Patent Description:
It is common place to store a bicycle in a shed or other form of storage unit remotely located from an owner's house which immediately increases the risk of the storage unit being broken into and the contents thereof being damaged or stolen. Typically, a wall panel or closure of the storage unit is prised open to gain access to the contents therein. Increased security of storage containers/units is therefore desired. Additionally, unauthorised access into conventional storage containers/units is made relatively easy in view of the relative weakness of the container/unit itself, particularly in relation to the joints between connecting sections of the container/unit. Increased strength of storage containers/units is therefore also desired. A variety of storage containers/units are described in <CIT>, <CIT>, <CIT> and <CIT>.

It is an aim of certain embodiments of the present invention to provide a storage unit which is particularly difficult, if not impossible, to unlawfully break into.

It is an aim of certain embodiments of the present invention to provide a storage unit having a strong and secure joint construction which minimises flat surface area otherwise prone to attack and breach.

It is an aim of certain embodiments of the present invention to provide a storage unit which is non-complex and efficient to assemble, aptly by one person, and requiring minimal tooling.

According to a first aspect of the present invention there is provided a lockable storage container comprising:.

Optionally, the first engagement surface is vertically offset with respect to a lower surface of the skirt portion.

Optionally, the first engagement surface is substantially parallel with the lower surface of the skirt portion.

Optionally, the outer surface of the rail portion is oriented substantially perpendicularly to the first engagement surface and/or the lower surface of the skirt portion.

Optionally, the outer edge region of the base member comprises a lower support surface vertically offset with respect to the upper support surface of the rail portion to provide a stepped cross section.

Optionally, the lower support surface is configured to engage with and support the lower surface of the skirt portion.

Optionally, the upper and lower support surfaces are substantially parallel with respect to each other.

Optionally, the lower edge region of the wall member comprises a flange portion downwardly extending from the first engagement surface to provide a second inner abutment surface for abutment with the inner surface of the rail portion.

Optionally, the first and second inner abutment surfaces of the lower edge region of the wall member are substantially parallel with respect to each other.

Optionally, the first engagement surface and the upper support surface of the rail portion comprise a plurality of spaced apart through holes each configured to receive an elongate fastener for securing the wall member to the base member.

Optionally, the at least one base member comprises a plurality of interconnected elongate base panels.

Optionally, the at least one wall member comprises a plurality of interconnected elongate wall panels.

Optionally, a first wall panel comprises a first edge region defining an elongate channel portion, and an adjacent second wall panel comprises a second edge region defining an elongate rail portion configured to locate in the channel portion.

Optionally, the rail portion is configured to engage with inner surfaces of the channel portion.

Optionally, the rail portion and the channel portion each comprise a plurality of spaced apart through holes configured to receive an elongate fastener for fastening the adjacent wall panels together.

Optionally, the rail portion and the channel portion are configured such that outer wall surfaces of the first and second wall panels provide a substantially continuous outer wall surface when the adjacent wall panels are connected together.

Optionally, the at least one wall member comprises a first box-like section mounted on a second box-like section mounted on the base member comprising a base box-like section.

Optionally, the base box-like section has a length and width which is less than a length and width of the second box-like section which in turn is less than a length and width of the first box-like section to thereby provide a tiered container body.

Optionally, the container comprises a lockable lid member hingedly coupled to the first box-like section.

According to a second aspect of the present invention there is provided a kit of parts for assembling a lockable storage container, comprising:.

such that a first inner abutment surface of the lower edge region of the wall member abuts the outer surface of the rail portion, and a first engagement surface of the lower edge region of the wall member engages the upper support surface of the rail portion.

Optionally, the at least one base member comprises a plurality of interconnectable elongate base panels.

Optionally, the at least one wall member comprises a plurality of interconnectable elongate wall panels.

Optionally, the kit comprises at least one closure member for closing an opening of the container in use.

Certain embodiments of the present invention will now be described with reference to the accompanying drawings in which:.

