Abstract
The present invention is directed to a method of forming a container comprising forming a basket portion of metal mesh material and a rail connected to the basket portion. The rail extends substantially outwardly from the outer surface of the basket portion and the rail extends continuously around the outer surface of the basket portion. In one example, the method includes forming the rail so that it does not contain or surround a free edge of the basket portion. In another example, the method includes forming the rail so that it includes an opening for containing or surrounding a free edge of the basket portion. The method may also include forming a lower rail. The present invention is also directed to a container formed by such method.
Claims
1. An apparatus comprising: a basket including an inner surface, an outer surface, a substantially flat bottom wall, substantially flat and upwardly and outwardly extending from said bottom wall first and second spaced apart sidewalls, and substantially flat and upwardly and outwardly extending from said bottom wall third and fourth spaced apart sidewalls, said first, second, third and fourth sidewalk connected to each other to form four corners, each of said corners extending upwardly and outwardly from said bottom wall; a rail including a substantially flat horizontal portion and a substantially flat vertical portion connected to each other at a junction; said basket further including an upper section of said first, second, third and fourth sidewalls, said upper section extending only vertically and having a first end that terminates said upper section at said junction; wherein said vertical portion of said rail is attached to said upper section of said inner surface of said basket and has a lower second end that terminates said vertical portion, said horizontal portion of said rail having a third end that terminates said horizontal portion, said vertical portion and said horizontal portion extending substantially continuously around said basket; further comprising a frame, said basket being moveable with respect to said frame between retracted and extended positions via said rail.
2. The apparatus according to claim 1, wherein said frame comprises a rack having vertical support members arranged in a substantially rectangular configuration, said rack having opposed pairs of runners connected horizontally between said support members.
3. The apparatus of claim 1, wherein said upper section of said basket is supported only by said vertical portion of said rail.
4. The apparatus according to claim 1, wherein said vertical portion is attached to said upper portion only on said inner surface of said basket portion.
5. The apparatus according to claim 1, wherein said first, second, third and fourth sidewalls are formed of a single loop of material.
6. The apparatus according to claim 1, wherein said horizontal portion and said vertical portion form an approximate right angle with respect to each other.
7. A container, comprising: a basket having a bottom wall from which upwardly and angularly outwardly extends substantially flat first and second spaced apart sidewalls and substantially flat third and fourth spaced apart sidewalls, said sidewalk having an upper portion joined to a horizontally extending upper section, the intersection of said upper portion of said sidewalk and said upper section forming a junction; a horizontally extending rail including a first section, a second section, and a curved, U-shaped section joining said first and second sections to define an opening, said first, second and U-shaped sections being of substantially the same thickness; said upper section of said basket positioned in said opening, said first and second sections having first and second ends, respectively, each of which extends over said junction; said upper section of said basket being secured in said opening by compression of said first and second sections of said rail so as not to be removable from said opening; said upper section of said basket and said rail horizontally extending outwardly away from said upper portion of said sidewalls, and extending substantially continuously around said first, second, third and fourth sidewalk of said basket; further comprising a frame, said basket being moveable with respect to said frame between retracted and extended positions via said rail.
8. The apparatus according to claim 7, wherein said frame comprises a rack having vertical support members arranged in a substantially rectangular configuration, said rack having opposed pairs of runners connected horizontally between said support members.
9. The container of claim 7, wherein said first and second ends terminate at approximately at the same position opposite to each other.
10. The container according to claim 7, wherein said first, second, third and fourth sidewalls are connected to each other to form four corners.
11. The container according to claim 7, wherein said first, second, third and fourth sidewalls are formed of a single loop of material.
12. A container, comprising: a basket having a bottom wall from which upwardly and angularly outwardly extends substantially flat first and second spaced apart sidewalls and substantially flat third and fourth spaced apart sidewalls, said sidewalls joined to a horizontally extending upper section of said basket, said upper section and said sidewalls meeting at a junction; a rail extending horizontally and including a first section, a second section, and a U-shaped connecting section joining said first and second sections to define an opening therein, said first, second and connecting sections all being of substantially the same thickness, said upper section of said basket positioned in said opening; said first section and said second section of said rail extending from said connecting section to at least said junction of said upper section and said sidewalls; said upper section being secured in said opening by compression of said first and second sections of said rail so as not to be removable from said opening; said upper section of said basket and said rail horizontally extending outwardly away from said junction substantially continuously around said first, second, third and fourth sidewalls of said basket; and wherein said first, second, third and fourth sidewalls are formed of a single piece of material.
13. The container according to claim 12, wherein said first and second sections terminate at approximately the same position opposite to each other.
14. The container according to claim 12, further comprising a frame, said basket being moveable with respect to said frame between retracted and extended positions via said rail.
15. The container according to claim 14, wherein said frame comprises a rack having vertical support members arranged in a substantially rectangular configuration, said rack having opposed pairs of runners connected horizontally between said support members.
16. The container according to claim 12, wherein said first, second, third and fourth sidewalls are connected to each other to form four corners.
17. The container according to claim 16, wherein each of said four corners extend upwardly and outwardly from said bottom wall.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention will be more fully appreciated as the same becomes understood from the following detailed description of the best mode presently contemplated for carrying out the present invention when viewed in conjunction with the accompanying drawings, in which:
(2) FIG. 1 is front, perspective view of a first example of a system of drawers of the present invention, where the drawers are in a retracted position;
(3) FIG. 2A is an enlarged, perspective view of an L-connector for use with the system of FIG. 1;
(4) FIG. 2B is an enlarged, end view of the L-connector shown in FIG. 2A;
(5) FIG. 2C is an enlarged, perspective view of a T-connector for use with the system of FIG.
