Abstract:
A power module that fits to the top of a storage chest or cabinet is connected to electrical power and routes the electrical power to drawers and/or cavities within the chest or cabinet. The electrical power is continuously available while the power module is connected to electrical power so that the drawers or cavities have a continuous source of power whether or not the drawers or cabinet doors are open or closed. The chest or cabinet may include receptacles having a standard configuration that connects to a variety of devices including, for example, lights, heaters, and battery chargers. The chest or cabinet may include electrically powered features, such as, for example, lights, clocks, audio/visual equipment, computers, tool chargers, air compressors, refrigerators, wireless communications devices, and heaters. The chest or cabinet may also include one or more exterior lights.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This non-provisional application claims the benefit of U.S. Provisional Patent Application Nos. 60/808,707, entitled “Tool Chest with Light” and filed on May 26, 2006, 60/811,183, entitled “Powered Toolbox” and filed on Jun. 6, 2006, 60/874,547, entitled “Storage Container” and filed on Dec. 13, 2006, and 60/916,601 entitled “Modular Power for Chests and Drawers” and filed on May 8, 2007. The entire disclosure of the listed provisional applications is incorporated herein by reference for all purposes, to the extent that it is not conflicting with the present application. 
     
    
     TECHNICAL FIELD  
       [0002]     The invention pertains to the field of storage chests and cabinets.  
       BACKGROUND  
       [0003]     Certain drawer chests include limited connections to an electrical power source for a dedicated purpose. For example, U.S. Patent Publication No. 2002/0171335 to Held describes a chest of drawers in which at least one of the drawers includes a built-in current storage means, such as a battery. When the drawer is closed, the current storage means is connected to a power source and the storage means is charged. When the drawer is open, the current storage means can be used to power an electrical accessory until the stored energy is depleted. U.S. Pat. No. 5,276,310 to Schmidt et al. concerns a toolbox with drawers that include electric heaters to heat tools held within the drawer. The heater is connected to a power source in the back of the toolbox when the drawer is closed. tools held within the drawer. The heater is connected to a power source in the back of the toolbox when the drawer is closed.  
       SUMMARY  
       [0004]     A power module that fits to the top of a storage chest or cabinet is connected to electrical power and routes the electrical power to drawers and/or cavities within the chest or cabinet. One or more power receiving devices is present in the power module such as, for example, a wiring harness, audio visual equipment, a message center, an ultrasonic cleaner, a wireless communication device, a battery charger, a refrigerator, or an air compressor. The electrical power is continuously available while the power module is connected to electrical power so that the drawers or cavities have a continuous source of power whether or not the drawers or cabinet doors are open or closed. The chest or cabinet may include receptacles having a standard configuration that connects to a variety of devices including, for example, lights, heaters, and battery chargers. The chest or cabinet may include electrically powered features such as, for example, lights, clocks, audio equipment, computers, and heaters. The chest or cabinet may have one or more drawers or pull-out work surfaces with underside lighting.  
         [0005]     Further features and advantages of the invention will become apparent from the following detailed description made with reference to the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]     In the accompanying drawings, which are incorporated in and constitute a part of this specification, embodiments of the invention are illustrated, which, together with the description of the invention 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 any subsequent claims in any way. Instead, the drawings and description only describe embodiments of the invention and other embodiments of the invention not described are encompassed by this disclosure of the invention.  
         [0007]      FIG. 1  is a perspective view of a chest that includes a power top module constructed in accordance with an embodiment of the present invention;  
         [0008]      FIG. 2  is a front perspective view of the power top module of  FIG. 1 ;  
         [0009]      FIG. 3  is a top perspective view of the power top module of  FIG. 1 ;  
         [0010]      FIG. 4  is a bottom view of the power top module of  FIG. 1 ;  
         [0011]      FIG. 5  is a rear perspective view of the power top module of  FIG. 1 ;  
         [0012]      FIG. 6  is an exploded fragmentary view of the power top module of  FIG. 1 ;  
         [0013]      FIG. 7  is a rear view of the chest of  FIG. 1  with the rear wall removed to reveal a wiring harness that can be used in conjunction with power top module of  FIG. 1 ;  
         [0014]      FIGS. 8-9  are bottom views of a drawer in the chest of  FIG. 1  that receives power from the power top module of  FIG. 1 ;  
         [0015]      FIG. 10  is an exploded bottom view of the drawer of  FIGS. 8 and 9 ;  
         [0016]      FIG. 11  is a bottom view of the chest of  FIG. 1  that includes an under chest light;  
         [0017]      FIG. 12  is a perspective view of a storage unit that includes a power module constructed in accordance with an another embodiment of the present invention;  
         [0018]      FIGS. 13A and 13B  are fragmentary views of pull-out members of the storage unit of  FIG. 12 ;  
         [0019]      FIG. 14  is a schematic circuit diagram that can be used to provide electrical features to a storage unit constructed in accordance with an embodiment of the present invention; and  
         [0020]      FIGS. 15A and 15B  are perspective views of a tool storage unit constructed in accordance with an embodiment of the present invention. 