As illustrated in <FIG>, a storage container/unit <NUM> according to certain embodiments of the present invention includes a substantially flat base <NUM>, a pair of opposed and substantially parallel side walls <NUM>,<NUM> extending upwardly from the base, a rear end wall <NUM> extending upwardly from a rear edge region of the base, a pitched roof <NUM> supported on the side walls and rear end wall, and a pair of lockable doors <NUM> respectively mounted on hinges to the front ends of the side walls. An optional ramp <NUM> extends from a front edge region of the base to allow a bicycle or the like to be efficiently wheeled into the container. The container <NUM> as illustrated in <FIG> is in a closed state with the doors closed and the container as illustrated in <FIG> is in an open state with the doors open.

As illustrated in <FIG>, the side walls <NUM>,<NUM> and rear end wall <NUM> are each made up of a plurality of interconnecting panels. Each side wall <NUM>,<NUM> of the illustrated container <NUM> comprises five substantially planar panels and the rear end wall <NUM> comprises a single planar panel <NUM> located between a pair of opposed corner panels <NUM> each including a relatively long rear wall portion <NUM> and a shorter side wall portion <NUM> orientated substantially perpendicularly to the longer rear wall portion <NUM>. The base <NUM> is also provided by a plurality of interconnecting base panels <NUM>.

As illustrated in <FIG>, the connected base panels <NUM> provide a base tray having an edge profile <NUM> along at least its sides and rear edge regions which is configured for engagement with correspondingly shaped lower end regions of the side wall panels <NUM>,<NUM> and the rear end wall panels <NUM>,<NUM>.

As illustrated in <FIG>, the edge profile <NUM> of the base tray comprises a stepped cross section having a first base portion <NUM> spaced apart from a second base portion <NUM> both engageable with the ground. The first base portion <NUM> is spaced from the second base portion <NUM> for ease of forming the profile but it may extend closer towards, or engage with, the second base portion <NUM>. A first riser portion <NUM> extends vertically upwardly and perpendicularly from the first base portion <NUM>, a first support portion <NUM> extends horizontally and perpendicularly inwardly from the first riser portion <NUM>, a second riser portion <NUM> extends vertically upwardly and perpendicularly from the first support portion <NUM>, a second support portion <NUM> extends horizontally and perpendicularly inwardly from the second riser portion <NUM>, and an inner wall portion <NUM> extends downwardly from the second support portion <NUM> towards the second base portion <NUM>. The first support portion <NUM> provides a lower support surface <NUM>, the second riser portion <NUM> provides an abutment surface <NUM>, and the second support portion <NUM> provides an upper support surface <NUM>. The upper and lower support surfaces <NUM>,<NUM> are adapted to correspondingly engage with respective lower edge region surfaces of the side wall panels and the rear wall panels. The upper and lower support surfaces <NUM>,<NUM> are substantially horizontal and abutment surface <NUM> is substantially vertical. The abutment surface <NUM> engages with a respective flat surface of the side wall panels and rear wall panel of the unit as described further below.

Alternatively, the angle of the upper and lower support surfaces and the abutment surface may not be substantially horizontal and vertical. For example, one or both of the support surfaces may be angled downwardly in the outboard direction such that any water ingress in the joint is directed outwardly to prevent ingress into the storage unit and/or corrosion etc. The support surfaces may be different angles, such as the upper support surface being substantially horizontal and the lower support surface being angled downwardly and outwardly. Likewise, the abutment surface of the cross section need not be substantially vertical and may be angled inwardly or outwardly with respect to the vertical.

As illustrated in <FIG>, the lower edge regions of the side wall panels <NUM>,<NUM> and the rear wall panels <NUM> are correspondingly shaped to engage with the stepped peripheral cross section of the base tray. The wall panels each comprise a substantially hooked cross section <NUM> at their lower edge region including a substantially vertical outer wall portion <NUM> providing an outer surface of the wall panel, a first engagement portion <NUM> extending inwardly and perpendicularly from the outer wall portion <NUM>, an abutment portion <NUM> extending upwardly and perpendicularly from the first engagement portion <NUM>, a second engagement portion <NUM> extending inwardly and perpendicularly from the abutment portion <NUM>, and a flange portion <NUM> extending downwardly and perpendicularly from the second engagement portion <NUM>. The first engagement portion <NUM> provides a first engagement surface <NUM>, the abutment portion <NUM> provides a first inner abutment surface <NUM>, the second engagement portion <NUM> provides a second engagement surface <NUM>, and the flange portion <NUM> provides a second inner abutment surface <NUM>. The first and second engagement surfaces <NUM>,<NUM> are substantially horizontal and are adapted to engage with the upper and lower support surfaces <NUM>,<NUM> of the base tray stepped profile. The first and second inner abutment surfaces <NUM>,<NUM> are substantially vertical and adapted to engage with outer abutment surface <NUM> of the second riser portion <NUM> and the outer surface of the inner wall portion <NUM>, i.e. with the raised rail portion of the base tray profile, to laterally constrain the wall panels with respect to the rail portion of the base tray profile during assembly and use.

