Patent Publication Number: US-2007103039-A1

Title: Tool storage system

Description:
FIELD OF THE INVENTION  
      This invention relates generally to tool storage systems and relates specifically to arrangements and methods for shipping tool storage systems.  
     BACKGROUND OF THE INVENTION  
      Tool storage systems are commonly used by businesses and consumers to store and organize tools, spare parts, fasteners, and the like. Tool storage systems range from single cabinets with one storage receptacle to systems with multiple cabinets, each with multiple storage receptacles configured to meet a variety of needs. Businesses commonly use tool storage systems in manufacturing facilities or on shop floors to store and organize tools and components to facilitate efficient manufacturing or similar processes. Consumers commonly use tool storage systems in garages, basements or other areas where repair, maintenance, or similar work is conducted.  
      Tool storage systems can be designed to store large items or a large number of items and, thus, can be relatively large and bulky. The size and volume of such systems add to the cost of shipping tool storage systems from a manufacturing or assembly facility to a distributor, retailer, or end user. It is desirable to design and develop arrangements and methods for reducing the size or volume of a tool storage system packaged for shipment from one location to another.  
     SUMMARY OF THE INVENTION  
      This invention and disclosure are directed to arrangements and methods for packaging tool storage systems. The arrangements and methods disclosed and claimed herein reduce the volume of a tool storage system configured for shipment.  
      An embodiment of the invention provides for a tool storage system kit. The kit includes an assembled primary cabinet and an unassembled secondary cabinet. The assembled primary cabinet includes primary cabinet storage receptacles and the unassembled secondary cabinet includes secondary cabinet storage receptacles. 
    
    
     DESCRIPTION OF THE DRAWINGS  
      In the accompanying drawings, which are incorporated in and constitute a part of this specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below serve to illustrate the principles of this invention. The drawings and detailed description are not intended to and do not limit the scope of the invention or the claims in any way. Instead, the drawings and detailed description only describe embodiments of the invention and other embodiments of the invention not described are encompassed by the claims.  
       FIG. 1  is a perspective view of a tool storage system, including a main cabinet, an intermediate chest, and a top chest;  
       FIG. 2  is a perspective view of the tool storage system of  FIG. 1  with the intermediate chest and top chest exploded;  
       FIG. 3  is a schematic illustration of the tool storage system of  FIG. 1  with components of the intermediate chest and the top chest positioned within the drawers of the main cabinet;  
       FIG. 4  is a side view schematic illustration of the tool storage system of  FIG. 1  with the components of the intermediate chest and top chest positioned within the drawers of the main cabinet;  
       FIG. 5  is a exploded view of a intermediate chest drawer;  
       FIG. 6  is a schematic illustration of the components of the intermediate chest drawer of  FIG. 5  positioned within a main cabinet drawer;  
       FIG. 7  is a perspective view of hinged body panels of the intermediate chest of  FIG. 1 ;  
       FIG. 8  is a perspective view of the hinged body panels of  FIG. 7  positioned within a main cabinet drawer;  
       FIG. 9  is a perspective view of a tool storage system including a main cabinet, with a bulk storage compartment; an intermediate chest; and a top chest;  
       FIG. 10  is a perspective view of the tool storage system of  FIG. 9  with the intermediate chest and top chest exploded;  
       FIG. 11  is a schematic illustration of the tool storage system of  FIG. 9  with the components of the intermediate chest and the top chest positioned within the bulk storage compartment of the main cabinet;  
       FIG. 12  is a side view schematic illustration of the tool storage system of  FIG. 9  with the components of the intermediate chest and top chest positioned within the bulk storage compartment of the main cabinet;  
       FIG. 13  is a perspective view of an intermediate chest including a drawer and a parts case;  
       FIG. 14  is an exploded view of the tool storage system of  FIG. 10  arranged for shipment;  
       FIG. 15  is a schematic illustration of a subcomponent of  FIG. 9  wrapped in a protective sheet; and  
       FIG. 16  is a schematic illustration of protective spacers positioned within a drawer of the main cabinet of  FIG. 9 .  
    
    
     DETAILED DESCRIPTION  
      This Detailed Description of the Invention merely describes embodiments of the invention and is not intended to limit the scope of the invention in any way. Indeed, the invention as described in the claims is broader than and unlimited by the preferred embodiments, and the terms used have their full ordinary meaning.  
