BACKGROUND OF THE INVENTION
Field of The Invention
[0001] The present invention relates to containers, a system using such containers, and
a method of making such containers. More particularly, the present invention relates
to drawers made of mesh material.
Description of Related Art
[0002] Forming containers out of sheet metal is well known. United States Patent No. 903,848
to Donnelly and 1,107,014 to Avery disclose such containers. In order to make these
containers, a single blank of flat material is cut out and folded with overlapping
sections. Sheet metal does not provide desirable characteristics such as drainage
and ventilation.
[0003] In an effort to make a well-ventilated container, United States Patent No. 645,344
to White discloses a container formed of perforated sheet metal, wire-netting or another
open-work material. The White container is intended to have a folded state and a flat
state. This container is designed to be readily knocked down from its folded state
to its flat state and to be easily constructed without tools.
[0004] Other patents attempt to make lightweight, drainable and/or ventilated containers.
United States Patent No. 1,994,553 to Wolcott discloses one such container of finely
woven wire screening. United States Patent No. 2,825,481 to Glenny discloses another
such container of finely woven wire screening. In order to make the White, Wolcott
and Glenny containers, a single blank of flat woven wire is cut out and folded with
overlapping sections.
[0005] Another wire container that is commercially available under the brand name Elfa®
is formed of a wire grid with a plurality of separately formed wires welded together.
The Elfa® container includes a basket portion and a flat rail around the top edge
of the basket portion. The Elfa® baskets are designed for use in a frame having a
plurality of pairs of runners. When the baskets are inserted in the frame, the flat
rail is supported by a pair of runners and is movable between retracted and extended
positions. The wire grid used for the Elfa® basket has large holes measuring about
1 inch by 1 inch. The Elfa® basket also has openings at its corners. If a user desires
to store small objects in these baskets, a plastic liner can be used. The liner has
a bottom wall and upwardly bendable sidewalls, with slits between the sidewalls to
allow for such bending. The open corners of the basket and the slits between the sidewalls
of the liner may allow small objects to fall out of the basket, which is undesirable.
[0006] Mesh material is typically formed by perforating or slitting a piece of sheet metal
and stretching it. A sheet of mesh material requires less raw sheet metal than a non-mesh
piece of sheet metal and a perforated piece of sheet metal. United States Patent No.
1,408,026 to Ochiltree discloses a desk tray or basket formed of "expanded metal"
or mesh material. Similar to the previous containers, the Ochiltree container is formed
by a single blank of flat material that is cut out and folded.
[0007] ROC (Taiwan) Patent Application No. 086202709 to Chih-Ming, Ko (in transliteration),
filed February 21, 1997, discloses a system of containers supported by a frame. The
containers are formed of a single piece of mesh with a rim connected thereto. Additionally,
the containers do not move with respect to the frame so that the contents of the lower
container are not easily accessible.
[0008] A number of mesh containers are made by Design Ideas, Ltd. One of these containers
is the "Mesh Storage Nest." This container is formed using a first piece of mesh that
has the ends welded together to form a loop. A second piece of mesh is welded to the
lower edge of the loop so that the first piece of mesh forms sidewalls and the second
piece of mesh forms a bottom wall. The seam at the bottom of the container is covered
by a bottom rail. A top rail is connected to the upper edge of the container. The
sidewalls can be shaped to include a plurality of corners.
[0009] A need exists for a lightweight container that can be incorporated into a system
for storing objects. It is also desirable that the contents of such a container be
made easily accessible and be prevented from accidentally falling through holes in
the container. Furthermore, it is desirable that the container be formed by an economical
method in unlimited sizes. The present invention was developed with the above-noted
general objects in mind.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a container or drawer comprising first and second
pieces of mesh material. The first piece of mesh forms a bottom wall and two spaced
apart first and second sidewalls that extend upwardly from the bottom wall. The second
piece of mesh material is formed separate from the first piece of mesh material. The
second piece of mesh material includes third and fourth sidewalls. The second piece
of mesh material is joined to the first piece of mesh material to form a basket portion.
The basket portion may further include a runner portion that may be a rail separately
formed from the basket portion.
[0011] In one embodiment, the basket portion includes open corners between the sidewalls.
In another embodiment, the third and fourth sidewalls include extensions for overlapping
the first and second sidewalls so that closed corners are formed between the sidewalls.
