Patent Publication Number: US-2023159264-A1

Title: Secure storage container

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a non-provisional application which claims a benefit of priority to U.S. Provisional Application No. 63/263,383, filed Nov. 1, 2021, the entire contents of which are hereby incorporated by reference herein. 
    
    
     BACKGROUND 
     Storage carts are necessarily present at construction sites to secure valuable tools not in active use, in a temporary and mobile fashion. Storage carts typically are provided pre-assembled, and disposed after a particular construction project is complete or when the cart becomes unfit for practical use through normal wear. Storage carts have also been provided as a kit for on-site assembly, however, such carts often suffer from disadvantages including high tolerances at the edges and corners of frame where frame panels connect, difficult and tedious assembly and edges and corners. Large tolerances in the assembled cart can suggest an insecure construction to the user that generates vibration and noise during transport of the cart. Large tolerances in the assembly also can have a deleterious effect on the security of the cart, as a common point of failure in secure carts are edges and corners that allow a tool to be inserted as a wedge to pry frame panels apart. 
     Accordingly, it would be advantageous to provide a storage cart kit for on-site assembly of a storage cart, where the storage cart demonstrate and maintain decreased tolerances following assembly and extended use. Storage carts having improved assembly methods, with respect to ease of assembly, security of the assembled storage cart, and adjustability of relative position of individual components to the cart at large, including as the angle of door panels relative to the cart, the position of the handle relative to the cart, and the tolerance between frame panels of the cart. 
     SUMMARY 
     Disclosed herein are secure storage carts configured to be assembled from a packaged kit on-site without skilled labor or specialized tools. 
     Kits for on-site assembly of a storage cart of carts disclosed herein are also contemplated, and can comprise a door panel, a plurality of frame panels, and a tolerance adjustment mechanism configured to apply a preloading force to the plurality of frame panels when the storage cart is assembled, each as unassembled and individual component of the kit. Kits disclosed herein also can comprise an adjustable depth hinge. Kits disclosed herein also can comprise a handle comprising a handle base that extends between, and is secured within, each of a first and second handle receiver, wherein each of the first and second handle receiver is welded to one of the plurality of frame panels. 
     Methods for assembling kits disclosed herein are also contemplated and can comprise fastening a plurality of frame panels to each other, attaching a door panel to one of the plurality of frame panels, and applying a preloading force to the plurality of frame panels using the tolerance adjustment mechanism. Methods disclosed herein also can comprise attaching the door panel by advancing a threaded portion of a hinge to the door panel to an appropriate depth, inserting an opposing, unthreaded portion of the hinge into a receiving slot of one of the plurality of frame panels, and optionally, locking the hinge. Methods disclosed herein also can comprise alternating a handle position from a storage position to an operational position without fastening, removing, or displacing a fastener. 
    
    
     
       BRIEF DESCRIPTION OF FIGURES 
         FIG.  1    depicts an embodiment of a storage cart, assembled, and with a handle in an operational position. 
         FIG.  2    depicts an exploded view of the storage cart of  FIG.  1   , as a kit, and with a handle in a storage position within a frame panel. 
         FIG.  3 A  depicts a perspective view of an embodiment of a handle receiver having a pitched restricted portion. 
         FIG.  3 B  depicts a front view of an embodiment of a handle receiver having a pitched restricted portion. 
         FIG.  4 A  depicts a side view of an embodiment of an adjustable depth hinge pin. 
         FIG.  4 B  depicts a perspective view of a hinge knuckle as part of the hinge. 
         FIG.  4 C  depicts a perspective view of a hinge lock for operation with the hinge knuckle and hinge pin represented in  FIGS.  4 A and  4 B . 
     