      Referring to  FIG. 1 , a typical tool storage system  10  is illustrated. The tool storage system  10  includes a main cabinet  12 , an intermediate chest  14 , and a top chest  16 . Tool storage systems  10  typically have a primary or base unit, such as the main cabinet  12 , and secondary or companion units, such as the intermediate chest  14  and top chest  16 . Primary  12  and secondary  14  and  16  cabinets typically have storage receptacles, such as drawers, into which items can be stored. In the embodiment shown, the main cabinet  12  has five drawers  18 . These main cabinet drawers  18  range in size to allow for storing items of various sizes and shapes. Although the illustration in  FIG. 1  shows five drawers  18 , a main cabinet  12  can include any number and size of drawers.  FIG. 1  also shows two secondary cabinets, the intermediate cabinet  14  and the top cabinet  16 . These secondary cabinets  14  and  16  differ from one another by providing different sized and types of storage compartments. Although the illustration in  FIG. 1  shows two secondary cabinets  14  and  16 , a tool storage system  10  may include any number of secondary cabinets, or may not have any secondary cabinet. By allowing for flexibility in the number of drawers  18  in a primary cabinet  10 , along with flexibility in the number of secondary cabinets, a tool storage systems  10  can be readily configured to meet a variety of consumer and industrial needs and applications.  
      A tool storage system  10  is typically designed to store items that can be heavy and commonly made of steel or other metals. In order to hold such items, the system should be durable and resistant to impacts. To meet these needs, a tool storage system  10  is often made of steel, typically in the form of heavy gauge sheet metal. A tool storage system  10  can also be designed to store lighter weight or plastic items. In such an application, the system  10  can be constructed of less durable materials, such as, for example, plastics or light weight sheet metal.  
      The intermediate chest  14  can be fastened or coupled to the main cabinet  12  or can simply rest on top of the main cabinet  12 . The main cabinet  12  and intermediate chest  14  can include matching apertures (not shown) through which fasteners can pass to secure the chest  14  to the cabinet  12 . Alternatively, as shown in  FIG. 1 , the main cabinet  12  includes a lip  20  that extends upward from a top edge of the cabinet  12  and runs along at least a portion of the top edge of the cabinet  12 . This lip  20  forms a recess  22  in the top of the cabinet  12 . The intermediate chest  14  can be sized to rest within this recess  22 . In this arrangement, the lip  20  can limit the lateral movements of the intermediate cabinet  14  and restrain the intermediate cabinet  14  from sliding off of the top of the main cabinet  12 . Similarly, the top chest  16  can be fastened or coupled to the intermediate chest  14  or the top chest  16  can rest on top of the intermediate chest  14 , which can include a lip (not shown) similar to the main cabinet  12 .  
      Referring to  FIG. 1 , the main cabinet  12  includes a body  24 . The body  24  is a shell into which the drawers  18  can be arranged to slide into and out of the body  24  in order to open or close the drawers  18 , respectively. Optionally, the main cabinet  12  can include casters  26  to facilitate manually moving the tool storage system  10  from one location to another by rolling the tool storage system  10  on such casters  26 . Although the illustrated embodiments herein show casters  26  coupled to the main cabinet  12 , it should be understood that a main cabinet  12  may include other components to facilitate movement, such as wheels or slides. In addition, a main cabinet  12  may be configured to remain stationary once positioned and not include any components, such as casters  26 , that facilitate movement.  
      The intermediate cabinet  14  also includes drawers  28  for storage and a body  30  into which the drawers  28  can be opened and closed. As shown, each drawer  28  spans the width of the intermediate cabinet  14 . Optionally, drawers  28  can be sized such that two or more drawers  28  are positioned next to each other in a single drawer slot or opening to span the width of the cabinet  14 . These split drawers allow for greater versatility in designing a tool storage system  10 . As best seen in  FIG. 2 , the body  30  includes two side panels  32  and  34 , a back panel  36 , a top panel  38 , and a bottom panel  40 . Each drawer  28  slides into and out of the body  30  along a rail system. The rail system typically includes a pair of drawer rails  42 , a pair of body rails  44 , and a pair of connector rails  46 . The pair of drawer rails  42  are mounted on opposite outside surfaces of the drawer  28 . The pair of body rails  44  are mounted on opposite inside surfaces of the side panels  32  and  34 , via a mounting bracket  48 . The connector rails  46  interface with and slideably couple to both the drawer rails  42  and the body rails  44 . This rail system allows for the drawers  28  of the intermediate cabinet  14  to slide in and out of the intermediate cabinet body  30  to open and close the drawers  28 , respectively.  