In such an embodiment, the corners may be curved.
[0012] Preferably, one drawer and more preferably, a plurality of drawers are useful with
a frame in a storage system. Each drawer is moveable with respect to the frame between
retracted and extended positions. In such an embodiment, the frame may further include
a pair of runners with a gap therein for slidably receiving the runner portion of
each drawer.
[0013] The present invention is also directed to a container comprising first, second, and
third pieces of mesh material. The first piece of mesh forms a bottom wall and first
and second spaced apart sidewalls that extend upwardly from the bottom wall. The second
piece of mesh material is formed separate from the first piece of mesh material. The
third piece of mesh material is formed separate from the first and second pieces of
mesh material. The second and third pieces of mesh material are joined to the bottom
wall by a pair of bottom seams. Additionally, the second and third pieces of mesh
material are joined to the end walls by a plurality of generally vertically extending
side seams that all combine to form a basket portion.
[0014] The basket portion may further include runner portion. In such an embodiment, the
runner portion may be a rail that may be separately formed from the basket portion.
[0015] In one embodiment, the rail is preferably a flat piece of material and can include
a curved portion. In the latter rail embodiment, the curved portion defines an opening
in an uncompressed state for receiving the upper section of the basket portion, and
in a compressed state the opening is minimized.
[0016] The present invention is also directed to a method for forming a container comprising
the steps of: forming a first piece of mesh material; bending the first piece of mesh
material into a bottom wall and first and second spaced apart sidewalls extending
upwardly from the bottom wall; forming at least one second piece of mesh material
separate from the first piece of mesh material including forming the second piece
of material to include third and fourth sidewalls; and connecting the first piece
of mesh material to the second piece of mesh material to form a basket portion with
an upwardly-extending opening.
[0017] The method can include the step of forming second and third separate pieces of mesh
that will form the third and fourth sidewalls.
[0018] According to one aspect of the inventive method, the connecting steps may be performed
by welding.
[0019] The method may further include the step of forming a runner portion on the top of
the basket portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] 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:
FIG. 1 is front, perspective view of a first preferred embodiment of a system of drawers
of the present invention, where the drawers are in a retracted position;
FIG. 2A is an enlarged, perspective view of an L-connector for use with the system
of FIG. 1;
FIG. 2B is an enlarged, end view of the L-connector shown in FIG. 2A;
FIG. 2C is an enlarged, perspective view of a T-connector for use with the system
of FIG. 1;
FIG. 2D is an enlarged, end view of the T-connector shown in FIG. 2C;
FIG. 3 is an enlarged, rear, perspective view of a first preferred embodiment of a
drawer shown in FIG. 1;
FIG. 3A is an enlarged, perspective view of a portion of the drawer shown in FIG.
3;
FIG. 4 is an exploded, rear, perspective view of the drawer shown in FIG. 3;
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;
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;
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;
FIG. 7 is a schematic representation of some of the mesh pieces of FIG. 5 and another
portion of the welding machine of FIG. 6;
FIG. 8 is a partial, elevational view of a first embodiment 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;
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;
FIG. 10 is a partial, elevational view of a second embodiment of an upper rail separated
from a mesh piece;
FIG. 11 is a partial, elevational view of the upper rail joined to the mesh piece
of FIG. 10;
FIG. 12 is an exploded, rear, perspective view of a second embodiment of a basket
using the upper rail and mesh piece shown in FIGS. 10 and 11;
FIG. 13 is an exploded, rear, perspective view of a third embodiment of a drawer for
use in the system of FIG. 1, wherein an alternative embodiment of two side pieces
of mesh material are used;
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;
FIG. 15 is an enlarged, rear, perspective view of a fourth embodiment of a drawer
useful in the system of FIG. 1;
FIG. 16 is an exploded, rear, perspective view of the drawer shown in FIG. 15;
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; and
FIG. 18 is front, perspective view of a second preferred embodiment of a system of
drawers of the present invention, where the drawers are shown in a retracted position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 1, a preferred, first embodiment of a 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, the 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.
[0022] The drawer system 10 includes a frame 12 and a plurality of containers or drawers
14a-d. The drawer 14a is smaller than the drawers 14b-c so drawer 14a can hold a smaller
volume than the other drawers 14b-d. The drawers 14a-d are movable with respect to
the frame 12 between a retracted position (shown in FIG. 1) and an extended position.