    
    
     DETAILED DESCRIPTION 
     Both the foregoing overview and the following example embodiments are examples and explanatory only, and should not be considered to restrict the disclosure’s scope, as described and claimed. Further, features and/or variations may be provided in addition to those set forth herein. For example, embodiments of the disclosure may be directed to various feature combinations and sub-combinations described in the example embodiments. 
       FIGS.  1 - 2    show an embodiment of a storage cart contemplated herein, assembled as a storage cart and in an exploded kit view, respectively. As shown in  FIG.  1   , storage cart  100  can take a conventional shape with several rectangular mesh panels to prevent entry into the cart when closed. Use of wire mesh can allow the user to see into the cart without opening, and also prevent dirt and debris from accumulating in the cart during use. Cart  100  can comprise a tolerance adjustment mechanism  110  configured to apply a preloading force to the cart, a handle  120  configured to alternate between storage and operational positions, and hinge  130  configured to allow angular adjustment between panels connected to the hinge. 
     As shown in  FIG.  2   , cart  100  can comprise a plurality of frame panels, each connecting to constitute the primary structural component of the cart. Side frame panels  140   a - d  define the perimeter of cart  100 , and are fixed in position relative to the cart once assembled. Top panel  150  and bottom panel  160  each enclose cart  100  at its respective vertical extremes. Door panels  170   a , b  complete the perimeter of cart  100 , and provide access to the interior of cart  100  when opened. Shelf panels  180   a - d  provide internal storage space to the cart and additional dimensional stability. Central interior panel  190  also provides dimensional stability along the width of cart  100 , and provides medial supports  192   a , b  for shelf panels  180   a - d , also supported at the edges of the cards by supports  142   a - d  present on side panels  140   a , b . 
     Each frame panel can provide support for additional cart components. For instance, tolerance adjustment mechanism  110  comprises first aperture  114  housed on top panel  150 , a second aperture  116  housed on side panel  140   a  and aligned with the first aperture to receive knob screw  112 . In this arrangement, tolerance adjustment mechanism  110  shown in  FIG.  1    can apply a preloading force between side panels  140   a  and top panel  150  directly, and indirectly to frame panels connected to panels  140   a  and  150 , by advancing knob screw  112  within second aperture  116 . As for perimeter panels, tolerance adjustment mechanism  110  can reduce the a tolerance between the shelf panel  180 , and central panel  190 , with respect to any of the plurality of frame panels. 
     Generally, tolerance adjustment mechanisms disclosed herein are not limited to a particular design, and can be any that are capable of applying a preloading force to a plurality of assembled frame panels. Tolerance adjustment mechanisms disclosed herein therefore can act to reduce tolerances between the assembled panels and reduce vibration of the panels, particularly relative to the cart when empty (e.g., the cart does not have a load applied to the frame by stored tools and equipment). In certain aspects, tolerance adjustment mechanisms can comprise a fastener configured to be advanced across two or more frame panels, pulling the panels closer together as advanced. For instance, an embodiment of a tolerance adjustment mechanism disclosed herein can comprise a knob screw, a first aperture within one frame panel, and a second aperture within another frame panel, wherein each aperture is configured to receive the knob screw. In certain aspects, the first and/or second apertures can be threaded apertures. 
     The preloading force applied by the tolerance adjustment mechanism can be in any range suitable to reduce or eliminate a tolerance between a plurality of frame panels, from 10 N to 1,000 N, or roughly equivalent to a load applied to the frame by 1 to 100 lbs of equipment stored within the cart. In other aspects, the preloading force may be in a range from 250 N to 5,000 N. 
     Tolerance adjustment mechanisms can be positioned such that operation is only possible from the interior of the cart, to prevent release of the preloading force by unauthorized parties. Any positioning within the cart, such as behind a guard, plate, or within a aperture, can be effective for restricting access to the tolerance adjustment mechanism from outside the locked cart. 
