Abstract:
A storage case includes a U-shaped structural frame that forms three closed sides of the case. Decorative panels are fastened to the frame to form exterior surfaces of the case.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This non-provisional application claims the benefit of U.S. Provisional Patent Application No. 60/861,877, entitled “Storage Container Frame,” filed on Nov. 30, 2006, the entire disclosure of which is incorporated herein by reference, to the extent that it is not conflicting with the present disclosure. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a storage container frame and to a storage container frame for use with a tool chest or tool cabinet. 
       BACKGROUND OF THE INVENTION 
       [0003]    Storage containers such as dressers, bureaus, and file cabinets having drawers are in popular use. Several exemplary storage devices include tool chests, tool cabinets, and combination tool chest and cabinet units. Tool chests, tool cabinets, and combination tool chest and cabinet units are in widespread use in residential, commercial and industrial settings. 
         [0004]    The manufacture of tool chests and tool cabinets is well-known. Tool chests and cabinets typically are constructed by welding together pieces of metal panel sections formed by blanking and bending operations. The welded pieces form a multiple sided box-shaped housing having an open front. Additional exterior panels may be welding on the housing to form a finished unit. The interior of the box conventionally includes two or more cooperatively aligned horizontal slide carriers for installing a plurality of drawers. After the entire unit has been formed and assembled, the drawers are installed. Subsequently, the box is painted or otherwise finished to produce an end product having a uniform finish and exterior surface appearance. 
       SUMMARY 
       [0005]    A storage case and method for assembling the same is provided. The storage case includes a U-shaped flame that forms three of the closed sides of the storage case. Decorative side and other exterior panels are fastened to the frame, preferably by means other than welding, to form exterior surfaces of the storage case. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Further features and advantages of this invention will become apparent from the following detailed description made with reference to the accompanying drawings. 
           [0007]      FIG. 1   a  is a front perspective view of a tool chest constructed with a case frame in accordance with an embodiment of this invention; 
           [0008]      FIG. 1   b  is a bottom perspective view of a tool chest constructed with a case frame in accordance with an embodiment of this invention; 
           [0009]      FIG. 2   a  is a front perspective view of a tool cabinet constructed with a case frame in accordance with an embodiment of this invention; 
           [0010]      FIG. 2   b  is a bottom perspective view of a tool cabinet constructed with a case frame in accordance with an embodiment of this invention; 
           [0011]      FIG. 3   a  is an exploded perspective view of a case frame in accordance with an embodiment of the present invention; 
           [0012]      FIG. 3   b  is a top plan view of a metal panel that can be used to construct a case frame in accordance with an embodiment of the present invention; 
           [0013]      FIGS. 4   a - 4   d  are various views of a decorative side panel that can be connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; 
           [0014]      FIG. 5  is a bottom perspective view of a decorative top panel that can be connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; 
           [0015]      FIG. 6  is a rear perspective view of a decorative rear panel that can be connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; 
           [0016]      FIG. 7   a  is a cross section view of the side panel of  FIG. 4   a  and the rear panel of  FIG. 6  connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; 
           [0017]      FIG. 7   b  is an exploded cross section view of the side panel of  FIG. 4   a  and the rear panel of  FIG. 6  connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; 
           [0018]      FIG. 8   a  is a cross section view of the side panel of  FIG. 4   a  connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; 
           [0019]      FIG. 8   b  is an exploded cross section view of the side panel of  FIG. 4   a  connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention; and 
           [0020]      FIG. 9  is a cross section view of the side panel of  FIG. 4   a , the rear panel of  FIG. 6 , and a front block panel connected to the case frame of  FIG. 3   a  to construct a tool chest or cabinet in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    This Detailed Description of the Invention merely describes embodiments of the invention and is not intended to limit the scope of the specification or claims in any way. Indeed, the invention as described by the specification and claims is broader than and unlimited by the preferred embodiments, and the terms used in the specification and claims have their full ordinary meaning. 
         [0022]    The present invention will be described for use with a tool chest and a tool cabinet. It should be understood that this is for exemplary purposes only and the invention can be applied to a wide variety of storage cases and applications. 
         [0023]    The invention is directed to a storage case frame and method of assembly of same. The invention provides flexibility in styling and aesthetic options for the resultant storage container. As a result, a variety of styles of non-welded, non-painted skin can attach directly to one frame. The performance of a storage case constructed in accordance with this invention compares favorably to existing storage cases. The invention further provides flexibility to allow manufacturing with a minimum of fabrication, weld, paint and assembly operations. The case frame produced without welding requires a lower skilled labor force and lower costs assembly techniques. The design however does not preclude the ability to weld the frame. 