In the retracted position, the contents of the 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.
[0023] With reference to FIG. 1, frame 12 includes two side frame members or ladders 16
that are spaced apart and joined by pairs of upper and lower cross members 18a,b,
respectively. The side frame members 16 and the pairs of upper and lower cross members
18a,b are formed to give the frame 12 a rectangular shape. The present invention is
not limited to this frame shape.
[0024] The frame 12 further includes L-connectors 20 (as best seen in FIG. 2A) and T-connectors
22 (as best seen in FIG. 2B) for joining the side frame members 16 to the cross frame
members 18a,b. Preferably, L- connectors 20 connect upper cross member 18a to the
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 the frame 12 shown in FIG.
1, T-connectors 22 are used to join upper cross members 18a to frame members 16. Preferably,
T-connectors 22 also connect lower cross members 18b to the side frame members 16.
Alternatively, the T-connectors 22 joined to the lower cross members 18b can be replaced
with plugs with casters (not shown) thereon to make the system 10 movable, as is apparent
to those of ordinary skill in the art.
[0025] Referring again to FIG. 1, each side frame member 16 includes a pair of spaced apart
vertical rods 24 coupled by vertically spaced apart horizontally-extending runners
26a-g. Each side frame member 16 is formed so that the runners 26a-g of each side
frame member 16 are aligned with the runners 26a-g of the other side frame member
16 to form a plurality of pairs of runners. Each runner 26a-g is a generally U-shaped
member with an inwardly extending gap 28 defined therein. The runners 26a-g may include
a bore (not shown) in the rear end for receiving a pin (not shown) for preventing
rearward movement of the drawers 14a-d out of the frame 12. To make the frame 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.
[0026] The frame 12 is preferably formed of any metal with sufficient rigidity and formability,
for example mild sheet steel, stainless steel, aluminum, copper or the like can be
used. The vertical rods 24 and the runners 26a-g are preferably welded together using
conventional welding techniques. The frame 12 may be subjected to a powder painting
treatment, similar to that discussed below for the drawers 14a-d.
[0027] Referring to FIGS. 1, 2A and 2B, the L-connector 20 includes a central body 30 and
first and second generally perpendicular legs 32 and 34 extending therefrom. Preferably,
the pairs of cross members 18a,b and vertical rods 24 are hollow so that the legs
32 and 34 are received therein to join these components together. Referring to FIGS.
1, 2C and 2D, the T-connector 22 includes a 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. Third
and second legs 40 and 42 are also generally perpendicular to one another. Preferably,
the first leg 38 and the third leg 42 may be inserted into the hollow vertical rods
24, and the second leg 40 is inserted in the hollow associated cross members 18a,b.
[0028] The L-connectors 20 and T-connectors 22 are preferably formed of any metal with sufficient
rigidity and formability. For example, the 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. These connectors 20 and 22, however, can also be formed of another material
like injection molded plastic.
[0029] Now, with reference to FIGS. 1, 3, and 3A, the details of the drawer 14b will be
discussed. The drawer 14b includes a runner portion that comprises upper rail 54 and
a basket portion 55. The basket portion 55 is coupled to the upper rail 54. In the
present embodiment, the basket portion 55 is formed of expanded metal plate (
i.e., sheet metal) or "mesh" and has small openings 55a 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. Preferably, the openings 55a (see
FIG. 3) in the mesh have an area less than 25.4 mm by 25.4 mm, more preferably less
than 20 mm by 10 mm, and most preferably, less than 6 mm by 3 mm.
[0030] The basket portion 55, preferably, is formed of any metal such as copper, steel,
stainless steel or aluminum, and the like. The basket portion 55 includes a bottom
wall 56, a pair of spaced apart sidewalls 58 and 60, and another pair of sidewalls
62. Preferably, the sidewalls 58, 60 and 62 are joined together to form closed curved
corners 64. The sidewalls 58, 60 and 62 extend upwardly from the bottom wall 56 to
form an upwardly-facing opening 66..
[0031] As shown in FIG. 3, the 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.
[0032] In this embodiment, the sidewall 58 forms a front end wall that includes a curved
cutout 68 bordered by a handle rail 70. The cutout 68 forms a place where a user can
easily grasp the drawer 14b to move it between the retracted and extended positions.