      The rail system can include ball bearing slides, roller slides, friction slides, or any other apparatus or method that allows for the drawers  28  to slide into and out of the body  30  to open and close the drawers  28 . In addition, the rail system can be designed to include only drawer rails  42  and body rails  44 , where the drawer rails  42  directly couple to the body rails  44  to allow for the drawer  28  to slide into and out of the body  30 . Furthermore, the mounting bracket  48  can be eliminated and the body rails  44  can be directly mounted to the inside surfaces of the side panels  32  and  34 .  
      Similar to the intermediate chest  14 , the top chest  16  includes a number of drawers  50  for storage and a body  52  into which the drawers  50  open and close. The top chest  16  optionally includes a lid  54  that is hinged to the body  52 . The lid  54  can be opened to reveal a storage tray  56 . The storage tray  56  can be arranged to include a number of recessed compartments (not shown) into which small items can be segregated. As shown, the top chest body  52  includes two side panels  58  and  60 , a back panel  62 , and a bottom panel  64 . As described above regarding the intermediate chest  14 , each top chest drawer  50  slides into and out of the body  52  along a rail system, which includes a pair of drawer rails  42 , a pair of body rails  44 , a pair of connector rails  46 , and a mounting bracket  48 . Again as described above for the intermediate cabinet  14 , the rail system can be arranged in a variety of ways to provide for the top chest drawers  50  to slide between open and closed positions.  
      Conventionally, cabinets of a tool storage system are manufactured and assembled prior to shipping the system to distributors, retailers, end users, and the like. Assembling all the cabinets prior to shipping maximizes the shipping volume. In this arrangement, the shipping volume will equal the volume of the finished tool storage system plus the volume of any packaging material used to protect the system during shipping. This arrangement of shipping leaves much of the volume, such as the inside of the main cabinet drawers, empty and unused.  
      As best seen in  FIG. 2 , the secondary cabinets  14  and  16  are constructed or assembled from a number of subcomponents. If these secondary cabinets  14  and  16  are shipped in an unassembled or disassembled state, the subcomponents can be arranged into the unused volume of the main cabinet drawers  18  to reduce the shipping volume of a system  10 . In this arrangement, the total shipping volume would be reduced by the volume of the assembled intermediate chest  14  and the volume of the top chest  16 . This arrangement could lead to a reduction of shipping volume in excess of fifty percent. This reduction in shipping volume typically will lead to a savings in the cost of shipping a tool storage system  10  from a manufacturing facility, through the supply chain, to an end user.  
       FIGS. 3 and 4  show arrangements for placing subcomponents of the intermediate chest  14  and top chest  16  into the main cabinet drawers  18  for shipping. The drawers  28  and  50  of the secondary cabinets  14  and  16 , respectively, are typically designed to be smaller, in both width and depth, than the main cabinet drawers  18 . In addition, the main cabinet drawers  18  are often designed to have a greater height than secondary cabinet drawers  28  and  50 . This arrangement allows for each main cabinet drawer  18  to accommodate at least one, and often multiple, secondary cabinet drawers  28  and  50 .  
      The relative size difference between the main cabinet drawers  18  and secondary cabinet drawers  28  and  50  allows for additional subcomponents of secondary cabinets  14  and  16  to be accommodated by the main cabinet drawers  18 . For instance, individual components of the intermediate cabinet body  30  can be stored in the bottom of main cabinet drawers  18 . As best seen in  FIG. 4 , the side panels  32  and  34 , back panel  36 , top panel  38 , and bottom panel  40  of the intermediate cabinet  14  are laid flat in the bottom of a main cabinet drawer  18  with the intermediate cabinet drawers  28  positioned on top. Also as best seen in  FIG. 4 , body rails  44  and connector rails  46  can be positioned within the main cabinet drawers  18  during shipping.  
      As shown the subcomponents of the secondary cabinets  14  and  16  are generally unassembled when placed into a main cabinet drawer  18 . In addition, as shown, when subcomponents are positioned within the main cabinet  12 , the subcomponents are placed into the main cabinet drawers  18 . However, it should be understood that two or more subcomponents of a secondary cabinet  14  and  16  can also be assembled when placed or positioned into the main cabinet  12 . In addition, it should be understood that subcomponents of secondary cabinets  14  and  16  can be positioned or placed into areas of the main cabinet  12  other then the main cabinet drawers  18 . For example, a back panel  36  could be positioned vertically in a gap between the main cabinet drawers  18  and the body  24  of the main cabinet  12 .  
      As shown, secondary cabinet drawers  28  and  50  slide into and out of the cabinets  14  and  16  along rail systems. It should be understood that other systems and other components can accomplish the function of opening and closing a drawer or other storage receptacle. These other systems and components can be placed or positioned into a main cabinet  12  for shipping in a similar manner to that shown and described for the rail system.  