     
    
     DESCRIPTION OF THE INVENTION  
       [0021]     The Detailed Description of the Invention merely describes preferred embodiments of the invention and is not intended to limit the scope of the specification or any issued claims in any way. Indeed, the invention as described is broader than and unlimited by the preferred embodiments, and the terms in the specification have their full ordinary meaning.  
         [0022]     Many storage chests and cabinets could provide increased utility by featuring convenient access to electrical power as part of the chest or cabinet. For example, a light source located within a drawer or cabinet may illuminate the contents or surroundings when the drawer or door is opened. Heating or cooling mechanisms within the drawer or cabinet may maintain the interior temperature within an acceptable range for the contents so that the chest or cabinet can be installed in a location exposed to extreme temperatures. A source of power within the drawer or cabinet can be used to energize battery chargers so that tools or other battery operated devices stored in the drawer or cabinet can be charged during storage.  
         [0023]      FIG. 1  shows a storage chest  10  that is adapted for use in storing tools. A chest is shown for exemplary purposes only. It should be apparent to one skilled in the art that the invention may be practiced on tool chests, tool cabinets, or combination tool chest and cabinet units. The chest  10  is formed by a structural weldment that includes rear wall  15 , side walls  13 , and bottom  17  ( FIG. 11 ). The weldment defines a cavity in which a number of drawers  20  are installed. The chest also includes a power top module  100  that can be connected to a source of electrical power, such as a household outlet (not shown). Prior to entering the power top module  100 , the AC power from a household outlet may be rectified into DC power with a standard AC to DC converter that is commonly used to power many devices. Other features of the power top module  100  include an LCD unit  12  that provides a user interface to a clock and radio that are part of the LCD unit and receive power from the power top module.  
         [0024]      FIGS. 2 and 3  show the power top module  100  removed from the chest  10 . In addition to providing a means for receiving power, the power top module includes other features such as a work surface  132  that is surrounded by a short wall  125  that projects vertically from surface around its periphery. The wall  125  helps prevent objects from rolling off the surface and contains liquid spills. A plurality of holding cups  110  of various sizes are molded into the power top module to contain small objects such as screws and small hand tools. A key cylinder  30  is present in the power top module  100  to allow a user to secure the drawers in the closed position. A lighted nameplate  134  holder is molded into the front surface of the power top module  100 .  
         [0025]      FIG. 4  is a bottom view of the power top module  100  that shows some aspects of the power management components that allow the top to be used to receive power from an external source and route the power to various locations within the chest. The power top module  100  is molded from plastic and includes a number of strengthening ribs arranged in a grid. A power module receptacle unit  140  is snapped into the back of the power top module  100 . Power from the power module receptacle unit is routed to a T connector  160  that is connected to a face connector  166 . The face connector provides power on a nameplate lead  162  to a light  135  that is positioned behind the nameplate holder  134  ( FIG. 3 ) to back-light a nameplate (not shown) that is installed in the nameplate holder. Several strengthening ribs include a notch  167  though which the various leads are routed. A harness connector  166  is connected to the T connector  160  and provides power on a harness lead  161  to a chest wiring harness  173  ( FIG. 7 ). As will be described in more detail below, the chest wiring harness  173  runs down the rear of the chest and includes leads that are configured to mate with the connector  186  and that can be used to power various features within the chest.  
         [0026]      FIGS. 5-6  illustrate the power module receptacle unit  140  in more detail.  FIG. 5  shows the installation of the power module receptacle unit in the rear of the power top module  100 .  FIG. 6  is an exploded view of the power module receptacle unit  140 . A receptacle plate  141  is sized to fit within a corresponding notch  151  in the rear of the power top module. The receptacle plate may be molded from plastic and includes an integrally molded fuse holder tang  153  and two mounting ears  157  with openings to accept mounting screws. A Molex type connector  147  is pressed into the receptacle plate. The connector  147  is configured to accept a standard plug from a AC to DC converter as discussed above. First and second power leads  148 ,  149  are connected to the connector  147 . The first power lead  148  is routed directly to a receptacle connector  143 . A fuse holder  145  is also pressed into the receptacle plate. The fuse holder includes internal electrical connections (not shown) that place a fuse (not shown) that is mounted within the fuse holder in series with the second power lead  149 . The second power lead terminates in the receptacle connector  143 . The fuse holder  145  and the connector  147  may be installed into the receptacle plate  141  prior to being installed in the power top module  100 . The receptacle plate  141  can then be mounted with screws or other fasteners to integrally molded mounting bosses  159  that align with the mounting ears  157 .  