In an alternative embodiment, the cutout 68 can be replaced with other methods to
aid the user in moving the drawer 14b, such as a protruding handle connected to wall
58. The handle rail 70 may have a circular cross-sectional shape and be cut and formed
to extend along the edge of cutout 68. Preferably, the rail 70 is of the same material
as upper rail 54 and is spot-welded to the basket portion 55. In this embodiment,
the sidewall 60 forms a rear end wall.
[0033] Referring to FIG. 4, the drawer 14b is shown in a disassembled state. The basket
portion 55 is formed by a first piece of mesh 72, a second piece of mesh 74 and a
third piece of mesh 76. The first, second, and third pieces of mesh are formed separately
from one another. The 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 sidewalls 62. The angle between the
bottom wall 56 and sidewalls 62 is greater than about 90°, but the present invention
is not limited to this configuration.
[0034] The second piece of mesh 74 includes an outer edge 74a, an inner edge 74b, a central
portion 74c, side extensions 74d, and a lower extension 74e. The central portion 74c
is between the outer edge 74a and the lower extension 74e and between the side extensions
74d. The side extensions 74d have a trapezoidal shape so that they taper downward
from the outer edge 74a to the lower edge 74b. The 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 an upper edge 76a, a lower
edge 76b, a central portion 76c, side extensions 76d, and a lower extension 76e.
[0035] In an alternative embodiment, the pieces of mesh 74 and 76 can be formed of a single
piece of material separate from the 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, the bottom wall of
basket 55 would be formed of two layers of mesh material that overlap.
[0036] Referring to FIG. 5A, the 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 the first piece of mesh 72 overlaps with lower extension
74e of the second and third pieces of mesh 74 and 76 (see FIG. 4). When the 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 the 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.
[0037] The method of making drawer 14b will now be discussed. Referring to FIGS. 4 and 5,
the first piece of mesh 72 is formed shaped as shown. This involves cutting a piece
of mesh 72 with the desired dimensions from a roll of mesh using a conventional press
machine. Then, the first piece of mesh 72 is bent into a U-shape that includes the
bottom wall 56 and end walls 62 (as shown in FIG. 5). A conventional hydraulic press
machine is used to bend the 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.
[0038] The second and third pieces of mesh 74 and 76 are formed and shaped as shown in FIG.
4. This involves cutting the pieces of mesh 74 and 76 with the desired dimensions
and shape from a roll of mesh using a conventional press machine. Then, the 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. The third piece of mesh 76 is bent similarly to second piece 74 (as shown
in FIG. 5). The handle rail 70 may be welded to mesh piece 74 at this point or later,
when the upper rail 54 is joined to basket portion 55.
[0039] After the drawer 14b is completely formed, optionally but preferably a process of
powder painting may be used to coat the drawer 14b, as is known by those of ordinary
skill in the art. One preferable paint is an epoxy coat. The painting may provide
a decorative (colored and/or metallic) finish to the drawer 14b, if desired, and will
also provide some protection for the drawer 14b from water and other corrosive elements.
[0040] Next, the lower extensions 74e,76e of each piece 74,76 are connected by welding to
the side edge of the bottom wall 56 of first piece 72 (as shown in FIG. 5A) to form
seams 78. Then, the 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).
[0041] Referring to FIGS. 5, 6, and 7, the equipment used to connect the first, second and
third pieces of mesh 72, 74, and 76 together will now be discussed. The equipment
preferably comprises a spot-welding machine 84 including a base 86, a clamp 88 supported
on the base 86, a movable elongated member 90 movable by the clamp 88 to provide a
clamping force F, and a pair of anode electrodes 92a and a pair of cathode electrodes
92b. The base 86, clamp 88, member 90, and cathode electrodes 92b form a fixture for
supporting the mesh pieces 72, 74, and 76 during welding. As shown, preferably, the
cathode electrodes 92b are preferably bar-like and parallel to one another to properly
support and clamp mesh pieces 72, 74, and 76. In an alternative embodiment, the spot-welder
can be used without the clamp 88 and elongated member 90, where the pieces may be
manually held during welding.
