Storage system within a door
10352094 ยท 2019-07-16
Inventors
Cpc classification
International classification
Abstract
A storage system positioned within a door is presented. The storage system is generally comprised of a storage unit attached within a door assembly by a mounting system.
Claims
1. A storage system comprising: a door assembly comprising: a door comprising: a plurality of door frame members, each having a channel disposed longitudinally along one side; wherein each of the plurality of door frame members attaches to another of the plurality of door frame members such that the channels align to define an inner perimeter in the shape of a square or rectangle complementary in size and shape to a storage unit; and a mounting system for attaching a storage unit within the inner perimeter of the door; and the storage unit positioned orthogonally within the door comprising: two thermoformed hard plastic box-shaped components having identical dimensions with each of the box-shaped components having one open side with an outer flange positioned around an outer perimeter of the open side of each of the box-shaped components wherein the open sides of each of the box-shaped components are attached together at the outer flanges to form an outer shell of the storage unit; a front side, a back side, a first sidewall, a second sidewall, a top side and a bottom side of the outer shell of the storage unit defining a space forming a cavity therein; and at least one storage means contained within the cavity; wherein the front side of the storage unit comprising at least one access door to provide access to the cavity of the storage unit.
2. The storage system of claim 1, wherein the mounting system comprises the channels of the plurality of door frame members positioned around the inner perimeter of the door.
3. The storage unit of claim 2, wherein the outer flange of the storage unit is positioned within the channels of the mounting system to attach the storage unit to the inner perimeter of the door.
4. The storage system of claim 1, further comprising: a door casing wherein the door casing comprising: a door frame; a front molding attached to a front side of the door frame; and a back molding attached to a back side of the door frame; wherein the door casing surrounds an outer perimeter of the door.
5. The storage system of claim 1, wherein the storage means are selected from the group consisting of at least one shelf, at least one hanging rod, at least one hook, at least one rack, at least one drawer or a combination thereof.
6. The storage system of claim 1, further comprising at least one handle positioned on a front side of the at least one access door of the storage unit.
7. A storage system comprising: a door comprising: a plurality of door frame members, each having a channel disposed longitudinally along one side; wherein each of the plurality of door frame members attaches to another of the plurality of door frame members such that the channels align to define an inner perimeter in the shape of a square or rectangle complementary in size and shape to a storage unit; and the storage unit positioned orthogonally within the door comprising: two thermoformed hard plastic box-shaped components having identical dimensions with each of the box-shaped components having one open side with an outer flange positioned around an outer perimeter of the open side of each of the box-shaped components wherein the open sides of each of the box-shaped components are attached together at the outer flanges to form an outer shell of the storage unit; a front side, a back side, a first sidewall, a second sidewall, a top side and a bottom side of the outer shell of the storage unit defining a space forming a cavity therein; wherein the outer flanges are is inserted into the channels of the door frame members to mount the storage unit within the door; at least one storage means contained within the cavity; and at least one access door on the front side of the storage unit to provide access to the cavity of the storage unit.
8. The storage system of claim 7, wherein the storage means are selected from the group consisting of at least one shelf, at least one hanging rod, at least one hook, at least one rack, at least one drawer or a combination thereof.
9. The storage system of claim 7, further comprising at least one handle positioned on a front side of the at least one access door of the storage unit.
10. A storage system comprising: a door assembly comprising: a door comprising a plurality of door frame members attached together by a tab and slot system and having a hollow center which defines an inner perimeter; and a mounting system for attaching a storage unit within the inner perimeter of the door wherein the mounting system is a channel; and the storage unit formed from thermoformed plastic positioned orthogonally within the door comprising: two thermoformed hard plastic box-shaped components having identical dimensions with each of the box-shaped components having one open side with an outer flange positioned around an outer perimeter of the open side of each of the box-shaped components wherein the open sides of each of the box-shaped components are attached together at the outer flanges to form an outer shell of the storage unit; a front side, a back side, a first sidewall, a second sidewall, a top side and a bottom side of the outer shell of the storage unit defining a space forming a cavity therein; and at least one storage means contained within the cavity; wherein the front side of the storage unit comprising at least one access door to provide access to the cavity of the storage unit; wherein a handle is positioned on a front side of the at least one access door; wherein the door is hingedly connected to a door frame.
11. The storage system of claim 10, wherein the channel of the mounting system is disposed longitudinally along one side of each of the plurality of door frame members.
12. The storage system of claim 11, wherein each of the plurality of door frame members attaches to another of the plurality of door frame members such that the channels align to define an inner perimeter in the shape of a square or rectangle complementary in size and shape to the storage unit.