The optional flange portion <NUM> is illustrated as being shorter in length than the abutment portion <NUM> but they may be the same length or different lengths. The first and second inner abutment surfaces <NUM>,<NUM> define a channel in the lower end regions of each wall panel <NUM>-<NUM> which is sized and shaped to locate over the elongate and substantially horizontal rail portion defined by the stepped cross section of the base tray. The second engagement surface <NUM>, i.e. base of the channel, of each wall panel engages with the upper support surface <NUM> of the base tray rail, and the first and second inner abutment surfaces <NUM>,<NUM> respectively engage with the outer surfaces of the elongate rail to laterally constrain each wall panel with respect to the base tray during assembly and in use. This 'hook and rail' arrangement also allows each wall panel <NUM>-<NUM> to be located on the assembled base tray by a single person and safely left in situ in a stable manner whilst the same person secures the wall panel to the base tray using suitable fasteners. The 'hook and rail' arrangement between the wall panels and the assembled base tray is illustrated in <FIG>.

As illustrated in <FIG>, the vertical edge regions of adjacent wall panels <NUM>-<NUM> interlock via a similar 'hook and rail' arrangement according to certain embodiments of the present invention. A first wall panel <NUM> includes a vertical edge region having a first wall portion <NUM> extending perpendicularly inwardly with respect to an outer surface <NUM> of the wall panel, a second wall portion <NUM> extending perpendicularly from the first wall portion <NUM> in a direction parallel with the outer surface <NUM> of the wall panel, and a flange portion <NUM> extending perpendicularly and outwardly from the second wall portion <NUM>. The vertical edge region of the first wall panel <NUM> thereby defines an inwardly extending hooked channel profile.

The adjacent second wall panel <NUM> includes a vertical edge region having a first wall portion <NUM> extending perpendicularly inwardly with respect to an outer surface <NUM> of the second wall panel, a second wall portion <NUM> extending perpendicularly from the first wall portion <NUM> in a direction parallel with the outer surface of the second wall panel, and a flange portion <NUM> extending perpendicularly and outwardly from the second wall portion <NUM>. The vertical edge region of the second wall panel <NUM> thereby defines an inwardly extending hooked rail profile which is shaped and sized to be received in the hooked channel profile of the first wall panel <NUM>.

During assembly, as illustrated in <FIG>, the adjacent wall panels <NUM>,<NUM> are located on the stepped profile of the base tray, and the hooked rail profile of the second wall panel <NUM> is located within the hooked channel profile of the first wall panel <NUM>, or vice versa. This 'hook and rail' arrangement desirably securely locates the adjacent wall panels together in at least an inboard direction and also in a direction along the elongate rail portion of the base tray, even before the wall panels have been secured to the base tray by suitable fasteners, such as bolts. The hooked channel and rail profiles of the wall panels may be sized to provide an interference fit to further constrain the wall panels together before being securely fastened together. During assembly, adjacent wall panels <NUM>,<NUM> may be coupled together via the vertical 'hook and rail' mechanism, located on the rail portion of the base tray profile, and slidably moved along the base rail until the wall panels are in a desired location thereon, before being secured thereto by suitable fasteners, such as bolts, from inside the unit. Alternatively, one of the panels may be located on the rail portion of the base tray profile before the other adjacent wall panel is located thereon before the wall panels are coupled and fastened together. The 'hook and rail' arrangement between adjacent wall panels is illustrated in <FIG>.