[0042] In order to join lower extension 74e of second piece 74 to bottom wall 56 of first
piece 72, the already-bent first piece 72 is disposed on cathode electrodes 92b so
that the 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, the clamp 88 is actuated so that the clamping force F moves the member
90 from a retracted position (shown in FIG. 6) into a clamping position (shown in
FIG. 7). In the clamping position, the mesh piece 74 is compressed between member
90 and cathode electrode 92b. The clamping force F must be sufficient to hold mesh
piece 74 into contact with mesh piece 72 for the welding operation.
[0043] Then, the anode electrode 92a moves in direction D1 into contact with pieces 72,74
adjacent extension 74e. These pieces 72,74 are tightly compressed between the electrodes
92a and 92b. The electrodes 92a,b then discharge electric welding current through
the place to be welded and seam 78 (see FIG. 5A) is formed. The third piece 76, as
shown in FIG. 5, is similarly joined to first piece 72. Preferably, the 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, the second and third pieces 74
and 76 can preferably be simultaneously welded to first piece 72.
[0044] 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.
[0045] With reference to FIG. 3, the upper rail 54 is subsequently connected to the upper
section of the end walls 58 and 60 and sidewalls 62 by spot-welding. Referring to
FIGS. 3 and 8-9, the step of connecting the upper rail 54 to the basket portion 55
further preferably includes the steps of forming a generally flat upper rail 54; contacting
rail 54 to basket portion 55 on a contact surface 54a so that an upper section 55a
of the basket portion 55 extends above the rail 54; and spot-welding the contact surface
54a to the outer surface of basket portion 55.
[0046] The upper rail 54 is preferably formed of the same material as the basket portion
55 so that these components can be welded together. Thus, preferably, the rail 54
is formed of any metal such as copper, steel, stainless steel, mild sheet steel or
aluminum, and the like. In a preferred embodiment 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.
[0047] 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 the upper rail 54.
[0048] The rail 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. The rail can
also be solid with various shapes, such as a circular cross-section. The rail can
also be formed of a plastic that is connected to the basket portion 55 by glue or
adhesive, for example.
[0049] Referring to FIGS. 8 and 9, the step of contacting rail 54 to basket portion 55 on
a contact surface 54a may preferably further include the step of using a spot-welding
machine with a fixture F for supporting the rail 54 at a sufficient elevation above
a table (not shown) so that the upper section 55a of the basket portion 55 extends
above the rail 54. The fixture F may also provide a clamping force for assuring the
surface 54a is in solid contact with the basket portion 55 or this force may be provided
by movable anode and cathode electrodes AE and CE, respectively. Preferably, electrodes
AE and CE are circular welding wheels. The anode electrode AE contacts the outer surface
of the rail 54 and the cathode electrode CE contacts the inner surface of the basket
portion 55 adjacent surface 54a, as shown in FIG. 9. An electric current is discharged
through the electrodes AE and CE, rail 54 and basket portion 55 to spot-weld the rail
54 to the basket portion 55. Preferably, sufficient electrodes AE and CE are provided
to make the welding of rail 54 to basket portion 55 efficient. Since the electrodes
AE and CE are movable vertically in directions V and horizontally in directions H,
the spot-welder can be used to weld variously size rails and baskets together.
[0050] The step of connecting the upper rail 54 may further include cutting and grinding
steps. In the cutting step, the 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, the exposed upper edge 55b (FIG. 9) of basket portion
55 is worked using a conventional grinding machine so that a smooth upper edge 55b
is formed. The rail 54 aids in providing structural rigidity to the basket portion
55 and is the only rail circumscribing each drawer's perimeter.
[0051] Referring to FIGS. 1 and 3, in use the drawer 14b is inserted into the system 10
by disposing upper rail 54 within gap 28 of opposed, aligned pair of runners 26b.
The rail 54 and gap 28 are sized to allow free sliding movement of the drawer 14b
with respect to the frame 12 between the retracted and extended positions.
[0052] Since the drawer 14b is formed of mesh with very small openings 55a (see FIG. 3),
small objects, such as pens, paper clips, and the like, can be stored in the drawer
without a liner and will not fall through the openings 55a. In addition, since the
drawer 14b has closed corners 64, small objects also cannot fall out of this area
of the drawer.
[0053] 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 the first piece
of mesh 72 and the height H of the 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 a 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. The 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.
[0054] FIGS. 10-12 illustrate an alternative embodiment of the upper rail 54' for use with
an alternative embodiment of basket portion 55'. To form the upper rail 54' raw material
is bent to include a curved portion 54a' with an opening 54b' and an extension 54c'
angularly offset from curved portion 54a' using a roll forming machine. The material
is bent into a closed rectangular loop and welded together, similar to rail 54.