(6) FIG. 2D is an enlarged, end view of the T-connector shown in FIG. 2C;
(7) FIG. 3 is an enlarged, rear, perspective view of the first example of a drawer shown in FIG. 1;
(8) FIG. 3 is an enlarged, perspective view of a portion of the drawer shown in FIG. 3;
(9) FIG. 4 is an exploded, rear, perspective view of the drawer shown in FIG. 3;
(10) FIG. 5 is an exploded, rear, perspective view of a portion of the drawer shown in FIG. 3, wherein all of the mesh pieces have been bent;
(11) FIG. 5A is a partially-exploded, rear, perspective view of the drawer shown in FIG. 4, wherein three pieces of mesh material have been joined together;
(12) FIG. 6 is a schematic representation of some of the mesh pieces of FIG. 5 and a portion of a welding machine for joining such pieces;
(13) FIG. 7 is a schematic representation of some of the mesh pieces of FIG. 5 and a portion of the welding machine of FIG. 6;
(14) FIG. 8 is a partial, elevational view of a first example of an upper rail joined to one of the mesh pieces shown in FIG. 5, wherein an upper portion of the mesh piece is uncropped;
(15) FIG. 9 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 8, wherein the upper portion of the mesh piece is cropped;
(16) FIG. 10 is a partial, elevational view of a second example of an upper rail separated from a mesh piece;
(17) FIG. 11 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 10;
(18) FIG. 12 is an exploded, rear, perspective view of a second example of a drawer using the upper rail and mesh piece shown in FIGS. 10 and 11;
(19) FIG. 13 is an exploded, rear, perspective view of a third example of a drawer for use in the system of FIG. 1, wherein an alternative example of two side pieces of mesh material are used;
(20) FIG. 14 is a partially-exploded, rear, perspective view of the drawer shown in FIG. 13, wherein three pieces of mesh material have been joined together;
(21) FIG. 15 is an enlarged, rear, perspective view of a fourth example of a drawer useful in the system of FIG. 1;
(22) FIG. 16 is an exploded, rear, perspective view of the drawer shown in FIG. 15;
(23) FIG. 17 is a partially-exploded, rear, perspective view of the drawer shown in FIG. 15, wherein three pieces of mesh material have been joined together;
(24) FIG. 18 is front, perspective view of a second example of a system of drawers of the present invention, where the drawers are shown in a retracted position;
(25) FIG. 19 is an exploded, perspective view of an exemplary drawer with a third example of an upper rail;
(26) FIG. 20 is a perspective view of the drawer and rail of FIG. 19, wherein the rail is coupled to the drawer;
(27) FIG. 21 is an enlarged, partial, perspective view of the upper rail of FIG. 19, wherein the rail is uncompressed;
(28) FIG. 22 is a partial, elevational view of the upper rail of FIG. 19 disposed upon a mesh piece, wherein the rail is uncompressed;
(29) FIG. 23 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 22, wherein the rail is compressed;
(30) FIG. 24 is a partial, elevational view of a fourth example of an upper rail separated from a mesh piece;
(31) FIG. 25 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 24;
(32) FIG. 26 is a partial, elevational view of a fifth example of an upper rail separated from a mesh piece;
(33) FIG. 27 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 26;
(34) FIG. 28 is a partial, elevational view of a sixth example of an upper rail separated from a mesh piece;
(35) FIG. 29 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 28;
(36) FIG. 30 is a partial, elevational view of a seventh example of an upper rail separated from a mesh piece;
(37) FIG. 31 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 30;
(38) FIG. 32 is a partial, elevational view of an eighth example of an upper rail separated from a mesh piece;
(39) FIG. 33 is a partial, elevational view of the upper rail joined to the mesh piece of FIG. 32;
(40) FIG. 34 is an exploded, perspective view of a drawer with a ninth example of an upper rail;
(41) FIG. 35 is a perspective view of the drawer and rail of FIG. 34, wherein the rail is coupled to the drawer;
(42) FIG. 36 is a partial, elevational view of the upper rail of FIG. 34 supported by a mesh piece, wherein welding has not occurred;
(43) FIG. 37 is a partial, elevational view of the upper rail joined to the mesh piece of HG. 36, wherein welding has occurred;
(44) FIG. 38 is a partial, elevational view of a tenth example of an upper rail supported by a mesh piece, wherein welding has not occurred;
(45) FIG. 39 is a partial, elevational view of the upper rail joined to the mesh piece of HG. 38, wherein welding has occurred;
(46) FIG. 40 is an exploded, perspective view of an alternative drawer example with an upper rail of FIG. 36 and a first example of a lower rail;
(47) FIG. 41 is a perspective view of the drawer and rails of FIG. 40, wherein the rails are coupled to the basket portion;
(48) FIG. 42 is a partial, elevational view of the upper and lower rails of FIG. 40 engaged with a mesh piece, wherein welding has not occurred;
(49) FIG. 43 is a partial, elevational view of the upper and lower rails joined to the mesh piece of FIG. 42, wherein welding has occurred;
(50) FIG. 44 is a partial, elevational view of the upper rail of FIG. 38 supported by a mesh piece and a second example of a lower rail, wherein welding has not occurred; and
(51) FIG. 45 is a partial, elevational view of the upper and lower rails joined to the mesh pieces of FIG. 44, wherein welding has occurred.
DETAILED DESCRIPTION OF EXAMPLES OF THE PRESENT INVENTION
(52) Referring to FIG. 1, a first example of drawer system 10 is shown. This drawer system 10 may be used to store a variety of housewares, such as kitchen items, clothing, accessories, sports equipment, shoes, bathroom supplies, tools, appliances, and the like. Additionally, system 10 can be used to store a variety of other items, for example food, office supplies, office equipment, file folders, papers/documents, bags, boxes, cans, bottles, etc.
(53) Drawer system 10 includes frame or rack 12 and a plurality of containers or drawers 14a-d. Drawer 14a is smaller than drawers 14b-c so drawer 14a can hold a smaller volume than other drawers 14b-d. Drawers 14a-d are movable with respect to frame 12 between a retracted position (shown in FIG. 1) and an extended position. In the retracted position, the contents of lower drawers 14b-d is difficult to access. In the extended position, the contents of the extended drawer are easily accessible; the extended drawer may be fully withdrawn from frame 12 if desired.
(54) With reference to FIG. 1, frame 12 includes two side vertical support frame members or ladders 16 that are spaced apart and joined by pairs of upper and lower cross members 18a,b, respectively. Side frame members 16 and pairs of upper and lower cross members 18a,b are formed to give frame 12 a rectangular shape. The present invention is not limited to this frame shape.