         [0024]    The storage case is assembled without welding using a joinery technique, such as for example, rivets, other hardware, or adhesive. A skin material can be subsequently applied to the frame to complete the assembly of the storage container. The skin may be attached without welding by press fitting the skin over flanges, by adhesive, or by other suitable methods. 
         [0025]    The assembly method allows for a variety of different finishes for the outer skin, such as for example, brushed stainless, painted, anodized, clear coat, and stained. The assembly method also allows for a variety of different material selection for the outer skin, such as for example, stainless steel, aluminum, carbon fiber, plastic, and wood. One standard case frame can be used with a variety of materials with only a minimum of tooling revisions. This beneficial feature provides flexibility to apply the design concept to allow a variety of the finished products within a single frame platform. Further, different styles and outside shapes could be used based on the base platform of the box and drawer shells. 
         [0026]    The invention allows for the manufacture of tool storage chest and cabinets without any painting equipment or finishing operations. This feature lowers capital equipment costs as compared to known designs and methods in the art. Any finishes or painting of the skin material can occur before blanking and forming. Alternatively, the material can be procured in pre-coat or mill finished form. 
         [0027]      FIGS. 1   a  and  1   b  are views of a tool chest  10  that has been constructed with a case frame  100  (shown in  FIG. 3   a ) and decorative exterior panels including side panels  12 , top panel  16 , rear panel  24 , bottom panel  20  and front finishing panels  13   a ,  13   b . The tool chest includes drawers  15  that slide on slider carriers (not shown) mounted to the case frame  100 .  FIGS. 2   a  and  2   b  are views of a tool cabinet  50  that has been constructed with a case frame  100  (shown in  FIG. 3   a ) and decorative exterior panels including side panels  12 ′, top panel  16 ′, bottom panel  20 ′ and front finishing panels  13   a ′,  13   b ′. The tool cabinet includes casters  34  and drawers  15 ′ that slide on slider carriers (not shown) mounted to the case frame  100 . The details of the slider carriers and drawers are not described herein, as this mechanism is known in the art. 
         [0028]      FIGS. 3   a  and  3   b  illustrate an exemplary case frame  100  that is used to construct the tool chest and cabinet shown in  FIGS. 1   a - 2   b . The case frame  100  has a U-shape made up of two side segments  110   a ,  110   b  connected at an edge to an intermediate segment  110   c . In the described embodiment, the intermediate segment  110   c  serves as the bottom surface of the tool chest or cabinet. However, in other embodiments, the intermediate segment may serve as the top or rear surface of the tool chest or cabinet. Various slider carrier mounting holes are shown in the side segments  110   a ,  110   b . Slider carriers are connected to these holes in the side segments. The intermediate segment includes mounting holes  134  to which the casters  34  are mounted when the case frame  100  is used to construct a tool cabinet  50 . The structure and construction of a tool chest frame is similar to a tool cabinet frame, with several common exceptions. A tool chest typically is without casters and has a bottom surface designed to accommodate resting on a flat surface, such as for example, a work bench or the top of a tool cabinet. The top surface of a tool chest may be hinged to allow for tool storage access within the tool chest. 
         [0029]    It may be advantageous to form the entire case frame  100  from a single flat panel of heavy gauge metal, such as, for example, 18 gauge galvanized steel, as shown in  FIG. 3   b . The material used for the case frame  100  can be selected to provide sufficient structural strength so that material selected for the decorative side, top, and rear panels need not provide significant structural strength. The vertical side frame segments include vertical frame flanges  115   a ,  115   b  on either edge of the vertical side frame segments and top frame flanges  121   a ,  121   b . The vertical frame flanges extend away from the interior of the case frame  100  at a substantially right angle to the side segments  110   a ,  110   b . The top frame flanges  121   a ,  121   b  extend toward the interior of the case frame  100  at a substantially right angle to the vertical side frame segments  110   a ,  110   b . The intermediate segment  110   c  includes front and rear flanges  117   a ,  117   b  that extend toward the interior of the case frame. 