13. The storage system of claim 10, wherein the outer flange of the storage unit is inserted into the channel of the plurality of door frame members to mount the storage unit within the door.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
(25) In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that there are other embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized, and structural changes may be made without departing from the scope of the invention.
Definitions
(26) As used in the specification and claims, the singular form a, an and the include plural references unless the context clearly dictates otherwise.
(27) Storage unit as used herein refers to an enclosed space used for storing items. Storage unit can be formed from any hard, sturdy material including, but not limited to, plastics, wood, and metal. In some embodiments, the storage unit is formed from a thermoformed plastic which may be formed into one continuous outer shell or alternatively, may be in two separate components which can be joined together to form one continuous outer shell. If formed by two separate components, the pieces may be fixedly attached by any means known in the art and may have a flange positioned along the outer perimeter which would allow for positional attachment of the two pieces together to form one cohesive unit as well as provide a means for attachment of the storage unit to the inner perimeter of the door. In this embodiment, the flange would be capable of being inserted into a channel forming a mounting system within the perimeter of the door to attach the storage unit to the door. Edges of storage unit may be at a sharp right angle or alternatively may be rounded.
(28) Door assembly as used herein refers to a door in combination with a mounting system for mounting the storage unit within the door.
(29) Door casing as used herein refers to a system used to frame the outer perimeter of a door. In some embodiments, the door casing is only a door frame while in other embodiments, the door casing includes a door frame that is inserted within the opening in the wall for the door to frame the door once inserted as well as front and back moldings that are connected to the front and back of the door frame as well as the corresponding wall. Moldings are used to cover insertion of door frame into opening in the wall.
(30) Mounting system as used herein refers to any system used that may be used to securely attach storage unit to inner perimeter of door. In one embodiment, mounting system may comprise one or more channels positioned within inner perimeter of the door for attachment of storage unit to door. In this embodiment, door itself may be formed from 4, 3, 2 or 1 individual frame components having a channel positioned in the inner perimeter thereof wherein the channels are of sufficient size and shape to house at least one flange positioned around perimeter of storage unit to attach storage unit to door. If formed from two or more individualized frame components, the frame components can be slid onto the flange of the storage unit so that the frame components surround the storage unit and are assembled to resemble a standard door.
(31) In another embodiment, mounting system may comprise a track system as defined herein. In other embodiments, mounting system may include using attachment means such as screws, nails, glue, strong adhesive, slots, channels, tracks or any other means capable of attaching storage unit to inner perimeter of door.
(32) Frame components or frame members or door frame members as used herein refers to 1 or more elongated individual components connected together and positioned around the perimeter of the storage unit to frame the storage unit and give the assembled storage system the appearance of a storage unit positioned orthogonally within a door. Door itself may be formed from 1, 2, 3 or 4 frame components. In the case of 2 or more individual frame components being used, each frame component may have a tab protruding from one end which fits into a corresponding slot on the adjacent frame component to attach the components together to form door surrounding storage unit. Door frame members represent individual components that when assembled form the hollowed-out door into which the storage unit is mounted. Conversely, door frame is used to represent the border outlining the threshold of a doorway with the door being positioned within, and attached to, the door frame.
(33) Track system as used herein refers to a system for attaching the storage unit to the inner perimeter of the hollowed-out door using a series of tracks to align storage unit within inner perimeter and securely attach it to door. Track system is comprised of at least 2, preferably 4, tracks having at least 2, preferably 3, u-shaped flanges having a channel disposed therein with the first and second flanges being connected but being positioned in opposing orientation (and thus the channels being in opposing orientation) and the third flange being oriented orthogonally to the first and second flanges. In this embodiment, the inner perimeter of the door is inserted into the channel of the first flange and a connection bar attached to the exterior surface of the storage unit is inserted into the channel of the second flange. Attachment means can be inserted into the channel of the third flange which, when tightened, act to compress the sides of the first and second flanges to provide a tight connection between the first flange and the inner perimeter of the door and the second flange and the connection bar of the storage unit to securely connect the storage unit to the door. While an exemplary embodiment of the track system is described, other track system configurations are contemplated.
(34) Storage means as used herein refers to an apparatus upon/within which objects can be stored including, but not limited to, shelves, drawers, hooks, racks, and hanging rods.
(35) Skins as used herein refers to a decorative exterior surface of either the front or the back side of the storage unit. In some embodiments, the skins are permanently attached to the exterior surface while in other embodiments, the skins are inserted into a transparent cavity/pouch and can be interchangeable by the user.