       FIGS. 3 and 4  illustrate select subcomponents of secondary cabinets  14  and  16  positioned in main cabinet drawers  18 . It should be understood that these schematic illustrations are exemplary and representative of positioning any or all of the subcomponents of a secondary cabinet  14  and  16  into main cabinet drawers  18   
      The casters  26  of the main cabinet  12  can be left unassembled or disassembled from the cabinet  12  and positioned in a main cabinet drawer  18  for shipping. This will further reduce the total shipping volume of a tool storage system  10  and reduce possible damage to the casters  26  during shipping.  
      The interior space of the secondary cabinet drawers  28  and  50  can also be utilized during shipping. For instance body rails  44 , connector rails  46 , mounting brackets  48 , or casters  26  can be positioned within the intermediate cabinet drawers  28  or the top cabinet drawers  50  to further use space efficiently.  
      As shown in  FIG. 4 , additional packaging material can be used to organize the interior space of the main cabinet drawers  18  during shipping. For instance, a cardboard box  66  or tube  68  can be used to hold any of the rails  42 ,  44 , and  46 , casters  26 , or fasteners needed to assemble the secondary cabinets  14  and  16 . These boxes  66  and tubes  68  can be designed to fit into unused space in either a main cabinet drawer  18  or a secondary cabinet drawer  28  and  50 , while being sized to efficiently hold specific secondary cabinet  14  and  16  components.  
      As shown in  FIGS. 3 and 4 , the secondary cabinet drawers  28  and  50  can be assembled when positioned in the main cabinet drawers  18 . In another embodiment, shown in  FIGS. 5 and 6 , a secondary cabinet drawer  28  can include a number of subcomponents.  FIG. 5  shows an intermediate chest drawer  28  in an unassembled state. The drawer  28  includes a front panel  70 , two side panels  72 , a back panel  74 , and a bottom panel  76 . As seen in  FIG. 6 , these subcomponents can be positioned in a main cabinet drawer  18  while in an unassembled state. This arrangement can offer greater efficiency and flexibility in storing secondary cabinet drawers  28  and  50  in main cabinet drawers  18 . For instance, when the height of a secondary cabinet drawer  28  and  50  is as tall or taller than a main cabinet drawer  18 , the secondary cabinet drawer  28  and  50  may still be accommodated by the main cabinet drawer  18  when the secondary cabinet drawer  28  and  50  is in an unassembled state.  
      Again referring to  FIGS. 3 and 4 , the body  30  of the intermediate chest  14  includes side panels  32  and  34  and a back panel  36 , which are unattached when the intermediate chest  14  is unassembled. In this embodiment, the end user fastens the side panels  32  and  34  to the back panel  36  during the assembly of the intermediate chest  14 . In the embodiment shown in  FIGS. 7 and 8 , the side panels  32  and  34  are coupled to the back panel  36  by hinges  78 . This arrangement simplifies the process of assembling the intermediate chest  14 . The hinged design removes the need to fasten the side panels  32  and  34  to the back panel  36 . As shown in  FIG. 8 , the hinges  78  allow for the side panels  32  and  34  to be folded onto the back panel  36  and lay relatively flat when positioned in a main cabinet drawer  18 . This arrangement simplifies the assembly process while still allowing for efficient use of space when positioning body panels  32 ,  34 , and  36  in a main cabinet drawer  18 . In addition to the arrangement shown, any two or more body panels can be hinged together. For example, the top  38  and bottom  40  panels of the intermediate cabinet  14  could be coupled to the back panel  36  in a similar manner to the illustration in  FIGS. 7 and 8 . In the illustration, coupling is facilitated by a hinge, however, any method of coupling that allows one subcomponent to move relative to a second subcomponent to reduce shipping volume is encompassed within this invention.  
      Another embodiment of a tool storage system  100  is shown in  FIGS. 9 through 12 . This embodiment is similar to that shown in  FIG. 1 , with the exceptions that, in addition to main cabinet drawers  18 , the main cabinet  102  includes bulk storage compartment  104 . As seen in  FIG. 10 , the bulk storage compartment has a cover  106  that can be lifted to reveal the compartment  104 . The bulk storage compartment  104  normally has a larger volume than a main compartment drawer  18  and is designed to accommodate relatively large items. In the embodiment shown, the secondary cabinets  14  and  16  are identical to those illustrated in  FIG. 1 .  