(55) Frame 12 further includes L-connectors 20 (as best seen in FIG. 2A) and T-connectors 22 (as best seen in FIG. 2C) for joining side frame members 16 to cross frame members 18a,b. For example, L-connectors 20 connect upper cross member 18a to side frame members 16, if no additional frames are to be added above the one illustrated in FIG. 1. If an additional frame is to be added above frame 12 shown in FIG. 1, T-connectors 22 are used to join upper cross members 18a to frame members 16. For example, T-connectors 22 also conned lower cross members 18b to side frame members 16. Alternatively, T-connectors 22 joined to lower cross members 18b can be replaced with plugs with casters (not shown) thereon to make system 10 movable, as is apparent to those of ordinary skill in the art.
(56) Referring again to FIG. 1, each side frame member 16 includes a pair of spaced apart vertical rods or support members 24 coupled by vertically spaced apart horizontally-extending runners 26a-g. Each side frame member 16 is formed so that runners 26a-g of each side frame member 16 are aligned with runners 26a-g of other side frame member 16 to form a plurality of pairs of runners. Each runner 26a-g is a generally U-shaped member with inwardly extending gap 28 defined therein. Runners 26a-g may include a bore (not shown) in the rear end for receiving a pin (not shown) for preventing rearward movement of drawers 14a-d out of frame 12. To make frame 12 independent of direction the bore (not shown) may be formed at both ends of each runner and the pin (not shown) disposed in the desired end for use.
(57) Frame 12 is, for example, formed of any metal with sufficient rigidity and formability, for example mild sheet steel, stainless steel, aluminum, copper or the like can be used. Vertical rods 24 and runners 26a-g are, for example, welded together using conventional welding techniques. Frame 12 may be subjected to a powder painting treatment, similar to that discussed below for drawers 14a-d.
(58) Referring to FIGS. 1, 2A and 2B, L-connector 20 includes central body 30 and first and second generally perpendicular legs 32 and 34 extending therefrom. For example, pairs of cross members 18a,b and vertical rods 24 are hollow so that legs 32 and 34 are received therein to join these components together. Referring to FIGS. 1, 2C and 2D, T-connector 22 includes central body 36 and first, second, and third legs 38, 40, and 42, respectively, extending therefrom. First and second legs 38 and 40 are generally perpendicular to one another similar to L-connector 20. Second and third legs 40 and 42 are also generally perpendicular to one another. For example, first leg 38 and third leg 42 may be inserted into hollow vertical rods 24, and second leg 40 is inserted in hollow associated cross members 18a,b.
(59) L-connectors 20 and T-connectors 22 are, for example, formed of any metal with sufficient rigidity and formability. For example, connectors 20 and 22 can be cast of die-cast aluminum or any alloy, using conventional techniques known to those of ordinary skill in the art. Connectors 20 and 22, however, can also be formed of another material like injection molded plastic.
(60) Now, with reference to FIGS. 1, 3, and 3A, the details of drawer 14b will be discussed. Drawer 14b includes a runner portion that comprises upper rail 54 and basket portion 55. Basket portion 55 is coupled to upper rail 54. In the present example, basket portion 55 is formed of expanded metal plate (i.e., sheet metal) or “mesh” and has small openings 56a therein. In the present specification and appended claims “mesh” means flat metal that is pierced and stretched so that no material is separated from the original raw material, as known by those of ordinary skill in the art. On the other hand, unlike mesh, punching portions of waste material out of sheet metal material forms perforated metal. For example, openings 56a (see FIG. 3A) in the mesh have an area less than 25.4 mm by 25.4 mm. In another example, openings 56a (see FIG. 3) in the mesh have an area less than 20 mm by 10 mm. In another example, openings 56a (see FIG. 3) in the mesh have an area less than 6 mm by 3 mm.
(61) Basket portion 55, for example, is formed of any metal such as copper, steel, stainless steel or aluminum, and the like, Basket portion 55 includes bottom wall 56, a pair of spaced apart sidewalk 58 and 60, and another pair of sidewalls 62. Bottom wall 56 and sidewalls 58, 60 and 62 are each substantially flat. For example, sidewalls 58, 60 and 62 are joined together to form closed curved corners 64. Sidewalls 58, 60 and 62 extend upwardly from bottom wall 56 to form upwardly-facing opening 66.
(62) As shown in FIG. 3, corners 64 are curved so that they deviate from straightness in a smooth, continuous fashion. The present invention, however, is not limited to drawers with curved corners and drawers with more angular corners are also considered inventive. The present invention is also not limited to drawers with a radius of curvature greater at the top of the drawer (adjacent the rail 54) than at the bottom, Thus, drawers with, for example, a constant radius of curvature are also considered inventive. Each of the corners 64 extend upwardly and outwardly from bottom wall 56.
(63) In this example, sidewall 58 forms a front end wall that includes curved cutout 68 bordered by handle rail 70. Cutout 68 forms a place where a user can easily grasp drawer 14b to move it between the retracted and extended positions. In an alternative example, cutout 68 can be replaced with other methods to aid the user in moving drawer 14b, such as a protruding handle connected to wall 58. Handle rail 70 may have a circular cross-sectional shape and be cut and formed to extend along the edge of cutout 68. In the present example, rail 70 is of the same material as upper rail 54 and is spot-welded to basket portion 55. In this example, sidewall 60 forms a rear end wall.
(64) Referring to FIG. 4, drawer 14b is shown in a disassembled state. Basket portion 55 is formed by first piece of mesh 72, second piece of mesh 74 and third piece of mesh 76. First, second, and third pieces of mesh 72, 74, 76 are formed separately from one another. First piece of mesh 72 is bent along lines 72a,b to form edges as shown in FIG. 5 to define bottom wall 56 and side ails 62. The angle between bottom wall 56 and sidewalls 62 is greater than about 90°, but the present invention is not limited to this configuration.
(65) Second piece of mesh 74 includes outer edge 74a, inner edge 74b, central portion 74c, side extensions 74d, and lower extension 74e. Central portion 74c is between outer edge 74a and lower extension 74e and between side extensions 74d. Side extensions 74d have a trapezoidal shape so that they taper downward from outer edge 74a to lower edge 74b. Second piece of mesh 74 is bent to form front end wall 58, curved corners 64, and lower extension 74e that is generally, perpendicular to front end wall 58 (see FIGS. 3 and 5). Third piece of mesh 76 is formed similarly to second piece of mesh 74 to include upper edge 76a, lower edge 76b, central portion 76c, side extensions 76d, and lower extension 76e.
