capturing recess  84 , thereby locking closure rod  24  is place. This results in moving of first bottom board  22  so that it is inserted into elongated board capturing slot  54  of first end wall  16  and moving second bottom board  24  in the opposite direction so that it is inserted into elongated board capturing slot  54  of second end wall  18 , thereby locking bottom boards  22 ,  24  in position, with upper surface  98  of closure rod  26  on opposite sides of insertion bar  100 , lying flush against the lower surfaces of bottom boards  22  and  24 . 
     Thereafter, as shown in  FIG. 24 , the assembly of  FIG. 23  is rotated back so that the bottom is facing down. In a fifth assembly step, removable cover  28  is then inserted in covering relation to the upper open end so that raised portion  108  sits within the upper ends of side walls  12 ,  14  and end walls  16 ,  18 , and shoulder  112  rests on top of side walls  12 ,  14  and end walls  16 ,  18 . 
     It will be appreciated that boards  22  and  24  can be replaced with a single board  223  or single equivalent flooring member, as shown in the modified embodiment toy box  210  of  FIGS. 25-35 , in which like elements from the first embodiment of toy box  10  are denoted by the same numerals. 
     Specifically, the differences are that, in addition to single board  223 , rod capturing recess  84  is formed at one end of first and second side walls  12  and  14 , in inner surface  66  just below elongated board capturing slot  82  and in open communication therewith. Further, rod entry recess  86  is formed in inner surface  66 , open at bottom surface  70  and extending toward rod capturing recess  84  but spaced therefrom by a land  88 . Rod entry recess  86  includes a ramp surface  90  that decreases in depth from bottom surface  70  toward the opposite end thereof. 
     A description of the assembly of toy box  210  will now be described. 
     As shown in  FIG. 25 , in a first assembly step, side walls  12 ,  14  are connected to first end wall  16 . In doing so, L-shaped connecting plates  74  at one end of side walls  12 ,  14  are inserted through inlet openings  42  into vertically oriented narrow recesses  38  of first end wall  16 . During this insertion, second elongated plates  78  thereof are inserted in capturing spaces  53  between bottom wall  48  of recesses  38  and side wall securing ribs  52 , until the upper ends of L-shaped connecting plates  74  abut against closure walls  40 . In such position, elongated board capturing slots  54  and  82  are in alignment in a common plane. 
     As shown in  FIGS. 26 and 27 , in a second assembly step, single board  223  is then slid into elongated board capturing slots  82  of side walls  12 ,  14  and board capturing slot  54  of first end wall  16 , with the opposite end of single board  223  spaced from the opposite free ends of side walls  12 ,  14 . 
     Thereafter, as shown in  FIGS. 28 and 29 , in a third assembly step, second end wall  18  is connected to the opposite ends of side walls  12 ,  14  in the same manner as in the first step of  FIG. 25 . Specifically, L-shaped connecting plates  74  at the opposite ends of side walls  12 ,  14  are inserted through inlet openings  42  into vertically oriented narrow recesses  38  of second end wall  18 . During this insertion, second elongated plates  78  thereof are inserted in capturing spaces  53  between bottom wall  48  of recesses  38  and side wall securing ribs  52 , until the upper ends of L-shaped connecting plates  74  abut against closure walls  40 . In such position, elongated board capturing slots  54  and  82  at the opposite side of box  10  are also in alignment in a common plane. 
     As shown in  FIG. 30 , in a fourth assembly step, the assembly of  FIG. 29  is rotated so that the bottom is facing up. Then, as shown in  FIGS. 31-33 , insertion bar  100  of closure rod  26  is force fit in the space  225  between single bottom board  223  and end wall  18 . For this purpose as shown in  FIGS. 31 and 32 , one end of closure rod  26  is inserted into one rod capturing recess  84 , and the opposite end of closure rod  26  rides up ramp surface  90  at the opposite side of toy box  210 , and is then force fit over land  88  until it snaps into place into the other rod capturing recess  84 , thereby locking closure rod  24  is place and thereby locking single bottom board  223  in position, with an upper surface  98  of closure rod  26  on one side of insertion bar  100 , lying flush against the lower surface of single bottom board  223 . 
     Thereafter, as shown in  FIGS. 34 and 35 , the assembly of  FIG. 33  is rotated back so that the bottom is facing down. In a fifth assembly step, removable cover  28  is then inserted in covering relation to the upper open end so that raised portion  108  sits within the upper ends of side walls  12 ,  14  and end walls  16 ,  18 , and shoulder  112  rests on top of side walls  12 ,  14  and end walls  16 ,  18 . 
     It will be appreciated that, although the present invention has been referenced in relation to a toy box, the present invention is not limited thereto, and can be used as a box for any purpose. 
     Having described a specific preferred embodiment of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to that precise embodiment and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined by the appended claims.