(36) Hinge as used herein refers to a joint that attaches two things together, in this case attaching door of storage unit to storage unit or attaching door containing storage unit to door frame, while allowing for limited movement of 180 or less, preferably 90. Hinges used to attach door of storage unit to storage unit may differ from hinges used to attach door containing storage unit to door frame.
(37) Storage system 10 is generally comprised of a customizable storage unit 160 mounted within door 170 via insertion of flange 150 into channel 140. Storage system 10 can be customized to fit different door sizes. Additionally, the interior of storage unit 160 can contain customizable shelving, hooks, hanging rods, racks such as shoe racks, etc.
(38) As shown in
(39)
(40) As shown in
(41) Door 170 of storage unit 160 may be attached via hinge 180 allowing limited movement of door of 180 or less, preferably 90. Hinge 180 may be a European hinge or cup hinge which is positioned and totally concealed within the interior of storage unit 160, similar to that used to attach doors to kitchen or bathroom cabinets. In other embodiments, different hinges may be used including, but not limited to, butt hinges, surface mount inset hinges and knife hinges. While
(42) Shelves 190 may be fixed, adjustable or arranged in a combination of both fixed and adjustable. In some embodiments, shelves 190 may be attached to permanent dividers that are fixedly attached to the sides and back of storage unit 160 so that shelves 190 themselves may not be in direct contact with interior surface of storage unit 160.
(43)
(44) Channel 140 is disposed within inner perimeter of each frame member 172. Channel 140 is of sufficient size so as to accommodate flange 150 of storage unit 160 and serves to mount storage unit 160 to door 170 formed from frame members 172. Channel 140 of each frame member 172 aligns to receive flange 150 and form door 170 around storage unit 160.
(45) While 4 frame members 172 are depicted in
(46) In manufacturing this embodiment of storage system 10, storage unit 160 can be comprised of two identical halves of thermoformed plastic resembling a box with one open side. Each half would have an identical sized flange positioned around the outer perimeter of the open side so that the open sides of each half can be attached together at their respective flanges to form the storage unit having an interior cavity therein. Any means known in the art can be used to attach the flanges of the two halves together including, but not limited to, glue and adhesive. Once assembled, one of the surfaces of one half which is directly opposite the opposing surface of the other half is removed and may be used as the door to the storage unit. This surface may be kept as one piece or divided into two if two doors are desired for the storage unit. In some instances, due to the thin nature of the removed surface, a laminated MDF backing may be added to the back surface to add stiffness and bulk. The door to the storage unit may be attached to the storage unit via hinges. The door frame members are then attached to the flange of the storage unit as well as to each other to form the door around the storage unit. This completed storage system may then be attached to a door frame.
(47) In an alternative embodiment of storage system, storage system 15 is generally comprised of a customizable storage unit 70 mounted within door 30 via use of track system 40. Storage unit 70 can be customized to fit within different door sizes and existing doors can be retrofitted to accommodate storage unit 70. Additionally, the interior of storage unit 70 can contain customizable shelving, hooks, hanging rods, racks such as shoe racks, etc. The exterior of storage unit 70 can also be customized with various skins that, in some embodiments, can be interchangeable. In other embodiments, the exterior of storage unit may have an indented pattern of a decorative inlay allowing it to appear as a conventional door.
(48) In some embodiments, storage unit 70 may extend forward from front 32 of door 30 and/or rearward from back 34 of door 30. The amount that storage unit 70 extends either forward or rearward depends on the placement of mounting system on storage unit 70. Storage unit 70 may extend forward at an amount that is greater than the amount extended rearward and vice versa. Alternatively, storage unit 70 may extend an equal amount forward and rearward. In some embodiments, front side 75 and/or back side 76 of storage unit may lie coplanar with exterior surface of door 30.
(49)
(50) Track system 40 is comprised of four tracks positioned on inner perimeter 36 of door 30, with two longitudinal tracks 42 corresponding in size to opposing longitudinal sides of inner perimeter 36 of door 30, a top track 42 corresponding to horizontal top side of inner perimeter 36 of door 30, and a bottom track 42 corresponding to horizontal bottom side of inner perimeter 36 of door 30. As depicted in
(51) In an alternative embodiment, channel of first u-shaped flange 44 is fixedly attached to inner perimeter 36 of door 30. In this embodiment, tightening of attachment means 50, after insertion of connection bar 90 into channel of second u-shaped flange 46, compresses only channel of second u-shaped flange 46 to securely attach storage unit 70 to door 30.