(66) In an alternative example, pieces of mesh 74 and 76 can be formed of a single piece of material separate from first piece of mesh 72. In such event, the two pieces of mesh 74 and 76 would be joined by another mesh segment (not shown) that would be shaped similar to bottom wall portion 56. As a result, bottom wall of basket 55 would be formed of two layers of mesh material that overlap.
(67) Referring to FIG. 5A, first, second, and third pieces of mesh 72, 74, and 76 have been joined together so that bottom seams 78 are formed. Seams 78 are where the material of bottom wall 56 of first piece of mesh 72 overlaps with lower extension 74e of second and third pieces of mesh 74 and 76 (see FIG. 4). When corners 64 are formed, side seams 80 (as shown in FIG. 3) are formed adjacent each corner 64. Seams 80 are where the material of sidewalls 62 of first piece of mesh 72 overlaps with side extensions 74d and 76d of second and third pieces of mesh 74 and 76, respectively. Seams 80 are generally vertically extending side seams.
(68) The method of making drawer 14b will now be discussed. Referring to FIGS. 4 and 5, first piece of mesh 72 is formed and shaped as shown. This involves cutting piece of mesh 72 with the desired dimensions from a roll of mesh using a conventional press machine. Then, first piece of mesh 72 is bent into a U-shape that includes bottom wall 56 and end walls 62 (as shown in FIG. 5). A conventional hydraulic press machine is used to bend mesh piece 72. The hydraulic press machine includes a mold for achieving the desired bent shape, as is known by those of ordinary skill in the art.
(69) Second and third pieces of mesh 74 and 76 are formed and shaped as shown in FIG. 4. This involves cutting pieces of mesh 74 and 76 with the desired dimensions and shape from a roll of mesh using a conventional press machine. Then, mesh piece 74 is bent using a conventional hydraulic press machine so that side extensions 74d are curved and lower extension 74e is angularly offset from center section 74c. The hydraulic press machine includes a mold, as is known by those of ordinary skill in the art. Third piece of mesh 76 is bent similarly to second piece 74 (as shown in FIG. 5). Handle rail 70 may be welded to mesh piece 74 at this point or later, when upper rail 54 is joined to basket portion 55.
(70) Next, lower extensions 74e,76e of each piece 74,76 are connected by welding to the side edge of bottom wall 56 of first piece 72 (as shown in FIG. 5A) to form seams 78. Then, curved side extensions 74d,76d of pieces 74,76 are connected by welding to sidewalls 62 of first piece 72 to form seams 80 (as shown in FIG. 3).
(71) After drawer 14b is completely formed (including attaching rail 54), a process of powder painting may be used to coat drawer 14b, as is known by those of ordinary skill in the art. One exemplary paint is an epoxy coat. The painting may provide a decorative (colored and/or metallic) finish to drawer 14b, if desired, and will also provide some protection for the drawer 14b from water and other corrosive elements.
(72) Referring to FIGS. 5, 6, and 7, the equipment used to connect first, second and third pieces of mesh 72, 74, and 76 together will now be discussed. The equipment, for example, comprises spot-welding machine 84 including base 86, clamp 88 supported on base 86, movable elongated member 90 movable by clamp 88 to provide clamping force F, and a pair of anode electrodes 92a and a pair of cathode electrodes 92b. Base 86, clamp 88, member 90, and cathode electrodes 92b form a fixture for supporting mesh pieces 72, 74, and 76 during welding. As shown, for example, cathode electrodes 92b are, for example, bar-like and parallel to one another to properly support and clamp mesh pieces 72, 74, and 76. In an alternative example, the spot-welder can be used without clamp 88 and elongated member 90, where the pieces may be manually held during welding.
(73) In order to join lower extension 74e of second piece 74 to bottom wall 56 of first piece 72, already-bent first piece 72 is disposed on cathode electrodes 92b so that sidewalls 62 extend downward (as shown in FIG. 6) toward the floor. Bent second piece 74 is disposed between member 90 and cathode electrode 92b, as shown in FIG. 7. Next, clamp 88 is actuated so that clamping force F moves member 90 from a retracted position (shown in FIG. 6) into a clamping position (shown in FIG. 7). In the clamping position, mesh piece 74 is compressed between member 90 and cathode electrode 92b. Clamping force F must be sufficient to hold mesh piece 74 into contact with mesh piece 72 for the welding operation.
(74) Then, anode electrode 92a moves in direction D1 into contact with pieces 72,74 adjacent extension 74e. Pieces 72,74 are tightly compressed between electrodes 92a and 92b. Electrodes 92a,b then discharge electric welding current through the place to be welded and seam 78 (see FIG. 5A) is formed. Third piece 76, as shown in FIG. 5, is similarly joined to first piece 72. In the present example, welding machine 84 is properly configured so that the fixture includes two clamps, two elongated members 90 and two pairs of electrodes 92a,b. As a result, second and third pieces 74 and 76 can, for example, be simultaneously welded to first piece 72.
(75) Another spot-welding machine similar to machine 84 is used to weld pieces 74 and 76 to piece 72 adjacent the corners 64 to form seams 80. This spot-welding machine for forming seams 80 has an appropriately sized fixture including clamp(s), elongated member(s) and cathode electrode(s) for smaller pieces 74 and 76. For example, the cathode electrode(s) may be tapered to match trapezoidal extensions 74d, 76d so that pieces 74 and 76 are suitably clamped to end walls 58 and 60 during welding.
(76) With reference to FIG. 3, upper rail 54 is subsequently connected to upper section of end walls 58 and 60 and sidewalls 62 by spot-welding. Referring to FIGS. 3 and 8-9, the step of connecting upper rail 54 to basket portion 55 further, for example, includes the steps of forming generally flat upper rail 54; contacting rail 54 to basket portion 55 on contact surface 54a so that upper section 55a of basket portion 55 extends above rail 54; and spot-welding contact surface 54a to outer surface of basket portion 55.
