Abstract:
A locker whose basic enclosure, and also its frame, are essentially formed from five sheet metal members. The sheet metal members form the sides, back, top and bottom of the locker. Certain of the sheet metal members (particularly the side and top members) also have respective portions of the frame integrally formed therewith. The frame portions, when interconnected, form the support frame for the locker and also join the sides, back, top and bottom members together to complete the locker&#39;s enclosure. The frame portions also define part of the front side of the locker, and form a door opening in the locker. A locker door is pivotally movable relative to the door opening to control access to the locker&#39;s interior. The top and bottom sheet metal members are structurally identical to each other, so that only a single type of forming operation is required to form both sheet metal members. The locker also has several additional new and useful features, including (i) a unique handle and locking clip structure connected with the door and frame, (ii) a unique hinge structure which pivotally connects the locker door from the frame, and (iii) a unique spring latch for retaining the locker door in a closed condition.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a new and useful locker construction. It relates specifically to a locker formed by a relatively few number of integral sheet metal parts that form both the locker&#39;s frame and its basic enclosure. The sheet metal parts are simple and economical to manufacture, and are readily assemblable by the end user to complete the locker. 
     Lockers for storing clothing, articles of merchandise, etc., are typically formed by (i) a series of longitudinally extending metal frame members which are interconnected with each other to form the locker&#39;s frame, (ii) a separate series of planar sheet metal members which are secured to the frame (by bolting or welding) to complete the locker&#39;s basic enclosure, and (iii) a door pivotally mounted to the frame (typically by means of a butt hinge) for opening and closing access to the interior of the locker. The frame members provide the basic skeletal structure for the locker, and add strength and rigidity to the sheet metal members. 
     The components for constructing a locker are often shipped in partially assembled condition to the site where the locker is to be installed, and are there assembled and interconnected to form the locker. For example, with prior lockers that have been manufactured and sold by the assignee of this application, the components that are often shipped to the customer include (i) a door and frame subassembly including (a) a welded frame, (b) a door assembly that has been hinged to the frame and includes lock bar and handle components connected thereto, and (ii) the remaining body parts of the locker (e.g., sides, top, bottom, back). Whether those components are shipped in bulk, or in individual locker kits, the more components that are needed to form a locker, the more cumbersome the final assembly process. Moreover, in the applicant&#39;s experience, the more types of different components that must be constructed to form a locker, the higher the manufacturing costs. 
     SUMMARY OF THE INVENTION 
     This invention provides a locker construction which simplifies the number of parts that are used to form the locker, and which is believed to faciliate the manufacture as well as the assembly of the locker. 
     According to the invention, the locker&#39;s basic enclosure, and also its frame, are essentially formed from five sheet metal members. The sheet metal members form the sides, back, top and bottom of the locker. Certain of the sheet metal members (particularly the side and top members) also have respective portions of the frame integrally formed therewith. The frame portions, when interconnected, form the support frame for the locker and also join the sides, back, top and bottom members together to complete the locker&#39;s enclosure. The frame portions also define part of the front side of the locker, and form a door opening in the locker. A locker door is pivotally movable relative to the door opening to control access to the locker&#39;s interior. 
     In a locker according to the invention, a particular advantage is provided in the fact that the top and bottom sheet metal members are structurally identical to each other. Thus, only a single type of forming operation is required to form both sheet metal members. Moreover, the sheet metal side members are virtually identical, except for some holes that are punched in the side members. Thus, common tooling can be used for blanking both sheet metal side members. 
     A locker according to the preferred form of the invention also has several additional new and useful features, including (i) a unique handle and locking clip structure connected with the door and frame, (ii) a unique hinge structure which pivotally connects the locker door from the frame, and (iii) a unique spring latch for retaining the locker door in a closed condition. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further features of the invention will become further apparent from the following detailed description taken with reference to the accompanying drawings wherein: 
     FIG. 1 is a three dimensional view of a locker constructed according to the principles of the invention; 
     FIG. 2 is a three dimensional view of a locker constructed according to the invention, with the locker door removed; 
     FIG. 3 is an exploded, three dimensional view of the principal components of the locker of the invention; 
     FIG. 4 is a sectional view of the locker of FIG. 1, taken along the reference plane shown in phantom in FIG. 1, and looking in a downward direction, as shown by the arrows 4--4; 
     FIG. 5 is an exploded view of the area of the locker frame shown at 5--5 in FIG. 2, taken from the direction shown by the arrow in that Figure; 
     FIG. 6 is an exploded, three dimensional, fragmentary view taken along one vertical side of the door opening of the locker; 
     FIG. 7 is a fragmentary, sectional view of the locker of FIG. 1, with portions omitted, and showing the locking action provided by the spring clip; 
     FIG. 8 is a fragmentary, sectional view of the clip portions carried by the locker&#39;s frame and door; 
     FIG. 9 is a sectional view of FIG. 8, taken along the line 9--9; 
     FIG. 10 is an exploded, fragmentary view of one of the lower corners of the locker door and the locker frame, showing the components for pivotally connecting the door to the locker frame; 
     FIG. 11 is a three dimensional view of a sheet metal member forming each of the top and bottom members of the locker of the invention; and 
     FIG. 12 is a fragmentary, three dimensional view of a portion of a locker, with the door removed, and showing structure for supporting part of a shelf in the locker. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As discussed above, the present invention relates to a locker in which a series of sheet metal members have frame portions integral therewith. In this application, where a frame portion is referred to as &#34;integral&#34; with a sheet metal member, the term &#34;integral&#34; is intended to mean that the sheet metal member and the frame portion are a monolithic metal structure, and the frame portion is bent, stamped or otherwise formed out of the sheet metal member, and is not connected to the sheet metal member by some external means (e.g., bolts, welds, etc.). 