         [0027]      FIG. 7  is a rear view of the chest  10  with the rear wall removed to show the wiring harness  173  running down the back portion of the chest. A series of rear harness leads  185  extend out of the harness in alignment with each drawer&#39;s position in the chest. Each of these leads may be connected to a drawer to provide power to every drawer in the chest, or optionally, a subset of the harness leads may be connected to provide power to a selected group of drawers. The harness  173  may also be used to provide power to cavities within the chest that do not house drawers and are accessible by doors.  
         [0028]      FIGS. 8-10  are bottom views of a drawer  20  that receives power from the harness  173 .  FIG. 8  depicts a drawer in the closed position and  FIG. 9  depicts the drawer in the open position. A cable management module  209  that is installed in each powered drawer is shown in the exploded view in  FIG. 10 . The cable management module  209  is a molded plastic tray configured to connect to a bottom of a drawer to be powered. The cable management module  209  has a relatively shallow depth and includes a plurality of bosses  238  that mount cable management components to the bottom of the drawer. A drawer wire  232  is located in the cable management module  209 . The drawer wire  232  is shown connected to a light module  234  that illuminates the space below the drawer. However, the drawer wire could also be routed to an in-drawer power jack, one example of which is indicated generally with reference numeral  265  in  FIG. 7 .  
         [0029]     Referring now to  FIG. 8 , a harness routing channel  216  is shown running up the rear wall  15  of the chest. The channel serves to locate the harness  173  on the rear wall of the chest. A drawer pigtail  232   a  terminates in a drawer connector  186  that is configured to mate with the harness pigtail  185 . A telescoping rod  215  is housed within a rod bracket  217  that is closely fit around the telescoping rod while allowing the rod to slide within the bracket. The drawer wire  232  passes through a first end of the telescoping rod  215  and extends through the rod to exit at a second end as the drawer pigtail  232   a . The rod bracket  217  is connected to the drawer with fasteners in the bosses  238 . The telescoping rod is fixed to the back of the chest with a chain  225  (best seen in  FIGS. 9 and 10 ) that allows the rod to be pulled away from the back of the chest by a distance equal to the length of the chain. The additional rod travel allowed by the chain permits the drawer to be pulled out a distance that is greater than its own depth without being limited by the length of the telescoping rod  215 . The chain  225  is connected between a keyhole notch  228  punched in a distal end of the telescoping rod  215  and a keyhole notch  183  that is cut in one flange that forms the channel  216 . A grommet  212  is pressed into either end of the telescoping rod. A rod clearance notch  213  is provided in the back of the cable management module  209  to permit the telescoping rod to extend out the back of the drawer when the drawer is opened.  
         [0030]      FIGS. 8 and 9  show relative positions of the cable management components as the drawer is moved from the closed position ( FIG. 8 ) to the open position ( FIG. 9 ). In  FIG. 8 , a majority of the telescoping rod  215  is located within the cable management module. In  FIG. 9 , as the drawer is opened, the telescoping rod  215  remains in a relatively fixed position with respect to the rear wall  15  of the chest by virtue of the chain  225  being connected to the keyhole  183 . The telescoping rod  215  is pulled through the rod bracket  217  until the rod reaches an end of travel and then the telescoping rod is pulled away from the rear wall  15  until the drawer reaches its end of travel position as determined by the mechanical interaction between the drawer and the slides within which it rides. A sufficient length of chain, such as, for example, three inches, is selected so that the chain will not usually be pulled taut when the drawer reaches the end of its travel. When the drawer is opened, the wire  232  moves within the cable management module  209 , but the wire is of sufficient length that it is not pulled taut. The electrical path to the drawer is thus maintained regardless of the drawer&#39;s position.  
         [0031]      FIG. 10  illustrates the individual wire management components in more detail. Wire clearance notches  219  can be seen at either end of the telescoping rod  215 . The wire notches provide an opening through which the drawer wire  232  is routed and then contained by a frictional engagement with the grommet  212  when the grommet is pressed into the telescoping rod. The chain  225  is of a commonly known type that includes a string of small metal balls connected together with a space in between. The chain can thus be installed in the keyhole  228  in the telescoping rod and the keyhole  183  in the channel  216 . This arrangement permits the rod to be fixed to the rear wall  15  while providing additional clearance for increased drawer travel.  
         [0032]      FIG. 11  illustrates a bottom view of the chest of  FIG. 1 . An under chest light  212  powered by the power top module is illustrated. This light illuminates the floor to aid in locating items that may have fallen as well as providing a pleasing aesthetic affect.  