(77) Upper rail 54 is, for example, formed of the same material as basket portion 55 so that these components can be welded together. Thus, for example, rail 54 is formed of any metal such as copper, steel, stainless steel, mild sheet steel or aluminum, and the like. In an example using sheet steel, a roll of sheet steel strip material with a circular cross-section is used. This material is passed through a conventional roll forming machine with a number of pairs of rollers using a predetermined compression pressure to continuously and gradually change the circular cross-section into a generally flat rectangular cross-section, as is known by those of ordinary skill in the art.
(78) The material with the flat rectangular cross-section is then fed into a bending machine that includes spaced apart pairs of guide rollers for guiding the material through the machine and bending the material into four spaced apart right angles to form a rectangular ring. Hydraulic power can be used to provide the bending force to the associated pairs of guide rollers. Where the bending pairs of guide rollers are located, the machine further includes rollers for preventing vertical expansion of the material. Once the rectangular ring is formed, the free ends of the ring are joined by welding to form upper rail 54.
(79) Rail 54 is not limited to the above configuration, shape and materials. For example, it can be hollow with various shapes, such as a circular cross-section. Rail 54 can also be solid with various shapes, such as a circular cross-section. Rail 54 can also be formed of a plastic that is connected to basket portion 55 by glue or adhesive, for example.
(80) Referring to FIGS. 8 and 9, the step of contacting rail 54 to basket portion 55 on contact surface 54a may, for example, further include the step of using spot-welding machine with fixture F for supporting rail 54 at a sufficient elevation above a table (not shown) so that upper section 55a of basket portion 55 extends above rail 54. Fixture F may also provide a clamping force for assuring surface 54a is in solid contact with basket portion 55 or this force may be provided by movable anode and cathode electrodes AE and CE, respectively. For example, electrodes AE and CE are circular welding wheels. Anode electrode AE contacts outer surface of rail 54 and cathode electrode CE contacts inner surface of basket portion 55 adjacent surface 54a, as shown in FIG. 9. An electric current is discharged through electrodes AE and CE, rail 54 and basket portion 55 to spot-weld rail 54 to basket portion 55. For example, sufficient electrodes AE and CE are provided to make the welding of rail 54 to basket portion 55 efficient. Since electrodes AE and CE are movable vertically in directions V and horizontally in directions H1, the spot-welder can be used to weld variously size rails and baskets together.
(81) The step of connecting upper rail 54 may further include cutting and grinding steps. In the cutting step, upper section 55a (as shown in FIG. 8) of basket portion 55 is severed using a conventional severing apparatus, such as one including a reciprocating saw blade. In the grinding step, exposed upper edge 55b (FIG. 9) of basket portion 55 is worked using a conventional grinding machine so that upper edge 55b becomes smooth. Rail 54 aids in providing structural rigidity to basket portion 55 and is the only rail circumscribing each drawer's perimeter.
(82) Once rail 54 is joined to the outer surface of the basket portion, a substantial portion of rail 54 extends substantially outwardly from the outer surface of first, second, third and fourth sidewalls of basket portion 55 and rail 54 extends continuously around the outer surface of basket portion 55 (as shown in FIG. 3).
(83) Referring to FIGS. 1 and 3, in use drawer 14b is inserted into system to by disposing upper rail 54 within gap 28 of opposed, aligned pair of runners 26b. Rail 54 and gap 28 are sized to allow free sliding movement of drawer 14b with respect to frame 12 between the retracted and extended positions.
(84) Since drawer 14b is formed of mesh with very small openings 56a (see FIG. 3), small objects, such as pens, paper clips, and the like, can be stored in drawer 14b without a liner and will not fall through openings 56a. In addition, since drawer 14b has closed corners 64, small objects also cannot fall out of this area of drawer 14b.
(85) As shown in FIG. 1, drawers 14b-14d are of medium size and vertically extend across two sets of vertically spaced runners. Drawer 14a is a small size and consequently extends across only one set of vertically spaced runners. The drawers may be sized differently, see FIG. 4, particularly by changing the length L of first piece of mesh 72 and the height H of second and third pieces of mesh 74 and 76. This allows containers of a variety of sizes to be formed without excess machinery costs, particularly large containers having depth D from bottom wall 56 to top surface of top rail 54 (see FIG. 3) equal to or greater than about 11 inches. If larger baskets are desired, the basket material may need to be changed and/or thickened to provide more rigidity thereto. Width W of the mesh (FIG. 4) can be set by the machine forming the raw material so that the edges of piece 72 that will be connected to pieces 74 and 76 are smooth and require no cutting or grinding.
(86) FIGS. 10-12 illustrate an alternative example of upper rail 54′ for use with alternative example of basket portion 55′. To form upper rail 54′ raw material is bent to include portion 54a′ with opening 54b′ and extension 54c′ angularly offset from portion 54a′ using a roll forming machine. Portion 54a′ further includes first section A, second section B, and curved section C joining first and second sections A,B so that opening 54b′ is located therein. Sections A and B are generally flat and have parallel horizontal sections. Extension 54c′ is joined to first section A via curved section 54d′. The material for rail 54′ is bent into a closed rectangular loop and welded together, similar to rail 54 so that rail 54′ is continuous.
(87) Basket portion 55′ is formed similarly to basket portion 55 except end walls 58′, 60′ and sidewalk 62′ all have an outwardly bent upper section 55a′ terminating in an end or free edge 55c′. Upper section 55a′ is formed by a conventional hydraulic press machine with a mold at the same time other bends are formed in pieces 72, 74, 76 (see FIG. 5). That is when piece 72 is bent to form edges 72a and 72b, piece 72 is also bent to form upper section 55a′. Similarly, upper section 55a′ is formed on pieces 74 and 76, when edges 74d and 74e and edges 76e and 76d, respectively, are formed. Then, pieces 72, 74, 76 are welded together.