The first and second support portions <NUM>,<NUM> of the stepped profile of the base panels <NUM> and the first and second engagement portions <NUM>,<NUM> of the hooked profile of the wall panels <NUM>-<NUM> each include a plurality of spaced apart holes for receiving suitable mechanical fasteners, such as bolts, to secure the wall panels to the base. Likewise, the first and second wall portions <NUM>,<NUM> and <NUM>,<NUM> of the vertical edge regions of the adjacent wall panels <NUM>,<NUM> each include a plurality of spaced apart holes for receiving suitable mechanical fasteners, such as bolts, to secure the wall panels together along their vertical edge regions.

The holes in the base panels <NUM> and the second wall panel <NUM> may be threaded for receiving threaded bolts or may be non-threaded for a bolt to extend through and engage with a correspondingly threaded nut, e.g. a weld nut or hex nut insert fixed to an inner surface of the base or second wall portion. Aptly, a spring washer may be provided between each bolt head and the respective panel surface to prevent loosening of the fastenings over time due to vibrations in the panels during use. Alternatively, the fasteners may be rivets, self-tapping screws, plastic plugs with serrated barbs, or the like.

Desirably, the 'hook and rail' profiles allow the fasteners to be located on the inside of the unit to prevent any of the fasteners being maliciously removed in an attempt to gain unauthorised access into the unit. Furthermore, the 'hook and rail' profiles provide a particularly high bending strength and stiffness to the base tray and wall panels, and the connections therebetween, and also allow at least a pair of fasteners to be used at each fastening location, either along the base or up the wall panels, wherein one fastener of the pair is located inboard of the other fastener. The combination of the 'hook and rail' profile and the double fastening at each fastening location along the base tray/wall panel joint and the wall panel/wall panel joints provides an additional level of security against malicious attack and unauthorised attempts to enter the storage unit. The stepped profile of the base tray/wall panel joint and the hooked profile of the wall panel joints cause a change of direction of the joint which is in contrast to a conventional face-to-face joint. This change in direction provides more than one additional barrier against an unauthorised person using a tool, such as crowbar, in attempt to prise open the joint at the base or between adjacent wall panels and gain access into the unit.

Aptly, each base panel <NUM>, wall panel <NUM>-<NUM> and roof panel <NUM> is formed from folded sheet material, such as steel or aluminium, or for lighter weight applications the panels may be moulded from a plastics material.

As illustrated in <FIG>, the base panels <NUM> utilise the same 'hook and rail' connection such that if the unit is tipped over by a malicious person, access into the unit between the base panels is made equally difficult, if not prevented completely. Additionally, the base tray may be bolted from inside the unit to the ground.

To assemble the storage unit <NUM>, the base panels <NUM> are connected together by hooking the edge region of one base panel over the edge region of an adjacent panel until a base tray <NUM> having the desired length is formed. The base panels <NUM> are then fastened together using suitable fasteners, such as bolts. Adjacent rear wall panels <NUM> are then coupled together along their vertical edge regions using the 'hook and rail' arrangement and efficiently located on, and supported by, the stepped rail portion of the assembled base tray. The rear wall panels can then be fastened together and to the base tray from the inside of the unit by the same person. Alternatively, one of the rear corner wall panels <NUM> may be first mounted on and attached to the rail portion of the base tray, the other one of the rear corner wall panels <NUM> may then be mounted on and attached to the rail portion of the base tray, and then the centre rear wall panel <NUM> may be mounted on and attached to the rail portion of the base tray between the two rear corner wall panels <NUM> and then attached thereto. Side wall panels <NUM>,<NUM> are then efficiently located on, and supported by, the stepped rail portion of the assembled base tray, before being coupled together and to the rear wall panels by the 'hook and rail' arrangement. The side wall panels can then be fastened together and to the base tray and rear wall panels from the inside of the unit by the same person. The roof panels <NUM> can then be located on and fastened to the wall panels before the doors are hung to complete the assembly. Flashing strips may be located over the joints between adjacent roof panels to seal the roof and prevent ingress of water into the unit, if desired/required.