     In FIG. 1, a vertically extending locker, constructed according to the invention, is shown at 10. The sheet metal members comprise a pair of vertically extending side members 12, a vertically extending back member 14, and horizontally extending top and bottom members 16 and 18, respectively. Certain of the sheet metal members have integral frame portions that form part of the front side of the locker and define a door opening 17 in the front side of the locker (see FIG. 2). A door 19 is mounted for pivotal movement between open and closed positions relative to the door opening 17 to control access to the inside of the locker. 
     Referring to FIGS. 3-6, each of the sheet metal side members 12 has a planar, generally rectangular, vertically extending main body portion 30. At the front of the locker, each sheet metal side member 12 has an integral, vertical frame portion which includes (i) a proximal frame portion 32 which extends perpendicular to the plane of the main body portion 30, and (ii) a distal frame portion 34 which extends away from the proximal portion 32 and toward the back of the locker. The distal frame portion 34 is disposed in a plane that is parallel to the plane of the main body portion 30. As seen particularly from FIG. 6, the distal frame portion 34 of each side member extends longitudinally along the front edge of the main body portion 30, but terminates short of the top and bottom ends of the main body portion 30. Also, the distal frame portion 34 has tenons 38 at both of its longitudinal ends. 
     In the side member 12 disposed on one side of the door (i.e., the side member shown in FIG. 6) the distal frame portion 34 has a pair of spaced apart openings 35 about midway between its longitudinal ends. Furthermore, the distal frame portion 34 of that side member has a square opening 37 near its top end, for receiving a door stop member 72. 
     The proximal frame portion 32 of the sheet metal side member 12 shown in FIG. 6 has a rectangular opening 40 disposed between its longitudinal ends (see also FIG. 2). Additionally, the proximal frame portion 32 of each of the sheet metal side members 12 has a pair of bolt holes 42 near its top end and another pair of bolt holes 42 near its bottom end (FIGS. 3, 5 and 6). 
     At the rear of the locker, each sheet metal side member 12 has an integral, vertical, rear frame portion 36 that extends along the entire vertical length of the main body portion 30 in a plane that is perpendicular to the plane of the main body portion 30. The vertical rear frame portion 36 has a series of bolt holes 44 (FIG. 3) that are spaced apart and extend from the top to the bottom of the vertical rear frame portion. 
     Finally, the main body portion 30 of each sheet metal side member 12 has bolt holes that are used in securing shelves and hooks to the locker. In the illustrated example, the main body portion 30 of each sheet metal side member 12 has a pair of horizontally spaced bolt holes 39 for securing a shelf to the locker, and a pair of vertically spaced bolt holes 41 for securing a hook to the locker. 
     The sheet metal back member 14 comprises a rectangular, planar sheet metal member with a plurality of bolt holes 46 disposed about its periphery. The bolt holes 46 that extent vertically along the back member 14 are disposed so as to align with the bolt holes 44 in the vertical rear frame portions 36 of the sheet metal side members 12. The bolt holes 46 that extend horizontally along the back member 14 are disposed so as to align with bolt holes 67 in the top and bottom members 16, 18, as explained further hereinafter. 
     The horizontal top and bottom sheet metal members 16, 18 are structurally identical to each other. Each of the top and bottom members includes a planar, horizontal main body portion 50. Along the sides and the back of the locker, each of the top and bottom members has integral frame portions 55 that extend perpendicular to the plane of the main body portion 50. At the front of the locker, each of the top and bottom members has an integral front frame portion that includes (i) a proximal front frame portion 56 which extends perpendicular to the plane of the main body portion 50, and (ii) a distal front frame portion 58 which extends away from the proximal front frame portion 56 and toward the back of the locker. The distal front frame portion 58 is disposed in a horizontal plane that is parallel to the plane of the main body portion 50. 