(88) Bent upper section 55a′ is inserted into opening 54b′ of upper rail 54″ (as shown in FIGS. 10 and 11). Portion 54a′ is then compressed by a conventional press machine so that opening 54b′ is minimized and portion 54a′ tightly engages basket portion 55a′ so that inner surfaces of the flat, parallel horizontal sections of portion 54a′ contact basket portion 55a′. This step also results in front curved tip or portion 54e′ of rail 54′ engaging angled corner or junction 55b′ of basket portion 55′. Then, vertically-extending extension 54c′ is welded to the basket using a spot-welding machine and fixture similar to the method used for rail 54 (shown in FIGS. 8 and 9).
(89) Once upper rail 54′ is joined to basket portion 55′ in this manner, it provides additional structural rigidity to basket portion 55′. Using rail 54′ eliminates the need to cut upper section 55a of basket portion 55, as when using rail 54, as shown in FIGS. 8 and 9. Consequently, rail 54′ eliminates the need to deburr or grind basket portion 55′.
(90) In an alternative exemplary method, pieces 72, 74, 76 (see FIG. 5) are bent to form edges 72a and 72b in piece 72, edges 74d and 74e in piece 74, and edges 76e and 76d in piece 76. Then, pieces 72, 74, 76 are welded together. Next, joined pieces 72, 74, and 76 are placed in a conventional hydraulic press machine with a mold and bent to create outwardly bent upper section 55a′ on each piece 72, 74, 76. Subsequently, rail 54′ is coupled to basket 55′ as previously discussed.
(91) Referring back to FIG. 1, basket 14a includes a rectangular cutout 68′ on front of wall 58′, Metal handle rail 70′ covers the free end of the mesh within cutout 68′. Handle rail 70′ is, for example, formed similar to rail 54′ (see FIG. 10) with an opening that is compressed about the mesh, once the mesh is inserted therein. For example, handle rail 70′ also includes an extension, similar to extension 54c′ of rail 54′, that can be spot-welded to securely attach rail 70′ to the mesh. In such an example, opening in rail 70′ extends vertically along with its extension similar to extension 54c′. In an example of handle rail 70′ without such an extension, rail 70′ may still be spot-welded to the mesh.
(92) Referring to FIGS. 13-14, third drawer example 114b is shown. Drawer 114b comprises runner portion or upper rail 154 and basket portion 155. Upper rail 154 may be formed like rail 54 or rail 54′ previously discussed. Basket portion 155 includes bottom wall 156, end walls 158 and 160, and sidewalk 162. Bottom and end walls 156 and 158 and 160 are also sidewalls. First piece of mesh 172 is bent to form bottom wall 156 and end walls 158 and 160. Sidewalls 162 are formed of separate second and third pieces of mesh 174 and 176, respectively. End wall 158 includes first piece of mesh 172 with cutout 168 similar to end wall 58.
(93) For drawer 114b, different from drawer 14b, second piece of mesh 174 includes central portion 174c, rectangular side extensions 174d and lower extension 174e. Third piece of mesh 176 has a similar configuration. When pieces 172, 174 and 176 are connected using a method similar to that used in forming drawer 14b, drawer 114b has closed smoothly curved corners similar to corners 64 (as shown in FIG. 3), but corners of drawer 114b will have a substantially constant radius. Drawer 114b also includes four side seams 80 at each corner and two bottom seams 178.
(94) Referring to FIGS. 15-17, fourth drawer example 214b is shown. Drawer 214b comprises runner portion or upper rail 254 and basket portion 255. Upper rail 254 may be formed like rails 54, 54′, 154′ or 254′ discussed above. Basket portion 255 includes bottom wall 256, end galls 258 and 260, and sidewalls 262. End walls 258 and 260 are also sidewalk. First piece of mesh 272 is bent to form bottom wall 256 and end walls 258 and 260. Side ails 262 are formed of separate second and third pieces of mesh 274 and 276. End wall 258 includes cutout 268 similar to end wall 58.
(95) In drawer 214b, different from drawers 14b and 114b, second and third pieces of mesh 274 and 276 do not include extensions. When pieces 272, 274 and 276 are connected using the method of forming drawer 14b, pieces 274 and 276 only overlap piece 272 on the bottom not on the sides. As a result, drawer 214b has open corners 264 (as shown in FIG. 15) and two bottom seams 278. Drawers configured like drawer 214b can be used in systems like system 10 (shown in FIG. 1) and move between extended and retracted positions. Drawers similar to drawer 214b can come in a number of sizes. Drawer 214b is formed similarly to drawer 14b by bending and spot-welding the mesh pieces.
(96) Referring to FIG. 18, a second example of drawer system 310 is shown. Drawer system 310 includes frame 312 and plurality of drawers 314a and 314b. Frame 312 includes four pairs of runners 326a-d. This example illustrates that any number of pairs of runners can be used depending on how large a system is desired. Frame 312 is otherwise configured and formed similarly to frame 12 (shown in FIG. 1). System 310 further may include solid table top or shelf 327 that is securely connected to the top of frame 312 by a press fit so that objects can be stored or displayed thereon. Alternatively, shelf 327 may be sized differently (larger or smaller than) frame 312 and connected to frame 312 with conventional fasteners such as screws and L-brackets. Drawer 314a is small and extends across one pair of runners 326a. Drawer 314b is large and extends vertically across three pairs of runners 326b-d. Drawers 314a and 314b are configured and manufactured similar to drawer 14b (see FIG. 1), but drawers configured like drawers 114b and 214b can also be used with system 310.
(97) FIGS. 19-23 illustrate an alternative third example of upper rail 354 for use with basket portion 355. As shown in FIG. 21, upper rail 354 is formed similar to rail 54′ to include curved portion 354a with opening 354b and first and second extensions 354.sub.c and 354e angularly offset from curved portion 354a. Curved portion 354a further includes first section A, second section B, and curved section C joining first and second sections A, B so that opening 354b is located therein. In the present example, first section A has a length less than second section B. First extension 354c is joined to first section A. Second extension 354e is joined to second section B. Rail 354 is bent so that curved portion 354a has a generally V-shape form, as shown in FIG. 21.
