Patent Document

FIELD OF THE INVENTION 
       [0001]    This invention relates generally to a leg assembly, and more particularly to a leg assembly that may be removably secured to a storage case to provide a stable and lightweight base so that the case may be optionally used as a support structure such as a table. 
       BACKGROUND OF THE INVENTION 
       [0002]    Known storage cases may be selectively converted for use as a support structure such as a table. One such case has been used in military applications and in particular as a chest to store equipment for use by medical personnel. The case is manufactured from metal and includes four relatively wide metal legs that attach to both a base portion of the case and a lid portion, which forms a support surface. These cases are typically rectangular and include front, back and sidewalls. When configured as a table, the base portion has an open interior cavity that can be accessed by reaching between the legs. 
         [0003]    Such cases are relatively unstable, however, as the legs are secured through a passive bracketing system. This system employs substantially U-shaped brackets secured to exterior walls of the base and lid. The legs slide into the brackets and are held against the exterior walls of the case. The brackets are located on the sidewalls of the base and lid and on the back walls of the same. The brackets are passive in that they merely receive the legs and do not clamp or tighten down on them in any way. As will be appreciated, wear and tear on these cases during use can cause tolerances between the passive brackets and the legs to increase. Tolerance increases can, in turn, result in lateral movement of the lid relative to the base and instability of the support structure. 
         [0004]    Additionally, known cases do not include any ancillary structural supports, such as cross members, that bridge and stabilize the legs and help support the weight of the relatively heavy metal lid. This lack of supplemental support further adds to the instability of the legs and impairs the efficacy of such cases in the field. 
         [0005]    Moreover, the legs of known cases do not allow attachment of lids with varying depths. As will be appreciated, cases with larger capacities have lids and bases with deeper sidewalls. In known systems, different sets of legs are required for each size lid to keep the support surface of the lid at a height that is comfortable for use as a table or the like. This requires the manufacture, stocking and deployment of multiple legs depending on the capacity of the case and size of the lid. 
         [0006]    The legs of these cases are also quite wide and spaced in a configuration that does not allow for easy access to an interior cavity of the base. As stated above, two of the legs are secured to the sidewalls of the case. More specifically, the legs are secured to a portion of the sidewalls that is proximate the front wall of the base. Given the width of the legs, access to the interior cavity of the base is partially obstructed. This can be problematic if the cases are deployed for field use by military medical personnel who need to quickly locate and extract equipment. 
         [0007]    With the foregoing problems and concerns in mind, the general object of the present invention is to provide a leg assembly for a storage case, in particular a leg assembly that provides superior stability, allows for attachment of case lids of various sizes, and provides easy access to an interior cavity of a storage case base. 
       SUMMARY OF THE INVENTION 
       [0008]    It is an object of the present invention to provide a leg assembly. 
         [0009]    It is an additional object of the present invention to provide a leg assembly for a storage case. 
         [0010]    It is an object of the present invention to provide a lightweight leg assembly for a storage case. 
         [0011]    It is a further object of the present invention to provide a leg assembly for a storage case that can be used to securely and stably support a lid of the case to that the case may be used as a support structure such as a table. 
         [0012]    It is yet another object of the present invention to provide a lightweight leg assembly for a storage case that can be used to securely and stably support a lid of the storage case to that the case may be used as a support structure through the use of an active bracketing system and cross-braces. 
         [0013]    It is an additional object of the present invention to provide a leg assembly for a storage case that may be used with case lids of varying sizes. 
         [0014]    It is a further object of the present invention to provide a leg assembly for a storage case that allows for unobstructed access to an interior cavity of a base of the storage case. 
         [0015]    These and other advantages of the present invention will be better understood in view of the Figures and preferred embodiment described herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  shows a perspective view of a closed storage case for use with a leg assembly according to the preferred embodiment of the present invention. 
           [0017]      FIG. 2  shows a perspective view of a leg assembly according to the preferred embodiment of the present invention, with the leg assembly secured to a base and lid of the storage case of  FIG. 1 . 
           [0018]      FIG. 3   a  shows a front view of a single leg and mounting bracket of the leg assembly of  FIG. 2 . 
           [0019]      FIG. 3   b  shows a back view of the single leg and mounting bracket of  FIG. 3   a.    
           [0020]      FIGS. 4   a - 4   c  show various additional views of the single leg and mounting bracket of  FIG. 3   a.    
           [0021]      FIGS. 5   a  and  5   b  show various views of the mounting bracket of the single leg of  FIG. 3   a.    
           [0022]      FIG. 6  shows a side view of a cross-brace according to the preferred embodiment of the present invention. 
           [0023]      FIG. 7  shows an enlarged perspective view of the bottom portion of the single leg of  FIG. 3   a  wherein the leg has been secured to a base of a storage case through a latching mechanism. 
           [0024]      FIGS. 8   a - 8   d  show the leg assembly and storage case of  FIG. 1  and graphically illustrate the process by which the leg assembly is secured to the storage case for use as a support structure. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]      FIGS. 1 and 2  show a perspective view of a preferred embodiment of a storage case  10  and leg assembly according to the present invention. The case  10  includes a bottom portion or base  12  and a top portion or lid  14 . The base  12  has a horizontal bottom panel  16  and four vertical panels or walls, which include a front wall  18 , a rear wall  20 , and two sidewalls  22 . The vertical walls form an inner cavity  24 . The base  12  also has a parting line edge  26  member around the periphery of the vertical walls. The term “parting line” refers to the portion of a case where the base and lid meet. Similarly, the lid includes four vertical panels or walls, i.e., a front wall  28 , a rear wall  30 , and two sidewalls  32 . The lid  14  includes a horizontal bottom panel  34  and peripheral parting line edge member  36 , which aligns with the parting line member  26  of the base  12  when the case  10  is closed. The bottom panel  34  and vertical panels of the lid  14  form an inner cavity  38 . 
         [0026]    The case is secured in a closed position through the use of multiple latching mechanisms  40  spaced apart along the vertical walls of the base and lid. Each latching mechanism  40  is comprised of a strike  42  that is secured to the case lid  14  and a latch  44  on the base  12  that is in alignment with the strike  42 . The latch  44  has a hooked upper portion  46  that is designed to engage the strike  42 . The latch also includes a cam member  48 , which allows the hooked upper portion  46  to be clamped down on the strike  42  to secure the lid  14  to the base  12 . Each strike  42  and latch  44  are located in aligned recesses in the lid and base,  50 ,  52  respectively. The general operation of the above-described latching mechanism is described in U.S. Pat. No. 5,370,254, which is incorporated by reference in its entirety herein. 
         [0027]    The case  10  is preferably manufactured from plastic through a rotomolding process. As will be readily appreciated, however, other materials and processes may be utilized provided they are suitable to protect whatever equipment or supplies are stored within the case. 
         [0028]    The preferred embodiment of the inventive leg assembly for use with the case  10  is depicted in  FIG. 2 . As shown, the assembly is comprised of four generally linear legs  54 . The legs  54  are attached to the front and back walls of the base,  18 ,  20 , and the front and back walls of the lid,  28 ,  30 . The legs  54  extend from the base  12  to the lid  14  to support and stabilize the lid  14  enabling it to function effectively as support surface. The legs  54  are attached to portions of the front and back walls of the base  12  and lid  14  that are proximate the sidewalls,  22 ,  32 . The legs are preferably manufactured from a lightweight metal and, in one configuration, are 0.06-inches thick. The legs also have a series of spaced apart apertures or holes  55  which reduce weight. 
         [0029]    The location of the legs on the base and lid are an important aspect of the present invention as they allow easy access to the interior cavity  24  of the base. Prior art support structures have relatively wide legs located on the sides and back of base and lid hindering access to the interior of the base. As will be appreciated, in military and medical applications efficiency is critical. Moreover, the legs are located such that they do not extend out from the base or lid and therefore do not require any additional floor space. 
         [0030]    As shown, the legs  54  have a lower portion or end  58  and a generally U-shaped upper portion or end  60  and a central body portion  61 . The upper end  60  attaches to the lid  14  and the lower end  58  attaches to the base  12 . The upper end  60  includes a flat portion  57  and upper and lower slots  64 ,  66 . The legs  54  are shaped to fit into the lid and base recesses  50 ,  52 , respectively. Preferably, the legs  54  have a corrugated cross-section or profile, which corresponds to the shape of the recesses  50 ,  52  and increases strength of the legs. The inter-engagement or mating of the legs  54  and recesses  50 ,  52  helps align the lid  14  and base  12  for use as a support structure. As discussed in greater detail below, the legs  54  are also connected and stabilized by two cross members  56 , which extend between the front and back leg on opposite sides of the base  12  and lid  14 . 
         [0031]    The mating relationship of the legs and the recesses of the base and lid are yet another important aspect of the present invention. The recesses help to locate the legs so that they are properly aligned and stabilize the support structure preventing lateral movement. Known cases do not include this feature. As such, the mating relationship imparts a structural stability not found in the art. 
         [0032]    Turning now to  FIG. 3   a - FIG. 5   b , the legs  54  are secured to the base  12  through mounting brackets  62 , that are attached to the lower end  58  of each leg. As shown in  FIGS. 4   a  and  4   c , the mounting bracket  62  and lower leg end  58  form a substantially U-shaped bracket or opening  80  in which the lower end of the leg  58  forms a first sidewall  82  and a downwardly extending portion of the mounting bracket  62  forms a second sidewall  84 . When installed, the first and second sidewalls  82 ,  84  of the legs  54  are placed over the front wall  18  of the base  12  so that the front wall  18  is between the sidewalls  82 ,  84 . When attached, the brackets  62  distribute weight from the legs, cross members and lid on the base parting line  26  and abutingly contact the interior and exterior of the front wall  18  of the base  12  providing stability to the legs  54 . The mounting brackets  62 , which are load bearing, are preferably manufactured from a strong, lightweight metal such as aluminum/magnesium alloy 5052-H32. Other materials may be used as long as they are sufficiently strong to prevent a material failure. 
         [0033]    The first and second sidewalls  82 ,  84  are important aspects of the present invention. Unlike known support structures which attach to either a front or back side of a base wall, the present invention employs a U-shaped bracket having two side walls  82 ,  84  one of which contacts a front side of a base wall and the other a back or reverse side of a base wall. This configuration provides a degree of stability and strength not achieved with known systems. 
         [0034]    The brackets  62  also include a series of weight reducing holes  55  and are secured to the legs through a plurality of bolts or like fasteners. Further, the mounting bracket  62  preferably includes a rubber liner  69  on an inner portion of the bracket that contacts the parting line  26  to protect the line and base  12  from damage. As will be readily appreciated, it is desirable that the mounting bracket  62  be as wide as possible to distribute the weight of the legs, cross members and lid over a larger area and increase stability. The width of the mounting bracket  62  is limited, however, by an inside radius between the front wall  18  and sidewalls  22  of the base  12 . 
         [0035]    As shown in  FIG. 5   a , the downwardly extending leg or second sidewall  84  of the bracket  62  is angled outward and away from the leg  54  at an angle Θ. As will be readily appreciated the angle is acute. The angled sidewall  84  causes the legs to extend slightly outward and away from the base  12  when the cross member is not installed. Upon the addition of a cross member, the legs move inward to a substantially vertical position and the mounting bracket  62  contacts the latch  44  to effectively “preload” the leg  54  with the latching mechanism  40  so that the latch may then be cammed downward to secure the leg  54  to the base  12 . 
         [0036]    In addition to the mounting brackets  62 , the legs  54  are secured to the base  12  through the case&#39;s latching mechanism  40 . As shown in  FIGS. 3   a ,  3   b  and  7  the lower end  58  of each leg  54  includes a latching slot  63  that is sized to accommodate the hooked upper portion  46  of the latch  44  that is normally used to secure the lid  14  to the base  12 . When a leg  46  is secured to the base  12 , the mounting bracket  62  is first placed on the front wall so that it extends into the base inner cavity and the leg  54  is lowered toward the base. After the leg  54  has been lowered a certain distance, the hooked upper portion  46  of the latch  44  is placed through the latching slot  63  and the latch  44  is urged downward thereby securing the leg  54  to the base  12 . 
         [0037]    The attachment of the legs to the base  12  through the latching mechanism  40  is yet another important aspect of the present invention. Known cases use a passive attachment means in which legs are simply inserted in metal brackets on the exterior of a case. Repeated use of such cases in the field leads to increased lateral movement of the legs and renders the cases unstable. In sharp contrast, the present invention employs both a mounting bracket and an active latching system in which the mechanism used to latch the lid to the base is utilized to secure and stabilize the legs. As will be readily appreciated, stability of support structures is critically important in medical and military applications for which many of such cases are used. The active latching mechanism of the present invention provides a level of stability and strength not found in known cases. 
         [0038]    Referring back to  FIG. 2 , the lid  14  rests on the cross members  56  which are attached to the legs  54 . The lid  14  is held in place by the inter-engagement of the corrugated profile of the leg  54  and the lid recess  50  which have corresponding or mating surfaces. As discussed above, this inter-engagement prevents the lateral movement of the lid  14  relative to the legs  54  and base  12 . 
         [0039]    The cross members  56  are secured to the legs  54  at attachment points located on the legs. More specifically, the cross members  56  are attached to the legs  54  through slots machined in the body  61  of each leg. The slots are sized and shaped to accept the cross members  56 , support the lid  14 , and provide stability. As shown, there are two attachment points or slots per leg  54 , an upper slot  64  and a lower slot  66 . The cross members  56  may be placed in either the upper or lower slots  64 ,  66  depending on the size of the lid  14 . In its preferred configuration, the upper slot  64  allows a 2-inch deep lid to be employed. The lower slots  66  provide for the use of a deeper lid having 9-inch sidewalls. The upper slot  64  is located at the upper end  60  of each leg  54  and has an open end into which the cross member  56  is lowered. The lower slot  66  is located at approximately the midpoint of each leg  54  and does not include an open end. As such, the cross member  56  is inserted laterally into the lower slot  66  and then lowered into position. As will be appreciated, the upper and lower slots are located at the same positions on each leg  54  in the assembly so that the cross members  56 , when installed, are horizontal and parallel to the lid. Both the upper slot  64  and lower slot  66  have end portions  65 ,  67 , respectively, which support the weight of an inserted cross member  56  and the lid  14 . 
         [0040]    The slots  64 ,  66  are spaced on the leg body  61  so that top of the leg  54  is flush with the parting line  36  of the lids. That is, if the lower slot  66  is employed with a 9-inch lid  14 , the top of the legs  54  are flush with the parting line  36 . If the upper slot  64  is used with a 2-inch lid  14 , the top is flush with the parting line  36  as well. This keeps the lids  14 , i.e., the table top, at a consistent comfortable height regardless of whether a 2 or 9-inch lid is used. Additionally, the distance between the flat portion  57  of each leg  54  and the top of a cross member  56  installed in the upper slot  64  is great enough so that a lid  14  can be placed cavity side down without damaging the strikes  42  on the lid exterior. 
         [0041]    The leg slots are a significant aspect of the present invention as they allow cross members to be attached at multiple locations to accommodate lids, and cases, of various sizes. Known cases do not allow for this and would require multiple sets of legs for each size case. This would require the manufacture, stocking and deployment of multiple leg sets, which is inefficient and expensive. 
         [0042]    Turning now to  FIG. 6 , the cross members  56  are generally linear in shape and include two opposing end portions  68 . Each end portion  68  has a mounting slot  70  that is generally S-shaped with an open end  72  and a terminal end  74  having an abutment surface  76 . The abutment surface  76  contacts the end portions  65 ,  67  of the leg slots  64 ,  66  and is weight bearing. The mounting slot  70  is sized and shaped to accommodate attachment to the legs  54 . When a cross member  56  is inserted into a leg slot  64  or  66 , a portion of each leg  54  directly below each leg slot extends into the mounting slot  70  of the cross member  56  until the end portion  65 ,  67  of the mounting slot  70  contacts the abutment surface  76  of the leg slot. 
         [0043]    The shape of the mounting slot  70  is such that there are four points of contact between each leg  54  and an inserted cross-member  56 . The contact between the abutment surface  76  of the cross member  64  and the end portions of the leg slots  65 ,  67  is weight bearing. The remaining three points of contact between the mounting slot  70  and the body portion  61  of each leg  54  provide stability. This configuration, as opposed to a linear mounting slot, reduces friction between the legs and cross members and simplifies the manufacturing process. 
         [0044]    The cross members are preferably manufactured from a lightweight metal. In a preferred embodiment, the cross members are 0.25-inch thick aluminum. This thickness was chosen to maximize the contact area of each cross member  56  and the lid  14 . As will be appreciated, thicker materials may be used provided they are sufficiently lightweight and strong. The cross members also contain cut away holes  55  to reduce weight. 
         [0045]    As will be readily appreciated, the cross members are another important feature of the present invention. The cross members act to stabilize the legs and securely support the lid. Known cases do not include cross members or any ancillary support structure other than the legs themselves. The cross members of the present invention help create a support that can be used under the most rigorous of conditions and deployments. 
         [0046]    Although the cross members  62  are a critical component of the present invention, the legs  54  may be used temporarily without cross members if they are unavailable. In this configuration, the strike  42  of the lid  14  contacts the flat portion  57  of the leg  54  to support the lid  14  ( FIGS. 2 and 3   b ). 
         [0047]      FIGS. 8   a - 8   d  graphically depict the assembly of the preferred embodiment of the present invention. The mounting brackets  62  of the legs  54  are first attached to the base  12  by placing them over the front and rear walls  18 ,  20 . The cross members  56  are then inserted in the leg slots  64 ,  66  until the abutment surfaces  76  of the mounting slots  70  contact the terminal ends  74  of the leg slots. The hooked upper portion  46  of the latch  44  is then inserted through the latching slot and the latch is closed securing the legs to the base. The lid  14  is then lowered onto the cross members so that it rests on the cross members and so that its recesses  50  matingly engage the legs  54  securing the lid  14  and preventing its lateral movement. 
         [0048]    As will be appreciated, the present invention also has utility without the lid  14  and without all four legs  54 . For example, a single leg  54  may be attached to the base  12  for use as a support structure for hanging equipment such as IV bags. 
         [0049]    In sum, the present invention through the use of an active latching system, mounting brackets, slots, cross members and mating surfaces, provides a support structure that is stronger, lighter and more stable than known systems. Moreover, the present invention provides a versatile support assembly that can be used with cases of various sizes and capacities. Known cases do not provide these benefits. 
         [0050]    While many advantages of the present invention can be clearly seen from the preferred embodiment described, it will be understood that the present invention is not limited to such an embodiment. Those skilled in the art will appreciate that many alterations and variations are possible within the scope of the present invention.

Technology Category: 4