As illustrated in <FIG>, a storage container <NUM> according to certain embodiments of the present invention includes a tiered body <NUM> and a lid <NUM> hingedly mounted to the body <NUM>. <FIG> shows the container in a closed state with the lid closed, and <FIG> shows the container in an open state with the lid open. The body <NUM> of the container <NUM> comprises a plurality of interconnected sections; a base section <NUM>, an intermediate section <NUM>, and an upper section <NUM>. The lid <NUM> is mounted to the upper section <NUM>. Each section has a substantially rectangular cross section in plan view and the base section <NUM> is sized to fit in a correspondingly shaped tray <NUM> which may be fixed to a surface, such as the bed of a van or truck, to prevent the container sliding around during transit or the like. The container may be bolted to the tray <NUM> from the inside to prevent the container being maliciously removed from the tray, particularly when closed and locked. A handle <NUM> is provided on each end of the upper section <NUM> to allow a user to lift and manoeuvre the container. A handle <NUM> is also provided on a front region of the lid to allow a user to open and close the lid. A lock assembly <NUM> is provided to lock the lid in a closed state.

As illustrated in <FIG>, the lower edge region of the upper section <NUM> is configured to hook over the upper edge region of the intermediate section <NUM>. Likewise, the lower edge region of the intermediate section <NUM> is configured to hook over the upper edge region of the base section <NUM>. More specifically, the lower edge region of the upper and intermediate sections each include a peripheral skirt <NUM> having a cross section comprising a substantially vertical outer wall portion <NUM>, a skirt portion <NUM> extending inwardly and perpendicularly from the outer wall portion <NUM>, an abutment portion <NUM> extending upwardly and perpendicularly from the skirt portion <NUM>, and an engagement portion <NUM> extending inwardly and perpendicularly from the abutment portion <NUM>. The abutment portion <NUM> provides an inner abutment surface <NUM> for engaging a corresponding abutment surface of the body section below. The engagement portion <NUM> provides an engagement surface <NUM> for engaging a corresponding support surface of the body section below.

The upper edge region of the intermediate and base sections each include a peripheral rail <NUM> having a cross section comprising a substantially vertical outer wall portion <NUM>, a support portion <NUM> extending inwardly and perpendicularly from the outer wall portion <NUM>, and an inner wall portion <NUM> extending downwardly and perpendicularly from the support portion <NUM>. The outer wall portion <NUM> is configured to abut with the abutment surface <NUM> of the body section above. The support portion <NUM> provides a support surface <NUM> for engaging the engagement surface <NUM> of the body section above and supported thereon.

The angle of the various surfaces may not be substantially horizontal and vertical. For example, the support surface <NUM> and engagement surface <NUM> may be angled downwardly in the outboard direction such that any water ingress in the joint is directed outwardly to prevent ingress into the storage container and/or corrosion etc. Likewise, the abutment surface <NUM> need not be substantially vertical and may be angled inwardly or outwardly with respect to the vertical.

Aptly, each body section and the lid are formed from folded sheet material, such as steel or aluminium, or for lighter weight applications the sections and lid may be moulded from a plastics material. Aptly, the sheet steel may be around <NUM> thick.

The engagement portion <NUM> of an upper body section, e.g. the upper section, and the support portion <NUM> of the lower body section, e.g. the intermediate section, include a plurality of spaced apart holes each for locating a fastener, such as a bolt, to securely connect the body sections together. The holes may be threaded for receiving threaded bolts or may be non-threaded for a bolt to extend through and engage with a correspondingly threaded nut, e.g. a weld nut fixed to an inner surface of the section or a hex nut insert or the like. Aptly, a spring washer may be provided between each bolt head and the respective section to prevent loosening of the fastenings over time due to vibrations/impacts in use. Alternatively, the fasteners may be rivets, self-tapping screws, plastic plugs with serrated barbs, or the like.

Desirably, the 'hook and rail' joints between the different sections of the container body allow the fasteners to be located on the inside of the container to prevent any of the fasteners being maliciously removed in an attempt to gain unauthorised access into the container. Furthermore, the 'hook and rail' joints provide a particularly high bending strength and stiffness to the sections themselves, and the connections therebetween. The 'hook and rail' joints provide an additional level of security against malicious attack and unauthorised attempts to enter the container. The overlapping arrangement of the skirt/hook and rail profiles cause a change of direction of the joint which is in contrast to a conventional face-to-face and substantially flat joint. This change in direction provides more than one additional barrier against an unauthorised person using a tool, such as crowbar, in attempt to prise open the joint and gain access into the container.