         [0030]    To provide additional structural strength, cross members  135   a ,  135   b ,  135   c  are connected between the vertical side segments to provide strength to the top of the case frame. Four L brackets  142  are installed at the bottom corners of the case frame behind the front and rear flanges  117   a ,  117   b  and on an exterior surface of the vertical frame flanges  115   a ,  115   b . The L, brackets  142  maintain the relative position of the side segments  110   a ,  1110   b  and the intermediate segment  110   c . The connection of the cross members and L brackets to the case frame can be performed by welding or without welding by using rivets or other fasteners. 
         [0031]      FIGS. 4   a - 4   d  are various views of a decorative side panel  12  that can be connected to the case frame  100 . The side panel  12  forms an exterior surface of the tool chest or cabinet. The side panel  12  includes a top side panel flange  12  with mounting holes  153  that align with holes on the top frame flanges  121   a ,  121   b . The side panel is thus connected to the frame with fasteners inserted through top frame flange and top side panel flange. The side panel also includes a first vertical side panel flange  12   b  that is formed into a J shape with respect to the side panel  12 . The first vertical side panel flange  12   b  includes a front mounting surface with mounting holes  151  to which the front finishing panel  13   a  is connected, mounting holes  143  and a clearance slot  144 . An L bracket  155  protrudes through the slot  144  as shown in  FIG. 4   a . The L bracket is connected to the side panel  12  through the mounting holes  143  in the side panel. The L bracket  155  is thus used to connect the side panel to the lower front finishing panel  13   b  as will be described in connection with  FIGS. 7-9 . A top flange ear  12   e  protrudes from a top of the first vertical side panel flange. The side panel includes a second side panel flange  12   d  to which the rear panel  24  is attached and a bottom side panel flange  12   c.    
         [0032]      FIG. 5  illustrates the decorative top panel  60  as viewed from below the panel. The top panel  60  includes bent down top panel side flanges  60   a  and a bent down top panel rear flange  60   b . The top panel side flanges  60   a  include top mounting flanges  61  that connect to top frame flanges  121   a ,  121   b  ( FIG. 3   a ). The top panel rear flange  60   b  includes mounting flanges  60   c  that connect to the rear cross member  135   b  ( FIG. 3   a ).  FIG. 6  illustrates the decorative rear panel  24 . The rear panel  24  includes side flanges  24   a  that are connected to the second side panel flange  12   d  ( FIG. 4   d ) on either side panel  12 . The rear panel  24  includes a top flange  24   c  that is connected to the mounting flanges  60   c  on the top panel ( FIG. 5 ). The rear panel also includes a bottom flange that is connected to the rear flange  117   b  on the frame ( FIG. 3   a ). 
         [0033]    As already discussed above, the connections between the case frame  100  and the decorative external panels such as the side panels  12 , the rear panel  24 , and the top panel  60  can be made by welding or without welding using fasteners. In addition, because sufficient structural strength is provided by the frame  100 , L brackets  142 , and cross members  135   a ,  135   b ,  135   c , the decorative external panels may be constructed of thin or flexible material that provide pleasing aesthetic qualities without providing significant structural strength. 
         [0034]      FIGS. 7   a  and  7   b  illustrate the connection of the side panel  12  and the rear panel  24  to a rear portion of the frame  100 . As can be seen in  FIG. 7   a , the L, bracket  142  is connected to the rear flange  117   b  on the intermediate frame segment  110   c  with rivets or fasteners. In this manner, the side panel  12  is connected at its bottom to the frame  100  and provides an exterior surface that covers the side vertical frame segment  110   a . The rear panel  24  is connected with rivets or other fasteners to the second side panel flange  12   d .  FIGS. 8   a  and  8   b  illustrate the relative position of the side panel  12  and a front side of the frame  100 . As can be seen in  FIG. 8   a  and also  FIG. 9 , the first vertical side panel flange  12   b  fits against an end of the front flange  117   a  on the frame and fits adjacent the L bracket  142  that is installed on the vertical frame flange  115   a  on the side frame segment  110   a.    
         [0035]      FIG. 9  shows further details of the connections between the side panels  12 , rear panel  24 , and front finishing panel  13   b  to the frame  100 . A strengthening bracket  175  is installed between the side frame segment  110   a  and the intermediate frame segment  110   c . The front finishing panel  13   b  is connected to the L bracket  155  that protrudes from the side panel  12 . 
         [0036]    While several embodiments of the invention has been illustrated and described in considerable detail, the present invention is not to be considered limited to the precise constructions disclosed. Various adaptations, modifications and uses of the invention may occur to those skilled in the arts to which the invention relates. It is the intention to cover all such adaptations, modifications and uses falling within the scope or spirit of the specification filed herewith.