     The preloading force may be advantageously applied to the cart at more than one position, by the inclusion of more than one tolerance adjustment mechanisms within the assembled structure. In certain aspects, carts can comprise one, two, three, four, or more tolerance adjustment mechanisms to distribute the preloading force about the assembled frame panels. For instance, carts disclosed herein can comprise two tolerance adjustment mechanisms in opposing positions, or in other words, apply a preloading force in opposing directions. The embodiment shown in  FIGS.  1 - 2    provides an example of such a cart, where two tolerance adjustment mechanisms are provided at opposing top ends of the top panel  150  and each of side panels  140   a , b . Each tolerance adjustment mechanism  110  is positioned to apply the preloading force toward the center of the cart, and therefore tends to reduce the tolerance between assembled panels  140   a , b  and  150 , as well as other panels in contact with panels  140   a , b  and  150 . 
     Without being bound by theory, the application of a preloading force to the frame panels after assembly as described herein can allow greater manufacturing tolerances for the individual components of the cart provided as a kit to be assembled on site without sacrificing the low tolerances achieved by the assembled carts disclosed herein. The preloading force can overcome manufacturing tolerances of the frame panels, in certain aspects from 1/32” to 1”, while maintaining a tolerance between assembled frame panels of less than ½, less than ¼”, less than ⅛”, less than 1/16”, or less than 1/32”. In certain aspects, the sum of maximum tolerances between each of the assembled panels with application of the preloading force of the storage cart can be less than 2”, less than 1”, or less than ½”. 
       FIG.  2    also shows handle  120  supported on side panel  140   b , with handle grip  122  shown in a storage position. Handle  120  comprises handle grip  122  extending from handle base  124  formed from steel square tube. Handle receivers  126   a , b  are welded to the side panel  140   b  at a distance less than the length of handle base  122 , and handle base  122  extends into and is contained within, receiving portion  128  of both handle receivers  126   a , b . Thus, handle  120  can be permanently attached to side panel  140   b  by handle receivers  126   a , b , without using a fastener, or removable fastener (e.g., screw, bolt, hinge) securing the handle to the side panel. 
       FIGS.  3 A and  3 B  provide further detail on handle receivers  126 , particularly as to receiving portion  128 . As shown, receiving portion  128  represents an internal aperture generally having a keyhole shape with a rectangular, restricted portion  127  at its lower end and a rounded, unrestricted portion  129  at its upper end. Those of skill in the art will understand that as the square tube handle base  124  is advanced into restricted portion  127 , rotation of handle  120  will become restricted, securing the handle in a fixed position. Alternatively, as the handle base  124  is moved within the unrestricted portion  129 , handle  120  is able to rotate freely with respect to side panel  140   b . In this manner, handle  120  can be alternated between a secure storage position and a secure operational position, without removing and replacing a single fastener such as a screw, bolt, or retaining pin. 
     Generally, handle receivers contemplated herein can be any that comprise a restricted portion configured to restrict rotation of the handle relative to the frame panel and an unrestricted portion configured to allow rotation of the handle between a parallel orientation to a perpendicular orientation, relative to the fixed panel. The restricted portion is not limited to any particular shape or size, and can be driven by the shape and size of the handle base intended to be secured within the restricted portion. For instance, the square tube handle base  122  can be restricted within a rectangular-shaped area of similar dimensions, thus, the generally rectangular restricted portion  127  shown in  FIG.  3    can generally be considered appropriate for handle bases such as handle base  124  of the embodiment shown in  FIG.  2   . In contrast, the unrestricted portion of the handle receiver may generally be any shape that does not prevent or interfere with the rotation of the handle base. Again looking to  FIG.  3   , a generally circular, or rounded unrestricted portion allows rotation of the square tube handle base  122 , and so can be suitable for the intended purpose. Those of skill in the art will understand that additional shapes and sizes of handles and corresponding portions of the handle receiver may be implemented. 