[0055] The basket portion 55' is formed similarly to basket portion 55 except the end walls
58, 60 and sidewalls 62 all have an outwardly bent upper section 55a' 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).
[0056] The bent upper section 55a' is inserted into the opening 54b' of the upper rail 54'
(as shown in FIG. 11). The curved portion 54a' is then compressed by a conventional
press machine so that the opening 54b' is minimized and curved portion 54a' tightly
engages the basket portion 55a'. This step also results in the front curved tip 54d'
of the rail 54' engaging the angled corner 55b' of the basket portion 55'. Then, the
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). Once
the upper rail 54' is joined to basket portion 55' in this manner, it provides additional
structural rigidity to the basket portion 55'. Using the rail 54' eliminates the need
to cut the 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 the basket
portion 55'.
[0057] Referring back to FIG. 1, basket 14a includes a rectangular cutout 68' on the front
of wall 58'. A metal handle rail 70' covers the free end of the mesh within the cutout
68'. The handle rail 70' is preferably formed similar to rail 54' with an opening
that is compressed about the mesh, once the mesh is inserted therein. Preferably,
the handle rail 70' also includes an extension, similar to extension 54c' of rail
54', that can be spot-welded to securely attach the rail 70' to the mesh. In such
an embodiment, the opening in the rail 70' extends vertically along with the extension.
In an embodiment of the handle rail 70' without such an extension, the rail 70' may
still be spot-welded to the mesh.
[0058] Referring to FIGS. 13-14, a third preferred drawer embodiment 114b is shown. Drawer
114b comprises a runner portion or upper rail 154 and a basket portion 155. The upper
rail 154 may be formed like rail 54 or rail 54' previously discussed. The basket portion
155 includes a bottom wall 156, end walls 158 and 160, and sidewalls 162. The bottom
and end walls 156 and 158 are also sidewalls. A first piece of mesh 172 is bent to
form the bottom wall 156 and end walls 158 and 160. The sidewalls 162 are formed of
separate second and third pieces of mesh 174 and 176, respectively. The end wall 158
includes a first piece of mesh 172 with a cutout 168 similar to end wall 58.
[0059] For drawer 114b, different from drawer 14b, the second piece of mesh 174 includes
a central portion 174c, rectangular side extensions 174d and a lower extension 174e.
The third piece of mesh 176 has a similar configuration. When the pieces 172, 174
and 176 are connected using a method similar to that used in forming drawer 14b, the
drawer 114b has closed smoothly curved corners similar to corners 64 (as shown in
FIG. 3), but the 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.
[0060] Referring to FIGS. 15-17, a fourth preferred drawer embodiment 214b is shown. Drawer
214b comprises a runner portion or upper rail 254 and a basket portion 255. The upper
rail 254 may be formed like rail 54 or rail 54' discussed above. The basket portion
255 includes a bottom wall 256, end walls 258 and 260, and sidewalls 262. The end
walls 258 and 260 are also sidewalls. A first piece of mesh 272 is bent to form the
bottom wall 256 and end walls 258 and 260. The sidewalls 262 are formed of separate
second and third pieces of mesh 274 and 276. The end wall 258 includes a cutout 268
similar to end wall 58.
[0061] In drawer 214b, different from drawers 14b and 114b, the second and third pieces
of mesh 274 and 276 do not include extensions. When the 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, the 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.
The drawer 214b is formed similarly to drawer 14b by bending and spot-welding the
mesh pieces.
[0062] Referring to FIG. 18, a second preferred embodiment of a drawer system 310 is shown.
Drawer system 310 includes a frame 312 and a plurality of drawers 314a and 314b. The
frame 312 includes four pairs of runners 326a-d. This embodiment illustrates that
any number of pairs of runners can be used depending on how large a system is desired.
The frame 312 is otherwise configured and formed similarly to frame 12 (shown in FIG.
1). The system 310 further may include a 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, the shelf 327 may be sized differently (larger or
smaller than) the frame 312 and connected to the 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.