(52)
(53) In an embodiment, exterior surfaces of top side 71, bottom side 72, and both first 73 and second 74 sidewalls may contain a plurality of apertures 79 arranged linearly along a longitudinal axis where the longitudinal axis corresponds to the orientation of inner perimeter 36 of door 30. Preferably, apertures 79 do not extend through to interior surface. Apertures 79 correspond with apertures 92 in connection bar 90 for attachment of connection bar 90 to storage unit 70 by attachment means 94. Attachment means 94 may include any means capable of fixedly attaching connection bars 90 to exterior surface of top side 71, bottom side 72, and both first 73 and second 74 sidewalls including, but not limited to, screws, nails, and adhesive means. If adhesive means are used, the plurality of apertures in the exterior surfaces of storage unit 70 and in connection bar 90 are not needed.
(54) Connection bars 90 are designed to fit the entire length of top side 71, bottom side 72, first sidewall 73 and second sidewall 74 along the longitudinal axis. Connection bars 90 can be positioned at any point along exterior surface of top side 71, bottom side 72, first sidewall 73 and second sidewall 74 to allow for customization as to the amount storage unit 70 extends from either front 32 or back 34 of door 30.
(55) In an embodiment, interior surface of both first 73 and second 74 sidewalls may contain a plurality of orifices 77 which may be arranged linearly along a longitudinal or horizontal axis as depicted in
(56) In an alternative embodiment, interior surface of cavity of storage unit 70 is smooth with permanent dividers affixed in a vertical orientation to the interior of cavity. The dividers can be affixed via any means known in the art including, but not limited to, adhesive, glue, and epoxy. Shelves 80 can then be inserted between the permanent dividers so that shelves 80 are not in contact with interior surface of the cavity of storage unit.
(57) In an embodiment, front side 75 may be comprised of at least one storage unit door hingedly connected to first 73 or second 74 sidewall and capable of opening outwardly. In some embodiments, two storage unit doors comprise front side 75 as shown in
(58) In some embodiments, back side 76 may be comprised of a solid wall as shown in
(59) Alternatively, in other embodiments, back side may be comprised of at least one storage unit door 78 hingedly connected to first 73 or second 74 sidewall and capable of opening outwardly. In some embodiments, two storage unit doors 78 comprise back side as shown in
(60)
(61)
(62)
(63)
(64) Door 30 may be manufactured of a variety of materials including, but not limited to wood and metal. In an embodiment, door 30 is comprised of 4 separate frame elements which are interconnected to form door 30. These frame elements are positioned around and attached to the outer perimeter of storage unit 70. The frame elements are connected to each other at the 4 corners and each frame element is connected to outer perimeter of storage unit 70. In an embodiment, inner perimeter of each frame element contains a channel or slot which comprises a second embodiment of a track system. Channel is configured to house a lip or flange positioned on outer perimeter of storage unit 70 to attach storage unit 70 to door 30.
(65) Similarly, storage unit 70 may also be manufactured of a variety of materials including, but not limited to wood, hard plastics including thermoformed plastics, metal, and manufactured wood. In some embodiments, front and/or back sides/doors of storage unit can be manufactured of a wood stile having adhesive onto which a fiberglass skin is adhered. In some embodiments, a layer of foam having adhesive is positioned between fiberglass skin and wood stile.
(66) Track 42 can be manufactured of a material which allows for compression of sides of channels of first 44 and second 46 u-shaped flanges including, but not limited to, semi-flexible metals and plastics.
(67) In some embodiments, exterior surfaces of front and back sides of storage unit may be customizable with various skins being available including, but not limited to, mirrored skins, various printed designs, solid colors, etc. In some embodiments, these skins are permanently adhered to exterior surface of front or back side while in other embodiments, at least one clear sleeve may be attached to exterior surface of front or back side of storage unit to create a cavity having a closed bottom and sides and an open top into which different skins can be inserted to allow for the skins to be changed by the user as often as they wish.
(68) In conclusion, the instant invention overcomes the deficiencies of the prior art and allows for a customizable storage unit housed within a door which creates additional storage space in a dwelling without sacrificing valuable floor and wall space. Customization of the storage unit makes the storage system an attractive alternative to conventional storage units which take up significant floor and/or wall space.
(69) In the preceding specification, all documents, acts, or information disclosed does not constitute an admission that the document, act, or information of any combination thereof was publicly available, known to the public, part of the general knowledge in the art, or was known to be relevant to solve any problem at the time of priority.
(70) The disclosures of all publications cited above are expressly incorporated herein by reference, each in its entirety, to the same extent as if each were incorporated by reference individually.
(71) It will thus be seen that the objects set forth above, and those made apparent from the foregoing disclosure, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing disclosure or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
(72) It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein disclosed, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween. Now that the invention has been described,