     In certain aspects, the restricted portion can be pitched relative to the horizontal plane by an amount p, or relative to a plane generally perpendicular to the plane of side panel  140   b . Surprisingly, introducing pitch p to restricted portion  127  causes a shear force produced by pushing or pulling handle  120  to have a downward vector component to handle base  124 , such that pushing or pulling handle grip  122  causes the handle  120  to advance downward within restricted portion  127 . In this manner, the handle  120  tends to become more secure and solidly connected to the operation of the cart by its use, rather than loosening with use as commonly occurs on carts having handles connected by fasteners. In certain aspects, the restricted portion can comprise a pitch in a range from 0.5 to 5°, from 0.3 to 3° or from 0.5 to 2°, or from 0.5 to 1.5°, relative to horizontal. In certain aspects, the restricted portion can be pitched toward a direction can be directed either toward or away from the frame panel to which the handle is attached. Thus, in certain aspects, the restricted portion can be pitched p relative to horizontal and in a direction of the force applied by pushing the handle. 
     Returning now to  FIG.  2   , each door panel  170   a , b  may be secured to adjacent panels of the cart by hinge  130 . As shown, hinge  130  can comprise hinge pin  132  having a threaded portion extending orthogonally from the unthreaded pin, the threaded portion configured to be fastened within threaded hinge aperture  172  at a variable depth. The pin may then be inserted within hinge knuckle  134 , shown in  FIG.  2    welded to side panel  140   b , to allow rotation of door panel  170   b  about the hinge pin  132 . The angle of the door panel can therefore be adjusted in a straightforward manner, by adjusting the depth of the threaded portion of hinge pin  172  within threaded aperture  172  of door panel  170   b . Such adjustment ensures that the door panels will meet other frame panels at an appropriate position such that components of the cart are in alignment. For instance, door panel handle lock  174  can be aligned to the mating component of door panel  170   a . As for other panels, the tolerance between the door panels  170   a , b  also can be reduced by tuning the depth of the threaded portion of hinge pin  132  within aperture  172 . A hinge lock may also be provided to seat within the gap formed by plates of hinge knuckle  134  and secure the hinge pin  132  to knuckle  134  when assembled.  FIGS.  4 A-C  provide an example of a hinge  130  operable as described above.  FIG.  4 A  shows hinge pin  132  having threaded portion  133  that can be rotated into a mating threaded aperture of door panel  170   a , b  to an adjustable depth. Unthreaded portion  135  of hinge pin  132  can then be inserted within the aperture of hinge knuckle  134 , until washer stop  131  rests against the top surface of the hinge knuckle.  FIG.  4 C  depicts an embodiment of a hinge lock  136  that may be inserted within the hinge knuckle  134  in order to prevent hinge  130  from being disassembled without unlocking and opening the door panel  170   a , b . 
     The cart panel shown in  FIG.  2    also comprises several brackets  164  for securing the frame panels to one another, and several brackets  164  are shown welded to bottom frame panel  160 . Generally, the panels can be secured to panels by inserting fasteners through an internal face of the bracket to ensure that the assembled cart cannot be disassembled from the exterior. As will be appreciated, the shape and positioning of brackets may be any that allow the panels to be assembled to provide a secure and solid construction. Bottom frame panel  160  may also include footings  162 , to provide stability. In certain aspects, footings can be adjustable. In other aspects, footings can comprise wheels to impart mobility to the cart. 
     In addition to door panel handle lock  174 , door panel  170   b  comprises a pin lock  178  that can be seated within bottom frame  160  to retain door panel  170   b  in a closed position. Frame panels may also comprise additional internal supports, for instance diagonal support  176  of door panel  170   a  which provides dimensional support to the panel. 
     Certain aspects of the carts described above may be particularly useful as packaged as kits for carts intended for on-site assembly and disassembly. In certain aspects, the tolerance adjustment mechanism can provide an efficient method of assembling a storage cart that does not suffer from large tolerances typically associated with on-site assembled carts. Thus, in certain aspects, kits disclosed herein can comprise a plurality of frame panels, a door panel, and a tolerance adjustment mechanism. Similarly, kits comprising the adjustable depth hinges allow for an improved on-site assembly through straightforward adjustment of the door panel angle. 
     Methods for assembling a secure storage cart are also contemplated herein, and generally can include steps of adjusting the angle of a door panel by advancing an adjustable depth hinge pin into the door panel as described above. Methods may also include alternatively positioning a handle of any storage cart between an operating position and a storage position without removing or replacing fasteners to the handle. Methods disclosed herein also may comprise adjusting the tolerance of an assembled plurality of frame panels of the carts disclosed herein from the interior of the cart.