This overlapping hook/skirt and rail arrangement provides the tiered body <NUM> of the container which protects the container from the most severe attacks with each section overlapping by around <NUM>. This provides a particularly strong joint and a tiered body design also reduces the amount of flat area prone to attack and, in the unlikely event a joint is breached, only a relatively small aperture is created making it particularly difficult to access the contents of the container.

As illustrated in <FIG>, <FIG> and <FIG>, the lid <NUM> includes a locking bar <NUM> fixed therein by suitable fasteners, such as bolts or rivets or the like. The locking bar <NUM> includes a plurality of spaced apart and downwardly extending projections <NUM> along its length, each projection having a hammer-head lock formation <NUM> defining a pair of opposed lugs at their free ends. The lock formations <NUM> may alternatively define a single lug instead of a pair of opposed lugs.

A locking plate <NUM> is slidably mounted inside the upper body section <NUM> of the container. The locking plate <NUM> includes a plurality of elongate slots <NUM> oriented in the horizontal plane and configured to be mounted on a respective one of a plurality of pins <NUM> extending inwardly from the inner surface of the upper body section <NUM>, such that the locking plate <NUM> is slidably moveable in either direction. The main body of the locking plate is oriented substantially vertically inside the container. An upper portion <NUM> of the locking plate is oriented substantially horizontally and includes a plurality elongate slots <NUM> which are aligned with and configured in size and shape to receive a respective one of the lock formations <NUM> when the lid is closed and the locking plate <NUM> is in an unlocked position. When the lid is closed and the locking plate <NUM> is slidably moved to a locked position, the slots of the locking plate are moved over one of the lugs such that the lock formations <NUM> cannot be pulled through the locking plate slots, and in turn the lid cannot be opened. The illustrated lock assembly comprises five equally spaced lock formations and corresponding locking plate slots which provides a plurality of locking points along the opening of the container and in turn a particularly strong and secure locking assembly to prevent any malicious attempts to prise open the lid. This locking arrangement also ensures that the locking force is constant along the length of the container when in a locked state. Aptly, the locking bar <NUM> and locking plate <NUM> are formed from <NUM> heavy-duty steel, or the like.

As illustrated in <FIG>, the locking plate <NUM> is housed within the rail portion of the upper region of the upper box section <NUM>, wherein the upper surface of the rail portion includes slotted apertures to allow respective ones of the lock formations <NUM> to enter the rail portion when the lid is closed and engage with the locking plate <NUM>. This arrangement provides additional security and protects the locking plate from malicious attack or attempts to directly move the locking plate to gain unauthorised access into the container.

As illustrated in <FIG> and <FIG>, a lock shaft <NUM> is coupled to a key-operated lock barrel <NUM>. The lock shaft <NUM> is coupled to a first end region of an elongate cam plate <NUM> such that rotation of the lock shaft rotates a second end region of the cam plate. A drive pin <NUM> is coupled to the second end region of the cam plate <NUM> which in turn is coupled to the locking plate <NUM>, such that the locking plate is moved when the cam plate is rotated. The drive pin <NUM> may be mechanically coupled, such as by a screw or bolt, to the locking plate or it may be freely located in an aperture, such as a hole or slot, in the locking plate.

Claim 1:
A lockable storage container (<NUM>) comprising:
at least one base member (<NUM>) having an outer edge region (<NUM>) comprising a rail portion extending therealong; and
at least one wall member (<NUM>) mounted on the base member, wherein a lower edge region (<NUM>) of the wall member comprises a skirt portion (<NUM>) extending therealong,
characterised in that the rail portion extends upwardly and defines an outer surface (<NUM>), an inner surface opposed to the outer surface, and an upper support surface (<NUM>) extending therebetween, and wherein the skirt portion (<NUM>) extends downwardly such that a first inner abutment surface (<NUM>) of the lower edge region of the wall member abuts the outer surface (<NUM>) of the rail portion, and a first engagement surface (<NUM>) of the lower edge region of the wall member engages the upper support surface (<NUM>) of the rail portion.