     The proximal front frame portion 56 of each of the top and bottom members 16, 18 has pairs of bolt holes 60 which can align with the pairs of bolt holes 42 in the proximal front frame portions 32 of the side members 12. Each of the top and bottom members has a circular hole 61 in its main body portion 50 (FIG. 10) and an aligned circular hole 62 in its distal front frame portion 58 (FIG. 5). The circular hole 62 in the distal front frame portion 58 of the top member, and the aligned circular hole 61 in the main body portion 50 of the bottom member receive pivot members that pivotally connect the door 19 to the frame, as described more fully hereinafter. Finally, each of the top and bottom sheet metal members has rectangular slots 63 in its main body portion 50 (FIG. 6), and aligned rectangular slots 64 in its distal front frame portion 58 (FIG. 5). The rectangular slots 63 in the main body portion 50 of the bottom member, and the rectangular slots 64 in the distal front frame portion 58 of the top member receive the tenons 38 which extend from the distal front frame portions 34 on the side members 12. 
     In assembling the sheet metal members to form the locker, the tenons 38 on the distal front frame portions 34 of the side members 12 are inserted into the rectangular slots 63 in the main body portion 50 of the bottom member 18 and into the rectangular slots 64 in the distal front frame portion 58 of the top member 16. That engages and aligns the sheet metal side members 12 with the sheet metal top and bottom members 16, 18, and properly spaces the sheet metal side members 12 from each other. The pairs of bolt holes 60 in the proximal front frame portions 56 of the top and bottom members will align with the pairs of bolt 42 holes in the proximal frame portions 32 of the side members 12. The sheet metal side members 12 can thus be bolted to the sheet metal top and bottom members. 
     The back member 14 is positioned against the vertical frame portions 36 at the rear of the side members 12. The bolt holes 46 in the back member 14 are designed to align with the bolt holes 44 on the vertical rear frame portions 36 of the side members 12. Thus, the back member 14 can be bolted to the side member 12. 
     The frame portions 55 on the top and bottom members have bolt holes 67 (FIG. 3) which are designed to align with bolt holes 47 that extend horizontally along the side members 12, and with certain of the bolt holes 44 in the rear frame portions 36 of the side members. Thus, the top and bottom members can be further bolted to the side members 12 and the back member 14. 
     Bolting the side, top, bottom and back members to each other, in the manner set forth above, completes the locker&#39;s basic enclosure and also its frame. The proximal and distal front frame portions 32, 34 of the side members extend vertically along the door opening 17 and the proximal front frame portions 32, which are co-planar, also define part of the front side of the locker. The proximal and distal front frame portions 56, 58 on the top member 16 extend horizontally along the door opening 17, and the proximal front frame portion 56, which is co-planar with the proximal front frame portions 32 of the side members 12, also defines part of the front side of the locker. With this construction, the frame portions that are integral with the sheet metal members interconnect those members, and provide strength and rigidity to the locker. The frame portions also form part of the front side of the locker and define the door opening 17 therein. 
     When a shelf 69 (FIG. 3) is to be inserted in the locker, the shelf has depending flanges with bolt holes 71 which can align with the bolt holes 39 in side members 12 and with other bolt holes (not shown) in the back member 14, to allow the shelf 69 to be bolted to the back and side members. Additionally, the distal frame portions 34 of the side members 12 can have additional bolt holes, and metal clips 70 (FIG. 12) can be bolted thereto, for supporting the front end of the shelf. The bolt holes for the metal clips 70 are designed to be at the same vertical level as the vertical bolt holes 46, 44 along the back member 14, and the vertical rear frame portions 36 of the side members 12, respectively. The parts of the metal clips 70 that extend away from distal frame portions 34 of the side members are below the bolt holes in the front frame portions 34. Thus, the depending flange at the front of the shelf 69 can rest on the clips 70. 
     One or more plastic door stop members 72 is connected to the distal front frame portion 34 of the side member 12 that is shown in FIG. 6. The door stop member 72 preferably has a square stop portion 74 that protrudes out of the distal front frame portion 34, and a square neck portion 76 that is inserted in the square hole 37 in the distal front frame portion 34. A bolt 78 and nut (not shown) secure the door stop member 72 to the distal front frame portion 34. 
     Referring now to FIGS. 5 and 10, the locker has a simple and efficient structure for pivotally connecting the door 19 to each of the top and bottom sheet metal members 16, 18. That structure comprises a pivotal, internally threaded hinge pin 80, a lock washer 82, and a standard screw 84. The hinge pins 80 have respective cylindrical surfaces that are rotatably received in the circular opening 61 in the main body portion 50 of the bottom member 18 and the aligned circular opening 62 in the distal frame portion 58 of the top member 16, respectively. At both its top and bottom ends, the door 19 has a horizontal flange 83, and the screw 84 extends through a hole 86 in the horizontal flange 83. The lock washer 82 is disposed between the screw&#39;s head and the door flange 83. At each end of the door, the screw 84 is screwed into the respective internally threaded hinge pin 80, as depicted in FIGS. 5 and 10, to engage the hinge pin with the door 19, and to pivotally connect the door 19 with the frame for pivotal movement about a vertical axis. 