[0063] Those skilled in the art will 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 specifically
preferred embodiments depicted therein. For example, the features of one embodiment
disclosed above can be used with the features of another embodiment. Furthermore,
the two different runner portions or upper rail embodiments 54 and 54' 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 both types of rails 54 and 54'. 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 embodiment, 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 embodiment, 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 embodiment, the
end walls without the runner portions may have upper edges finished with portions
of metal, wood, plastic or some other suitable material. Thus, the details of the
present invention as set forth in the above-described preferred embodiments should
not limit the scope of the present invention.
[0064] 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.
1. A container comprising:
a first piece of mesh material forming a bottom wall and first and second spaced apart
sidewalls extending upwardly from said bottom wall; and
a second piece of mesh material formed separate from said first piece of mesh material,
said second piece of mesh material including third and fourth sidewalls, said second
piece of mesh material being joined to said first piece of mesh material to form a
basket portion.
2. The container of claim 1, wherein said basket portion includes open corners between
said first and second sidewalls and said third and fourth sidewalls.
3. The container of claim 1, wherein said third and fourth sidewalls each include extensions
for overlapping said first and second sidewalls and for forming closed corners between
said third and fourth sidewalls and said first and second sidewalls.
4. The container of claim 3, wherein said closed corners are curved.
5. The container of claim 1, wherein said basket portion further includes a runner portion
at the top thereof.
6. The container of claim 5, for use with a frame, said container being moveable with
respect to said frame between retracted and extended positions.
7. The container of claim 6, wherein said frame further includes a pair of runners each
having a gap therein for slidably receiving said runner portion.
8. The container of claim 5, wherein said runner portion is a rail separately formed
from said basket portion and welded thereto.
9. The container of claim 5, wherein said runner portion extends about the entire perimeter
of said basket portion.
10. A container comprising:
a first piece of mesh material forming a bottom wall and first and second spaced apart
sidewalls extending upwardly from said bottom wall;
a second piece of mesh material formed separate from said first piece of mesh material;
and
a third piece of mesh material formed separate from said first piece of mesh material;
said second and third pieces of mesh material being joined to said bottom wall to
form a pair of bottom seams and said second and third pieces of mesh material being
joined to said first and second sidewalls to form a plurality of generally vertically-extending
side seams, said first, second and third pieces of mesh material being joined to form
a basket portion.
11. The container of claim 10, wherein said basket portion further includes a runner portion.
12. The container of claim 11, wherein said basket portion further includes an upper section
bent to extend outwardly from the remainder of said basket portion, said runner portion
comprising a rail having a curved portion defining an opening for receiving said upper
section of said basket portion.
13. The container of claim 12, wherein said rail further includes a rail extension angularly
offset from said curved portion, said rail extension being welded to said basket portion
after said curved portion is compressed.
14. A method of forming a container comprising the following steps:
forming a first piece of mesh material;
bending said first piece of mesh material into a bottom wall and first and second
spaced apart sidewalls extending upwardly from said bottom wall;
forming a second piece of mesh material, separate from said first piece of mesh material,
to include third and fourth sidewalls; and
connecting said first piece of mesh material to said second piece of mesh material
to form a basket portion with an upwardly-extending opening.
15. The method of claim 14, furthering including the steps of forming a third piece of
mesh material separate from said first and second pieces of mesh material, wherein
said steps of forming said second and third pieces of mesh material include the steps
of forming each of said second and third pieces of mesh material with a central portion
and a pair of mesh extensions on both sides of said central portion and bending said
extensions to be angularly offset from said central portion.
16. The method of claim 15, furthering including the steps of overlapping said mesh extensions
with said first and second sidewalls and connecting said mesh extensions to said first
and second sidewalls.
17. The method of claim 14, wherein the step of connecting said first piece of mesh material
to said second piece of mesh material further includes the step of welding.
18. The method of claim 14, further including forming a runner portion on the top of said
basket portion.
19. The method of claim 18, wherein the step of forming said runner portion further includes
the step of forming a rail separate from said basket portion and connecting said rail
to said basket portion.
20. The method of claim 19, wherein the step of connecting said rail to said basket portion
further includes the step of welding.
21. The method of claim 16, wherein the step of connecting said mesh extensions to said
first and second sidewalls further includes the step of welding.
22. The method of claim 14, wherein the step of connecting said first piece of mesh material
to said second piece of mesh material further includes the step of using a fixture
to support said first and second pieces of mesh material, said fixture including an
electrode for supporting said first and second pieces of mesh material.