(98) Referring to FIGS. 22 and 23, bent upper section 355a of basket portion 355, which is similar to basket portion 55′, is inserted into opening 354b of upper rail 354′. As a result, first and second extensions 354c and 354e are adjacent to outer and inner surfaces, respectively, of basket portion 355. Curved portion 354a is then compressed, as indicated by arrows F in FIG. 22, by a conventional press machine. As a result, opening 354b is minimized (as shown in FIG. 23) and curved portion 354a tightly engages basket portion 355a. This compression also results in extensions 354c and 354e sandwiching basket portion 355 therebetween. Additionally after compression, extensions 354c, 354e are generally vertically oriented and first and second sections A,B are generally horizontally oriented (as best shown in FIG. 23). In addition, compression results in curved edge 354d of rail 354 engaging angled corner or junction 355b of basket portion 355 (see FIGS. 22-23). Then, the now generally vertically-extending extensions 354c and 354e are welded to outer and inner surfaces, respectively, of basket portion 355 using a spot-welding machine and fixture similar to the method used for rail 54 (shown in FIGS. 8 and 9).
(99) Rail 354 adds structural rigidity to basket portion 355 and eliminates the need to cut and deburr basket portion 355.
(100) FIGS. 24-25 illustrate an alternative fourth example of upper rail 454 for use with basket portion 55 (shown in FIGS. 8 and 24). Rail 454 is similar to rail 54′ as shown in FIG. 10 except as discussed below. Upper rail 454 is bent to include first portion 454a and angularly offset second portion 454b. Second portion 454b includes contact surface 454c.
(101) Second portion 454b of rail 454 is connected to basket portion 55 by spot-welding, similar to rail 54 shown in FIGS. 8 and 9. The step of connecting upper rail 454 to basket portion 55 further includes, for example, the steps of forming generally L-shaped rail 454, contacting contact surface 454c of rail 454 to basket portion 55 so that upper section 55a of basket portion 55 extends above rail 454 and first portion 454a is spaced from upper edge 55b, spot-welding contact surface 454c to outer surface of basket portion 55 (as shown in FIG. 25), and cutting upper section 55a of basket portion 55. A finishing or grinding step may be used to assure that upper edge 55b of basket portion 55 is not sharp. Alternatively, rail 454 can be joined to basket portion 55 so that free end of portion 454b is aligned with edge 55b. As a result, no additional cutting of basket portion is necessary. First portion 454a of the rail is operatively associated with runners 26a-g of frame 12 (see FIG. 1) during use.
(102) FIGS. 26-27 illustrate an alternative fifth example of upper rail 554 for use with basket portion 55 (shown in FIGS. 3 and 26). Upper rail 554 is similar to upper rail 454 except rail 554 is oriented differently when joined to basket portion 55. As shown in FIG. 27, when rail 554 is joined to basket portion 55, first portion 554a is aligned with upper edge 55b and second portion 554b is coupled to basket portion 55. Rail 554 is joined to basket portion 55 as previously discussed with respect to rail 454. Rail portion 554a is operatively associated with runners 26a-g of frame 12 (see FIG. 1) during use.
(103) FIGS. 28-29 illustrate an alternative sixth example of upper rail 654 for use with basket portion 55 (shown in FIGS. 3 and 28). Upper rail 654 is similar to upper rail 454 except as noted below. Rail 654 includes first portion 654a angularly offset from second portion 654b which is offset from third portion 654c to form recess 654d between second and third portions 654b, 654c. In the present example (as shown in FIG. 29), rail thickness t.sub.R of second portion 654b is less than mesh thickness t.sub.M of basket portion 55 so that upper edge 55b of basket portion 55 is not fully received within recess 654d and must therefore be ground to ensure edge 55b is smooth. Alternatively, the offset between second and third portions 654b, 654c can be increased so that edge 55b is fully received within recess 654d. In yet another alternative, rail 754 (see FIGS. 30-31) can be configured similar to rail 654, except rail thickness t.sub.R of second portion 754b is greater than mesh thickness t.sub.M of basket portion 55 so that upper edge 55b of basket portion 55 is fully received within recess 754b and thus does not require grinding.
(104) Rails 654, 754 are joined to basket portions 55 as previously discussed with respect to rail 454. Rail portions 654a, 754a are operatively associated with runners 26a-g of frame 12 (see FIG. 1) during use.
(105) FIGS. 32-33 illustrate an alternative eighth example of upper rail 854 for use with basket portion 55 (shown also in FIG. 3). Rail 854 is similar to rail 454 shown in FIG. 24, except second portion 854b of rail 854 is connected to curved section 854c, which is connected to extension 854d. Curved portion 854e of rail 854 is formed by second portion 854b, curved section 854c and extension 854.sub.d and also defines opening 854f. Rail 854 is bent so that curved portion 854e has a generally open V-shape (as shown in FIG. 32).
(106) Upper edge 55b of basket portion 55 is inserted into opening 854f so that when rail 854 is compressed by a conventional press machine, as shown in FIG. 33, second portion 854b and extension 854d are adjacent to outer and inner surfaces, respectively, of basket portion 55. Compression also minimizes opening 854f (as shown in FIG. 33) and causes curved section 854c to tightly engage basket portion 55. Additionally, after compression extension 854d is generally vertically-extending and second portion 854b and extension 854d are welded to the outer and inner surfaces, respectively, of basket portion 55 using a spot-welding machine and fixture similar to the method used for rail 54 (shown in FIGS. 8 and 9).
(107) Once upper rail 854 is joined to basket portion 55 in this manner, it provides additional structural rigidity to the basket portion 55. Using rail 854 eliminates the need to cut upper section 55a of basket portion 55 as when using rail 54, as shown in FIGS. 8 and 9. Consequently, rail 854 eliminates the need to deburr basket portion 55.
(108) FIGS. 34-37 illustrate an alternative ninth example of upper rail 954 for use with basket portion 955. Basket portion 955 terminates in an upper free edge or end 955b. Upper rail 954 is similar to upper rail 454 (shown in FIGS. 24-25), except vertical second portion 954b of rail 954 includes an outwardly extending or projecting connection portion or rib 954c. Rail 954 terminates at one end in a lower free edge or end 954d and at the other end a free edge or end 954e that is also the terminus of horizontal portion 954a. Horizontal portion 954a extends over and is in substantial contact with upper end 955b of basket portion 955. Vertical portion 954b and horizontal portion 954a intersect at junction 954f. This intersection of vertical portion 954b and horizontal portion 954a forms an approximate right angle. The location of rib 954c along vertical portion 954b can be varied. As shown in FIG. 37, when rail 954 is joined to basket portion 955, horizontal first portion 954a covers upper edge 955b (shown in FIG. 34) and second portion 954b and rib 954c contact basket portion 955. After joining rail 954 to basket portion 955, the use of electric welding could allow rib 954c and basket portion 955 contacting rib 954c to be fused into an integral structure (as shown in FIG. 37). This is due to the heat collection and pressure of resistors used during welding.