     In the locker shown in FIG. 1, the pivot axis is adjacent the right hand side of the door. The side of the door opposite the pivot axis, and the side member 12 which is adjacent to that side of the door, have respective portions of a unique clip and handle structure. A pair of metal clips 90, 92 are connected with the door and the side member, respectively. The clips 90, 92 have aligned holes 90c, 92c through which a padlock (not shown) can be inserted to securely lock the door to the frame of the locker. 
     The clip 90 includes a planar metal body member 90a, and a curved flange 90b at its distal end. The planar metal body member 90 lies adjacent the distal frame portion 34 of the one side member 12, and extends through the rectangular slot 40 in the proximal frame portion 32 of that side member. The planar metal body member 92a includes a locking hole 90c which is along the center line of the clip, i.e., equidistantly spaced between the top and bottom edges of the clip. The metal body member 90a also includes a bolt hole 90d, which is offset with respect to the center line of the clip. The bolt hole 90d is designed to align with one of the openings 35 in the side member 12, for receipt of a locking bolt 94 that fixedly connects the clip 90 to the side member 12 (FIG. 6). 
     The clip 92 is structurally identical to the clip 90. It is inverted, with respect to the clip 90, so that its main body portion 92a can be bolted to a vertical flange 95 (FIG. 8) on the door 19, and extends through a slot 97 in the front of the door. Its locking hole 92c is aligned with the locking hole 90c in the other clip 90, so that a padlock can be inserted through the locking holes 90c, 92c, in the two clips to lock the locker. Since the clips 90, 92 are structurally identical, the bolt hole 92d on the clip 92 will be offset from the bolt hole 90d on the other clip 90. Thus, when the clips 90, 92 are bolted to the side member 12 and door 19, respectively, the bolts do not interfere with each other (see FIGS. 8 and 9). Also, the curved portion 92b at the distal end the clip 92 extends away from the curved portion 90b of the other clip 90, and forms a finger hook that can be readily engaged by a person&#39;s finger to open the locker door. Thus, the clip 92 also constitutes a handle for opening the door. 
     A spring clip 110 is connected to the side member 12 on the other side of the door from the pivot axis (i.e., the side member 12 shown in FIG. 6). The spring slip 110 is designed to have a snap engagement with a mating hole in the door 19 to hold the door in a closed position. The spring clip 110 comprises a spring wire 112 whose configuration is shown in FIG. 6. The spring wire 112 is bent into a circular portion 114 defining an opening which can align with the same opening 35 in the side member 12 that the clip 90 is bolted to. A hex nut 99, a lock washer 101, and a flat washer 103 are provided, and the spring wire is attached to the side member 12 by the same locking bolt 94 that bolts the clip 90 to the side member 12. The spring wire 110 has a wedge-shaped portion 116 that extends through the other opening 35 in the distal frame portion 34 of the side member (FIG. 7). The wedge shaped portion 116 is dimensioned so that it can engage an opening 118 in the vertical flange 95 on the door 19 (FIG. 7) when the door is closed. 
     When the door 19 is being closed, the wedge shaped portion 116 of the spring wire 112 is initially cammed by the vertical flange 95 of the door 19, so that it moves out of the path of movement of the door. The wedge-shaped portion 116 then snaps into the opening 118 in the door 19, when the door is fully closed. The wedge shaped portion 116 is also cammed when the locker door is being opened, to release it from the opening 118 in the door. This provides a light holding action between the frame and the locker door 19 when the door is closed, but allows the locker door to be readily opened when desired. 
     As can be seen from the foregoing discussion, the locker of the invention is formed with relatively few parts that are simple to construct. The parts are readily assembled with each other, and are so designed that they can be shipped either in bulk or in an unassembled condition for subsequent assembly at the place where they are installed. Further, several significant pairs of components (i.e., the top and bottom members 16, 18 and the clips 90, 92) are formed by identical structural members. Thus, only a single type of forming operation is necessary to form both of the components. Moreover, the side members 12 are almost identical to each other except for (i) the presence of holes 35 and rectangular slot 40 in one side member, and (ii) the fact that the bolt holes 39, 41 in facing side members need to be mirror images of each other. Thus, all of the side members can be blanked by common tooling, and (i) one set of side members can be punched with an additional subdie for the bolt holes 35 and the rectangular slot 40, and (ii) punches for the bolt holes 39, 41 can be pulled and interchanged to punch those holes in both side members 12.