      As shown in  FIGS. 11 and 12 , the unassembled components of the secondary cabinets  14  and  16  can be accommodated in the bulk storage compartment  104  during shipping. Since the bulk storage compartment  104  typically has a larger internal volume than a main cabinet drawer  18 , the compartment  104  can allow for a greater versatility and flexibility in positioning secondary cabinet  14  and  16  components during shipment. Whereas some secondary cabinet drawers  28  and  50  may need to be unassembled to fit into main cabinet drawers  18 , those same secondary cabinet drawers  28  and  50  may be able to fit into the bulk storage compartment  104  in an assembled state. Therefore, less assembly time is required by the end user. Although this embodiment shows secondary cabinet  14  and  16  components stored only in the bulk storage compartment  104 , it should be understood that such components may also be stored in the main cabinet drawers  18  as well, and that the internal space of the secondary cabinet drawers  28  and  50  may be used to accommodate components.  
      The embodiments as shown herein include a main cabinet  12 , with either five drawers  18  or three drawers  18  and a bulk storage compartment  104 , and secondary cabinets with three drawers  28  or with five drawers  50  and a lid  54 . It should be understood that these embodiments are exemplary only and that a main cabinet and a secondary cabinet can be configured or arranged with any number and size of storage receptacles. Provided the storage receptacles of either the main cabinet or secondary cabinet can be used to reduce the volume needed to ship the tool storage system, the configuration and arrangement falls within the scope of this disclosure and invention.  
      The embodiments shown heretofore show three types of storage receptacles: drawers  18 ,  28 , and  50 ; a storage tray  56 ; and a bulk storage compartment  104 . It should be understood that these storage receptacles are exemplary only and that a storage receptacle of the present invention may take a variety of forms. For example, bins, parts organizers, hand boxes, satchels, parts cases, tool boxes, and the like all fall within the breath of storage receptacles as used herein. Referring to  FIG. 13 , a parts case  108  is illustrated. As shown, the parts case  108  slides into and out of a secondary cabinet  110 . The secondary cabinet  110  also includes a drawer  112 . The parts case  108  slides into and out of the secondary cabinet  10  along a rail system. A first rail  114  is incorporated into the side of the case  108 . The rail fits into a second rail or groove (not shown) incorporated into the inside of the second cabinet  110 . The rail system is designed such that the case  108  can be completely removed from the cabinet  110  and carried away. The parts case  108  can have any arrangement of internal compartments that allows for storage of spare parts, tools, fasteners, and the like. Alternatively, the parts case  108  can slide into or out of the secondary cabinet without the use of a rail system. In this embodiment, the case  108  can be sized to fit into a slot  116  formed in the cabinet  110 .  
      As shown in  FIGS. 14 through 16 , packaging material may be utilized to protect the main cabinet  102  and secondary cabinet  14  and  16  components during shipping. As shown in  FIG. 13 , once the secondary cabinet  14  and  16  components are positioned in the main cabinet  102  the main cabinet  102  can be packaged into a cardboard box (not shown). Flat panels  120  and corner pieces  122 , typically made of STYROFOAM, can be positioned around the main cabinet  12  to protect the cabinet  102  from damage during shipping.  
      As shown in  FIGS. 14 , sheets  124  of protective material can be wrapped around secondary cabinet  14  and  16  components prior to being positioned within a main cabinet drawer  18  or bulk storage compartment  104 . These sheets  124  can protect both the secondary cabinet  14  and  16  components as well as the inside of main cabinet drawers  18  or a bulk storage compartment  106  from damage during shipping.  
      As secondary cabinet  14  and  16  components are positioned in main cabinet drawers  18  or bulk storage compartments  104 , there is often free space surrounding the secondary cabinet  14  and  16  components. The free space can cause the secondary cabinet  14  and  16  components to move within the main cabinet drawers  18  or bulk storage compartments  104  during shipping. This movement increases the likelihood of damage to the main cabinet drawers  18 , bulk storage compartment  104 , and components positioned within. As seen in  FIG. 15 , spacers  126 , typically made from STYROFOAM, can be positioned to fill the free space and limit the movement of components stored in the main cabinet drawers  18  or bulk storage compartments  104 . These spacers  126  can also be used to frame a customized space into which a given subcomponent can be positioned.  
      While various aspects of the invention are described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects may be realized in many alternative embodiments not shown, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present invention. Still further, while various alternative embodiments as to the various aspects and features of the invention, such as alternative materials, structures, configurations, methods, devices, and so on may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the aspects, concepts or features of the invention into additional embodiments within the scope of the present invention even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the invention may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present invention however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated.