Patent Document

BACKGROUND OF INVENTION 
     The present invention relates to furniture and, more specifically, to drawer pedestals for office furniture. 
     Drawer pedestals are capable of increasing the storage space in office and home environments. Conventional drawer pedestals are constructed to either stand alone or be positioned under a desk, table or similar structure. 
     A typical drawer pedestal includes several drawers positioned one over the other in an open-faced box-like cabinet. The cabinet includes drawer slides fastened to its sidewalls. The drawers include rollers that interfit within the drawer slides to allow them to be individually slid in and out from the cabinet. Most of the components of the typical drawer pedestal are constructed of metal and fastened together with screws or bolts. 
     Although conventional drawer pedestals are capable of increasing storage space, they suffer a number of shortcomings. First, because the drawer components of the drawer pedestals are usually constructed from metal, the resulting unit is usually quite heavy. This makes shipping expensive, and makes movement of the pedestals around the office or home more difficult. Second, with various moving metal parts and fasteners to connect components, it is difficult and time consuming to assemble the drawer pedestals. Third, because the components are metal and relatively heavy, they usually do not withstand stacking, which makes storage of pre-assembly components space-consuming. 
     One solution to the problems associated with conventional metal drawer pedestals is to incorporate more plastic parts. This is done by replacing the metal panels of the drawer pedestal and drawers-with plastic panels. However, these plastic panels still are connected to one another with screws, bolts and other fasteners. These fasteners regularly are visible after assembly, leaving the finished product aesthetically unpleasing. 
     SUMMARY OF THE INVENTION 
     The aforementioned problems are overcome by the present invention wherein a plastic drawer pedestal is provided that includes an outer shell and a substructure that are snap-fit together. 
     In one aspect of the invention, the drawer pedestal unit includes a shell a substructure that interfits with the shell. The substructure has locking tabs or prongs around a flange. The shell includes corresponding slots or detents around a rim so that when the rim and flange are pushed together, the tabs and slots or detents engage one another and hold the parts together. Optionally, the slots or detents and tab or prongs may be disposed on either the shell or substructure. 
     In a variation of the first aspect, the locking tabs include are pairs or other select groups of side-by-side tabs. The slots are corresponding pairs or other select groups of relatively small apertures or detents into which the tabs snap and interlock to hold the shell and substructure together. 
     In a second aspect of the invention, guide tabs are included on the shell or substructure to assist a user in aligning and snapping the parts together. 
     The present invention also provides a method for assembling a drawer pedestal including: positioning the substructure adjacent the shell; aligning first and second locking structures on the substructure and shell; and moving at least one of the shell and the substructure toward one another until the first and second locking structure engages one another. 
     The drawer pedestal of the present invention offers many benefits. First, the invention improves upon existing plastic drawer pedestals by using a novel attachment mechanism including single or multi-tabbed interlocking structures and an easy-snap construction. By using interlocking structures including multi-tabbed locking tabs and corresponding, relatively small slots, as opposed to one large slot, a significant increase in the strength of the drawer pedestal is realized due to plastic processing limitations. Second, by eliminating, or at least reducing, the number of conventional fasteners used, the pedestal is less costly to produce, and has an improved finished look. Third, the components of the pedestal are constructed of relatively simple shapes that are conducive to easy stacking. Finally, the number of components of the pedestal is small, which decreases the overall cost of the unit. 
    
    
     These and other objects, advantages, and features of the invention will be readily understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a drawer pedestal according to a preferred embodiment of the present invention; 
     FIG. 2 is an exploded view of the drawer pedestal; 
     FIG. 3 is a left side elevational view of a substructure of the present invention; 
     FIG. 4 is a rear elevational view of the substructure; 
     FIG. 5 is a cross-sectional view of the substructure interlocked with a shell of the drawer pedestal taken along line  5 — 5  of FIG. 1; 
     FIG. 6 is a right side elevational view of the drawer pedestal, the left side elevational view being a mirror image thereof; 
     FIG. 7 is a fragmentary perspective view of a shelf opening defined by the shell; 
     FIG. 8 is an unexploded, cross-sectional view of a support of the drawer pedestal and the shell taken along line  8 — 8  of FIG. 2; 
     FIG. 9 is an unexploded, cross-sectional view of the support and the shell taken along line  9 — 9  of FIG. 2; 
     FIG. 10 is a cross-sectional view of the support taken along line  10 — 10  of FIG. 2; 
     FIG. 11 is an exploded view of a drawer of the drawer pedestal; 
     FIG. 12 is a perspective view of a handle of the drawer pedestal; 
     FIG. 13 is a front elevational view of the handle; 
     FIG. 14 is a cross-sectional view of the handle taken along line  14 — 14 ; 
     FIG. 15 is an exploded view of the handle and the drawer; 
     FIG. 16 is a cross-sectional view of the handle secured to the drawer; 
     FIG. 17 is a cross-sectional view of a first alternative embodiment of an interlocking structure of the drawer pedestal; 
     FIG. 18 is a perspective view of a first portion of the alternative interlocking structure; 
     FIG. 19 is a lower perspective view of another portion of the interlocking structure; and 
     FIG. 20 is a cross-sectional view of a second alternative embodiment of the interlocking structure. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A drawer pedestal  10  in accordance with a preferred embodiment of the present invention is shown generally in FIGS. 1 and 2. The pedestal  10  generally includes a top  6 , a bottom  8 , a substructure  12 , a shell  14 , and drawer  18 . The shell  14  includes slots  20  and the substructure  12  includes locking tabs  22 . The locking tabs  22  and slots  20 , however, may be associated with either the shell  14  or substructure  12 , in alternating or random combination. Locking tabs  22  interlock with slots  20  to hold the substructure  12  and shell  14  together. Optionally, a support  16  is interfit between the substructure  12  and the shell  14  to add rigidity and strength to the assembled drawer pedestal. Additionally, drawer  18  may be interfit within the assembled drawer pedestal. Although the present invention is described here in relation to a generally rectangular drawer pedestal, it is well suited for use with essentially any type of furniture unit of any shape. Moreover, the present invention may also be used in a variety of other products, for example, televisions, telephones, appliances, automotive trim and the like. 
     I. Construction 
     The components of the pedestal  10  are described in greater detail below with reference to FIGS. 2-19. In the preferred embodiment, the components are constructed from injection molded plastic, however other types of plastic, metal or other materials may be used as desired. Additionally, each component preferably is constructed as an integral piece, however, each component may be constructed from one or more separate parts as desired. 
     A. Substructure 
     Preferably, the substructure  12  includes a frame  39  and a compartment  40 . The frame  39  has a left side  36  and a right side  37  connected by and upper member  38  and a center member  34 . The upper member  38 , center member  34 , left side  36  and right side  37  form the front face  41  of the frame  39 . Optionally, additional members may attach the left side  36  and right side  37  of the frame  39 . Flanges  32  extend rearward from front face  41 . Preferably, a portion of the frame  39  forms part of the external surface of the pedestal  10 . The compartment  40  preferably includes compartment walls  42  bounded by a front compartment end  44  and a back compartment end  46 . The compartment walls  42  preferably define an opening  48  in the substructure  12 , and thus the pedestal  10  when assembled. In one embodiment, the compartment  40  resembles a tube. The front compartment end  44  of each compartment wall  42  is connected to a substructure internal surface  26  of the substructure  12 . The back compartment end  44  of each compartment wall  44  is connected to the shell  14  as will be explained in greater detail below. When the pedestal  10  is assembled, the compartment  40  forms a contained shelf inside the pedestal  10 . 
     The substructure internal surface  26  includes guide tabs  24  and locking tabs  22 . The guide tabs  24  are molded as part of the substructure  12 , but may also be separate components secured to the substructure internal surface  26 . Each guide tab  24  is substantially flat and includes curved corners having a first guide end  50  and a second guide end  52 . As will be appreciated, the guide tabs  24  may be other shapes. The first guide end  50  of each guide tab  24  preferably is secured to the substructure internal surface  26 . Multiple guide tabs  24  are secured along the left side  36 , right side  37  and upper member  38  of substructure  12 , along the substructure internal surface  26 . The second guide tab end  52  of each guide tab  24  extends beyond the flanges  32  of the substructure  12 . Optionally, the guide tabs  24  may extend a distance less than or greater than the depth of flange  32  from substructure internal surface  26 , depending on the application. Moreover, the guide tabs  24  may be connected to the substructure internal surface  26  of the center member  34  with a small gap between each guide tab  24  and the adjacent flange  32 . The number, shape and positioning of the guide tabs  24  along the substructure  12  may be varied as desired. The guide tabs  24  primarily function to align the flange  32  of substructure  12  with rim  86  of the shell. As shown in FIG. 5, however, they may also or alternatively function to press the rim  86  toward the flange  32 , thereby keeping the locking tabs  22  firmly interlocked or engaged with the slots  20 . 
     As shown in FIGS. 4 and 5, the substructure  12  includes locking tabs  22 , preferably attached to the substructure internal surface  26  on or near flange  32 . Each locking tab includes an angled front face  58  which facilitates moving the locking tab  22  over the corner  89  of rim  86  as the substrate  12  and shell  14  are mated. Optionally, the front face  58  may be curved to perform this function. The base  56  of tab  22  is secured to the substructure internal surface  26 . The locking tab  22  may be resilient to facilitate entry into slot  20  on shell  14 . In a preferred embodiment, the locking tabs  22  are attached to the substructure  12  in adjacent groups, and more preferably in pairs. Optionally, the tabs and slots are grouped in discrete pairs, that is, the distance between the two tabs or slots in a pair is less than the distance between adjacent pairs of tabs or slots. Optionally, groups of tabs and slots of other numbers may be used as desired. The locking tabs  22  are either molded as part of the substructure  12  or molded in pairs in the configuration explained above as separate parts and attached to the substructure  12  by any conventional means. 
     B. Housing 
     Referring to FIGS. 2,  6  and  7 , the shell  14  preferably includes a left shell wall  62 , a right shell wall  64 , a top shell wall  66 , and a back shell wall  68 . The shell  14  preferably is rigid enough to be self-supporting, that is, to stand firmly by itself. A compartment opening  70 , compartment guide tabs  72  and slots  20  preferably are included in the shell  14 . If a base panel  30  is used, it is attached to the bottom of each of the left shell wall  62 , right shell wall  64 , and back shell wall  68 . The base panel  30  may be attached to the pedestal  10  with the interlocking structures defined herein, or with any conventional fastener, for example screws, bolts or glue. 
     The shell  14  optionally includes compartment guide tabs  72 , which have a base end  82  and a tip  84 . The compartment guide tabs  72  preferably function to guide compartment  40  into compartment opening  70 . The compartment guide tabs  72  are preferably shaped like a right triangle, but other shapes may be used as desired. The compartment guide tabs  72  are attached to the shell  14  along the perimeter of shelf opening  70 . Any number of compartment guide tabs  72  may be attached to shell  14  in the following manner. Each compartment guide tab  72  is attached to the shell internal surface  79  so that the tip  84  of each compartment guide tab  72  is the point on the compartment guide tab  72  farthest from the compartment opening  70 . Preferably, there are several compartment guide tabs  72  along each of the left opening edge  74 , right opening edge  76 , top opening edge  78  and bottom opening edge  80  of the compartment opening  70 . 
     With reference to FIG. 2, each of the left shell wall  62 , right shell wall  64  and top shell wall  66  of the shell  14  includes a rim  86  having a peripheral edge  87 . The rim  86  may be associated with each of the walls collectively or independently. Preferably, the rim  86  is less thick than the left shell wall  62 , right shell wall  64  and top shell wall  66 . The rim  86  is substantially continuous with the shell internal surface  79  of the adjoining wall. 
     The rim defines slots  20  at or adjacent to the edge  87 . These slots preferably are dimensioned to receive the locking tabs  22  of the substructure and thereby interlock the shell  14  and substructure  12 . 
     The slots also are preferably grouped together in preselected numbers. For example, slots  20  may be grouped together in pairs as shown in FIG.  2 . Groups of relatively short slots, for example, pairs of slots or three or more slots, are preferred over longer single slots that traverse the same length of the rim or edge as the groups of relatively short slots. The reason being that as the region of the rim  86  between the slot  20  and the peripheral edge  87  becomes longer, i.e., extends a greater length along or parallel to the rim  86 , it becomes more flexible and/or weaker and thus prone to breaking. In contrast, the use of groups of closely situated slots  20 , for example, pairs of slots, as opposed to one large slot, results in stronger regions between the slot and edge and thus a stronger bond between the edge  86  and flange  32  when tabs  22  are interlocked with the slots. 
     Additionally, groups of relatively short slots are more easily and strongly formed in plastic forming processes, for example, injection molding. Specifically, in an injection molding process, the groups of short slots promotes stronger knit lines around each slot, thereby increasing the structural integrity of the rim around and between individual slots in the finished product. Moreover, with groups of shorter slots, the region of the rim  86  between the slot  20  and the edge  87  is more likely to be completely formed than a relatively longer slot. Specifically, groups of shorter slots are less likely to short-out in injection molding than single, long slots. 
     The groups of slots (and/or locking tabs) may be “independent” as desired, that is, the distance between separate groups of slots is greater than the distance between adjacent slots in each of the groups. Optionally, the slots also may be arranged in discrete pairs as discussed above. 
     In a preferred embodiment, the number of slots  20  is equal to the number of locking tabs  22 . Additionally, the thickness of the rim  86  is such that when the locking tabs  22  are connected to the slots  20 , the substructure external surface  85  is continuous or in substantially the same plane as the shell external surface  87 . 
     C. Support 
     Optionally, the pedestal  10  further includes support  16 , as shown in FIGS. 8-10. FIGS. 8 and 9 show a cross-section of the pedestal  10  at the point of connection between the substructure  12  and the shell  14  including the support  16 . FIG. 10 shows a cross-section of the support  16  itself. The support  16  includes a left support panel  90 , a right support panel  92 , and a top support panel  94 . The support  16  defines guide tab openings  95  to receive guide tabs  24  when the support  16  is positioned over the compartment  40 . The support  16  may be constructed from any material with sufficient strength to support objects placed on the top shell wall  66  of the pedestal  10 , for example, plastic, rubber and polystyrene foam. 
     The left support panel  90 , right support panel  92  and top support panel  94  cooperate to form a cross-section that fits over a portion of the compartment  40  so that each of the left support panel  90 , right support panel  92  and top support panel  94  contacts a portion, preferably substantially all, of the compartment wall  42 . Additionally, the top support panel  94  contacts a portion, preferably substantially all, of the shell internal surface  79  of the top shell wall  66  of the shell  14  when the pedestal  10  is assembled. The support  16  may function to transfer loads from the top shell wall  66  to the compartment  40  and further to the substructure  12  and other walls of the shell  14 . The support  16  preferably is frictionally fit between the compartment  40  and the shell  14 , but may be secured with conventional adhesives. 
     D. Drawer and Handle 
     Referring to FIGS. 11-16, an optional drawer  18  is interfit within the assembled pedestal  10 . The drawer  18  includes a drawer box  96 , front drawer panel  98  and handle  100 . The drawer box  96  is generally rectangular and includes drawer side walls  102 , a drawer bottom wall  104  and a drawer front wall  106 . A drawer slide  108  is mounted on the drawer bottom wall  104  and slidably fits within the guide groove  138  of the base panel  30  to allow the drawer  18  to be extended and retracted in relation to the pedestal  10 . As will be appreciated, other structures to facilitate movement of the drawer  18  relative to pedestal  10  may be used as desired. 
     The front drawer panel  98  includes top panel end  110  and a bottom panel end  112 , and an internal panel side  114  and an external panel side  116 . The internal panel side  114  of the front drawer panel  98  is attached to the drawer front wall  106  of the drawer box  96 . The front drawer panel  98  may be attached to the drawer box  96  by any conventional means. The front drawer panel  98  defines a U-shaped recess  118  along the top panel end  110 . A rib  120  protrudes from the recess  118 . The rib  120  includes a number of pockets  122 , which add strength to the rib  120 . Pockets  122  are located on both the internal panel side  114  and the external panel side  116 . Any number of pockets may be used as desired. 
     With further reference to FIG. 15, the front drawer panel  98  includes snaps  124  on the left recess side  126  and right recess side  128  of the recess  118 . Any number of snaps  124  may be used, but in a preferred embodiment there is one snap  124  on each of the left recess side  126  and right recess side  128  of the recess  118 . The snaps  124  are located in the top half of each of the left recess side  126  and right recess side  128  of the recess  118 . 
     With reference to FIGS. 12-14, the handle  100  includes a substrate  130  and a molding  132 . Preferably, the substrate  130  is made from any material with sufficient strength to be snapped onto the front drawer panel  98  and the substrate  130  is formed from a grippable plastic. The substrate  130  includes a substrate inner surface  134  and a substrate outer surface  136 . The substrate  130  has generally a U-shaped cross-section to adequately interlock over the rib  120 . 
     Additionally, the substrate  130  includes teeth  138  and catches  140 . The base  142  of each tooth  138  is attached to the substrate inner surface  134  so that when the substrate  130  is placed over the rib  120 , the tip  144  of each tooth  138  interlocks with a pocket  122 . Preferably, the rib  120  includes at least as many pockets  122  as there are teeth  138  on the substrate  130 . 
     Catches  144  are located on the substrate inner surface  134 . Each catch includes a catch base  146  and a catch tip  148 . The catch base  146  of each catch  140  is attached to the substrate inner surface  134  of the substrate  130  so that when the substrate  130  is placed over the rib  120 , the catch tip  148  of each catch  140  interlocks with a snap  124  on the front drawer panel  98 . The front drawer panel  98  includes at least as many snaps  124  as there are catches  140  on the substrate  130 , and in a preferred embodiment the number of snaps  124  is equal to the number of catches  140 . 
     The molding  132  is attached along substantially the entire substrate outer surface  136  of the substrate  130 . The molding  132  may be made of any material capable of being attached to the substrate  130 , but in a preferred embodiment the material is a textured plastic. The use of such material improves the feel and grip-ability of the handle  100 . The molding  132  is preferably injection molded over the substrate outer surface  136  of the substrate  130 . 
     II. Method of Assembly 
     To assemble a pedestal  10 , the base panel  30  is secured to the shell  14 . The support  16  is placed on top of the compartment  40 . The substructure  12  is inserted into the outer shell  14 . The guide tabs  24  align the locking tabs  22  with slots  20  so that the two may be secured along the rim  86  and flanges  32  to interlock the substructure  12  and shell  14 . Additionally, the compartment guide tabs  72  align the compartment  40  with the compartment opening  70 . To further aid with alignment, the guide tabs  24  and compartment guide tabs  72  are guided into the openings  95  on the support  16 . When the substructure  12  is fully inserted into the shell  14 , the locking tabs  22  interlock with the slots  20 . In this interlocked configuration, the support  16  is frictionally trapped between compartment  40  and shell  14 . 
     The handle  100  is assembled by forming a substrate  130  with teeth  138  and catches  140 . The molding  132  is attached to the substrate  130 . The drawer  18  is assembled by attaching the internal panel side  114  of the front drawer panel  98  to the front drawer wall  106  of the drawer box  96 . The handle  100  is pushed onto rib  120  until the teeth  138  interlock with pockets  122  and catches  140  interlock with snaps  124 . With the pedestal  10  assembled, the drawer  18  is interfit through drawer aperture  47 . Drawer slide  108  is slidably positioned in slide groove  138  of base panel  30 . 
     III. First Alternative Embodiment 
     A first alternative embodiment of the interlocking structures of FIG. 5 is shown in FIGS. 17-19. These alternative interlocking structures generally include a locking tab  122  that interlocks with a detent  120 . As with the preferred embodiment, the locking tabs  122  and detents  120  are in corresponding pairs, specifically, two locking tabs  122  register and interlock two corresponding detents  120 . However, each interlocking structure may include only a single locking tab  122  and single corresponding detent  120 , or any number of locking tabs  122  mated with any of the same number of detents  120 , as the application requires. 
     Each locking tab  122  includes a base  156  secured or integral with the flange  132  of the substructure  12 . The front face  158  of the locking tab  122  preferably is angled or curved to facilitate pushing the locking tab  122  and flange  132  over the corner  118  of the rim  186  during assembly. The locking tabs  122  shown also include additional support structure adjacent the front face  158  than the preferred embodiment. The detent  120  is defined at or adjacent the rim  186  of the shell  14 . The detents are shown as recesses that do not pass completely through the rim  186 . However, these detents may be replaced with slots that form an aperture completely through the rim. As used herein, slot may mean either “slot” or “detent” or both “slot” and “detent.” 
     Detents  120  receive corresponding locking tabs  122  to interlock the rim  186  to the flange  132 , thereby securing the shell  14  and substructure  12  together. Preferably, the locking tab  122  interfits within the detent  120  so that the shell external surface  87  and substructure external surface  85  are in substantially the same plane so that the finished pedestal appears smooth over the seam  160 . Although shown with the locking tabs  122  on the substructure  12  and the slots  120  defined by the shell  14 , the tabs and slots may be positioned on the other component. For example, the slots may be associated with the substructure and the tabs associated with the shell. Tabs and slots optionally may alternate, so that substructure and shell both include slots and detents in any order. 
     IV. Second Alternative Embodiment 
     A second alternative embodiment of the interlocking structures shown in FIG. 5 is shown in FIG.  20 . These second alternative interlocking structures generally include a locking tab  222  that interlocks with a slot  220 . Each locking tab  222  includes a base  259  and a member  260 . The base  259  has a first base end  256  and a second base end  258 . The first base end  256  is secured to the substructure internal surface  226 . The member  260  preferably is resilient and protrudes from the second base end  258 . When the locking tab  222  is positioned over and urged into a slot  220 , the member  260  and/or the base  259  flexes to allow entry of the member  260  into the slot  220 , the member  260  and/or the base  259  flexes to allow entry of the member  260  into the slot  220 . The locking tabs  222  and slots  222  of this second alternative embodiment may be grouped as in the other embodiments of the present invention. 
     The above description is that of preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said” is not to be construed as limiting the element to the singular.

Technology Category: 2