         [0033]      FIGS. 12 and 13 A- 13 B illustrate a storage unit  300  that includes a chest  326  and cabinet  328 . The chest  326  includes a plurality of drawers  360  and a power module  320 . The cabinet includes a power module  321 . Both power modules  320 ,  321  have similar internal power components and connections to those shown in  FIGS. 4 and 6  and internal wiring harnesses to provide power to individual drawers  360  similar to those shown in  FIG. 7  used to power individual drawers  20 . As such, the following description will be focused on unique aspects of the power modules  320 ,  321  with respect to the power module  100  in  FIGS. 1-11 . The chest power module  320  includes a locking cylinder  340 , a display  312  and lighted nameplate  334  ( FIG. 13A ). A top tray portion  327  of the power module  320  includes power connectors (not shown) that facilitate installation of one or more convenience accessory modules  325  that are configured to mount and connect within the top tray portion. The convenience accessory modules may be, for example, a deployable arm including a lighting module, a television, a CD player, a DVD player, a message center, an ultrasonic cleaner, a wireless communication device, a battery charger, a refrigerator, an air compressor, or a DC power jack having an industry standard configuration. Alternatively, the top tray portion  327  may not feature electrical components, but rather may serve as an additional work/storage area. A lighted drawer  330  is included in the power module  320  and a lighted pull-out work surface  350  is included in the power module  321 . The lighted drawer  330  can be seen pulled away from the chest in  FIG. 13A .  
         [0034]      FIG. 13A  illustrates the lighted drawer  330  pulled out of the chest  326 . A light module  234 ′ is mounted in the underside of the drawer  330  and can be used to illuminate the space below the drawer. The light module  234 ′ has the same electrical connections and cable management components that are shown and discussed in conjunction with  FIGS. 8-10 . The light module  234 ′ includes a normally closed activation switch  337  that is urged open when the drawer is positioned in the chest  326  to disconnect power to the light module  234 ′ and returns to its closed position to provide power to the light module when the drawer is pulled out of the chest. Other switching techniques such as, for example, a magnetic reed switch, a manual switch, or a motion detecting switch can be used to activate the light.  FIG. 13B  illustrates a drawer  360  pulled away from the chest to expose storage cups  310  molded into a front portion of the drawer. The pull-out work surface  350  ( FIG. 12 ) includes a light module in its underside configured similar to the light module  234 ′ in the lighted drawer  330 .  
         [0035]      FIG. 14  is a schematic circuit diagram of a power circuit  500  that can be used to provide power to the features described above including the power top modules  100 ,  320 ,  321 . The circuit  500  draws its power via a common wall plug. An over-current protection device  505  such as, for example, a fuse, thyristor, circuit breaker, or other similar device is provided to disconnect power to the circuit  500  in the event of a short circuit condition or abnormally high current draw by the circuit. An AC distribution module  510  with AC receptacles such as, for example, a terminal strip, pre-manufactured power strip or other enclosed and protected power distribution arrangement is provided to allow an AC device to be powered from the circuit  500  from either outside or inside the storage unit  300  ( FIG. 12 ). A voltage reducing transformer  520 , or other voltage reducing device, steps the supplied AC voltage down in preparation for conditioning that voltage to DC voltage. A rectifier circuit  530 , such as, for example, a full wave bridge rectifier, transforms the AC voltage to DC voltage. The rectified voltage is routed through an optional DC disconnect switch  533  and to an over current protection device  535 , such as, for example, a fuse or circuit breaker, that is also optional. A DC distribution circuit  570  such as, for example, a terminal strip or bus routes the DC voltage to a plurality of DC power consumer circuits  575 . The DC power consumer circuits include, for example, the wiring harnesses, accessories, and lights described above and also DC power jacks that provide a convenient DC power source to the consumer.  
         [0036]     A battery  550  is an optional electrical component in the circuit  500 . The battery  550  is charged by a battery charger  540  when the wall plug is connected to power. When the wall plug is not connected to power, the battery  550  can be used to provide power the DC distribution circuit  570  as well as AC power through an inverter  560  with AC convenience receptacles.  
         [0037]      FIGS. 15A and 15B  illustrate a tool storage unit  400  that includes two weldments stacked on top of one another: a chest  410  and cabinet  420 . The chest  410  includes external vertically oriented light modules  437  positioned on either side of drawers in the chest. The cabinet includes external vertically oriented light modules  447 . Of course, either the chest or cabinet, or both, as shown, may include the vertically oriented external light modules  437 ,  447 . Further, the light modules may be positioned on only one side of the chest or cabinet. The external vertically oriented light module includes a protective cover  467  that may have light manipulating features such as a diffuser or decorative pattern molded into the cover. The cover  467  may be connected to the chest or cabinet with hinges as shown or may be adapted to be snap-fit to the chest or cabinet. The cover  467  protects a light bulb  451 , which may be, for example, a fluorescent, neon, or incandescent bulb. The light modules  437 ,  447  are powered by a manual switch (not shown) and may also be powered by a motion detecting switch or other activation device.  
         [0038]     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 adapt 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.