(109) Rail 954 adds structural rigidity to basket portion 955 and eliminates the need to cut and deburr basket portion 955. Rail portion 954a is operatively associated with runners 26a-g of frame 12 (see FIG. 1) during use.
(110) FIGS. 38-39 illustrate an alternative tenth example of upper rail 1054 for use with basket portion 955. Upper rail 1054 is similar to upper rail 954 (shown in FIGS. 36-37), except rib 954c has been replaced with outwardly extending or projecting connection portion 1054c at the free end of vertical second portion 1054b. When rail 1054 is joined to basket portion 955, horizontal first portion 1054a covers upper edge 955b (shown in FIG. 34) and second portion 1054b and connection portion 1054c contact basket portion 955. After joining rail 1054 to basket portion 955, the use of electric welding could allow connection portion 1054c and basket portion 955 contacting connection portion 1054c to be fused into an integral structure (as shown in FIG. 39).
(111) FIGS. 40-43 illustrate an alternative example of basket portion 1155 with upper rail 954 and lower rail 1154. Basket portion 1155 is formed by four sidewalls 1155a of mesh and one bottom wall 1155b of mesh. Sidewalls 1155a are preferably joined by conventional methods such as welding. Bottom wall 1155b can be joined to sidewalls 1155a by welding and/or by rail 1154. Upper rail 955 previously described with reference to FIGS. 36-37 is joined to basket portion 1155 as previously discussed.
(112) Lower rail 1154 includes horizontal first portion 1154a and vertical second portion 1154b. Horizontal first portion 1154a includes inwardly projecting connection portion or rib 1154c. Vertical second portion 1154b includes inwardly projecting connection portion or rib 1154d. When rail 1154 is joined to basket portion 1155, first portion 1154a and rib 1155c contact bottom wall 1155b and second portion 1154b and rib 1155d contact sidewalls 1155a. After joining rail 1154 to basket portion 1155, the use of electric welding (using heat collection and pressure) could allow the ribs 1154c,d and basket portion 1155 contacting ribs 1154c,d to be fused into an integral structure shown in FIG. 43).
(113) FIGS. 44-45 illustrate basket portion 1155 with upper rail 1054 and alternative lower rail 1254. Basket portion 1155 is previously described with reference to FIGS. 40-41. Upper rail 1054 previously described with reference to FIGS. 38-39 is joined to basket portion 1155 as previously discussed.
(114) Lower rail 1254 is similar to lower rail 1154 (shown in FIGS. 42-43), except ribs 1154c,d have been replaced with inwardly extending or projecting connection portions 1254c,d at the free end of first and second portions 1254a,b, respectively. When rail 1254 is joined to basket portion 1155, first portion 1254a and rib 1254c contact bottom wall. 1155b and second portion 1254b and rib 1254d contact sidewalls 1155a. After joining rail 1254 to basket portion 1155, the use of electric welding (using heat collection and pressure) could allow connection portions 1254c,d and basket portion 1155 contacting the connection portions 1254c,d to be fused into art integral structure (as shown in FIG. 45).
(115) Rails 354, 454, 554, 654, 754, 854, 954, 1054, 1154 and 1254 are generally rectangular rings that are continuous about their respective basket portions. These rails are formed of materials similar to those discussed with respect to rails 54 and 54′.
(116) Those skilled in the a appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing other products for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention as defined in the appended claims. Therefore, this invention is not to be limited to the specific examples depicted therein. For example, the features of one example disclosed above can be used with the features of another example. Furthermore, the various rail examples 54, 54′, 354, 454, 554, 654, 754, 854, 954, 1054, 1154 and 1254 can be used exclusively in different systems of drawers to provide systems that cost different amounts, e.g., a high-priced system and a lower priced system. Alternatively, one system can have drawers with various types of rails 54, 54′, 354, 454, 554, 654, 754, 854, 954, 1054, 1154 and 1254. Additionally, a system can use all closed-corner drawers or combine closed-corner drawers with open-corner drawers in one system. The system may be used with sliding drawers and/or stationary and sliding shelves each supported by a pair of runners. The system frame may also include a section for holding hanging file folders and one or more of the inventive drawers. The drawers of the present invention may be used without a frame. In yet another alternative example, the containers/drawers of the present invention may be retained within a frame formed of wood, plastic, metal, or material with a wood finish, where the frame has components such as runners and rollers thereon. The frame would cooperate with a stationary holder with runners and rollers thereon so that the container does not move with respect to the holder, but when the holder moves between an extended and retracted position by moving with respect to the stationary component, the container likewise moves. In such an example, the runner portion serves to connect the container to the holder without a sliding engagement therebetween. In addition, the container can be formed without upper rail 54 (see FIG. 3) by forming the runner portion in another way, such as by folding the upper edge of the basket portion upon itself to form a sufficiently-rigid integral runner portion. Alternatively, the runner portion need not extend around the entire basket and may extend only on the sides to work with the runners 26a-g (see FIG. 1). In such an example, the end walls without the runner portions may have upper edges finished with portions of metal, wood, plastic or some other suitable material. Exemplary rails shown and described above with one basket construction can be used with basket constructions shown in other examples or with conventional basket constructions. For example, the exemplary rails shown and described above can be used with baskets that include sidewalls formed from a single loop of mesh material joined to a separate piece of bottom wall mesh material. Thus, the details of the present invention as set forth in the above-described examples should not limit the scope of the present invention.
(117) Further, the purpose of the Abstract is to enable the U.S. Patent and Trademark Office, and the public generally, and especially the designers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of the application, which is measured solely by the claims, nor is intended to be limiting as to the scope of the invention in any way.
