US20060066188A1

US20060066188A1 - Retractable storage system

Info

Publication number: US20060066188A1
Application number: US10/952,272
Authority: US
Inventors: John Crawford
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-28
Filing date: 2004-09-28
Publication date: 2006-03-30

Abstract

The system includes an enclosure provided upward through a hole provided in a ceiling. The enclosure includes a motor for lifting a set of shelves into the enclosure. The enclosure protects the set of shelves and its contents from moisture and heat, and prevents heat and moisture from escaping from one room to another, across the enclosure. The system is designed to allow installation of the entire system from the lower level, without requiring access to the upper level.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates in general to retractable storage systems and, more particularly, to storage systems which retract into a ceiling.
2. Description of the Prior Art
It is well known in the art to provide retractable storage systems. One such system is shown in U.S. Pat. No. 5,758,782 to Rupert. The system shows a movable storage organizer which may be provided in a closet or the like to utilize space above hanging clothes or the like. One drawback associated with such devices, however, is that they prevent full utilization of the area positioned below the movable storage organizer. Unless the ceilings are extraordinarily high or the movable storage organizer extraordinarily small, the space below the movable storage organizer would be too small for a person to walk below.
Additionally, Rupert teaches the utilization of a parallel linkage system to extend the movable storage organizer outward and downward when access is desired. Another drawback associated with such movable storage organizers is that they require unobstructed space both laterally and downwardly of the mobile storage organizer. Rupert also teaches the utilization of an over center parallel linkage to maintain the movable storage organizer in place when not in use. Yet another drawback of such systems is that they require additional unobstructed space above the movable storage organizer which cannot be utilized. It would, therefore, be desirable to provide a retractable storage system which did not require unobstructed lateral space, and which allowed a user to fully utilize the space below the storage system when the storage system is in the storage orientation.
Another retractable, overhead device is shown in U.S. Pat. No. 5,667,035 to Hughes. Hughes teaches the use of an overhead platform elevator for moving objects between a lower level of a building structure to an overhead storage space. Although Hughes has the capacity to move upward to a point where the space below the elevation device can be utilized by a user, and does not require an unobstructed lateral space, and may be designed to extend all the way to the floor, the Hughes device has several additional drawbacks. Most notably, the Hughes device is designed for moving large objects and, therefore, does not provide any means for storing a large number of small objects, such as files or the like. Additionally, as the Hughes device is designed for moving large objects, the device requires a large motor, a number of pulleys, and additional support being added to the ceiling.
Still another drawback associated with Hughes is the utilization of telescopic arms which require large vertical members to extend far beyond the uppermost portion of the elevator. Still another drawback associated with the Hughes is the inability to control the flow of air from the top floor to the bottom floor. In a situation, such as a home use, where the device may be desired to be used between a living area and an attic, the Hughes device would allow moisture and heat to flow between the two areas, and would not insulate any material provided on the platform from damage associated with climatic conditions in an attic. Still another drawback associated with the Hughes device is the lack of safety devices to warn individuals of the moving platform, or to prevent the moving platform from contacting, and injuring or killing, a user.
It would, therefore, be desirable to provide a system that allowed for full utilization of the area below the system, did not require an open lateral area for use, allowed for the storage of a plurality of small elements, protected the material from inclement conditions on the upper floor, prevented the egress of heat and moisture from one floor to the other, and which provided a warning system to prevent injury or damage during use. The difficulties encountered in the prior art discussed hereinabove are substantially eliminated by the present invention.

SUMMARY OF THE INVENTION

In an advantage provided by this invention, a retractable storage system is provided which is of a lightweight, low-cost manufacture.
Advantageously, this invention provides a retractable storage system which may be quickly and easily installed, requiring little or no access to the area above a ceiling.
Advantageously, this invention provides a retractable storage system with improved warning and safety systems to prevent injury to a user.
Advantageously, this invention provides a retractable storage system which provides a plurality of storage areas for files and the like.
Advantageously, this invention provides a retractable storage system which protects files and the like from temperature and humidity fluctuations which may be present in an attic or other unregulated storage area.
Advantageously, in the preferred example of this invention, a retractable storage system is provided with a rack and means for moving at least a part of the rack from a first position below a supportive ceiling to a second position above the supportive ceiling. Preferably, the supportive ceiling is provided with an opening into which is provided an enclosure. A motor is provided on the enclosure for extending the rack into the area below the supportive ceiling.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 illustrates a front elevation in cross-section of the retractable storage system of the present invention shown in the extended position;
FIG. 2 illustrates a front perspective view of the set of shelves, enclosure and lift system of FIG. 1;
FIG. 3 illustrates a bottom elevation of the set of shelves, shown retracted into the enclosure;
FIG. 4 illustrates a side elevation in cross-section of the retractable storage system of FIG. 1;
FIG. 5 illustrates a front elevation in cross-section of the retractable storage system of FIG. 1, shown in the retracted position.
FIG. 6 illustrates a front elevation in cross-section of an alternative embodiment of the present invention, utilizing a cable and winch system;
FIG. 7 illustrates a front elevation in cross-section of another alternative embodiment of the present invention, utilizing two large front doors and a cable and pulley system; and
FIG. 8 illustrates a front perspective view of the of another alternative embodiment of the present invention, having alternative male and female sections.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A retractable storage system according to the present invention is shown generally as (10) in FIG. 1. The retractable storage system (10) includes a multi-tiered rack, which in the preferred embodiment is a set of shelves (12), an enclosure (14) and a lift system (16). As shown in FIGS. 1-2, the set of shelves (12) is injection molded or rotomolded in a manner such as that known in the art. In the preferred embodiment the set of shelves (12) is injection molded of a copolymer of polypropylene and polyethylene. Of course, the set of shelves may be injection molded of nylon or any other desired material, or may be constructed using wood, metal or any other material known in the art for construction of such shelves. The set of shelves (12) is preferably molded with a face (18), a first side (20), a second side (22) a back (24), a bottom (26) and a top (28). Each side (20) and (22) is provided with three tongues (36), (37), (38) and (39), (40), (41) integrally molded as part of the sides (20) and (22). (FIGS. 1-2).
As shown in FIGS. 2-3, the top (28) is provided with a first lip (30) and second lip (32). As shown, each lip (30) and (32) is provided with a hole (90) and (92) which passes through the center tongue (37) and (40) of each side (20) and (22). Stainless steel threaded nuts (886) and (88) are bolted or otherwise secured to the lips (30) and (32) for a purpose described in more detail below.
As shown in FIG. 2, the set of shelves (12) is provided with a plurality of hinged doors (44). Although the hinged doors (44) may be of any type known in the art, in the preferred embodiment, the hinged doors (44) are of the type known to swing outward and upward to a substantially horizontal position, whereafter the hinged doors (44) may be slid inward along tracks (not shown) into the set of shelves (12) to allow access to files (46) and the like. (FIGS. 1-2). It should be noted, however, that the set of shelves (12) may be provided without any doors (44) whatsoever, hinged lateral doors, a removable top drawer, additional shelves releasably secured to the bottom of the set of shelves (12), doors on either side, or completely open on one or more sides.
The enclosure (14) includes a female member (48) and a male member (50), sized and configured for securement into mating alignment with one another as shown in FIG. 3. Preferably, the enclosure (14) is injection molded or rotomolded, in a manner such as that known in the art, of the same materials utilized to construct the set of shelves (12). As shown in FIGS. 2-3, the female member (48) is molded with a side (52), a top (54), a front (56) and a back (58). The top (54), front (56) and back (58) are each provided with a curved catch (60). Similarly, the male member (50) is provided with a side (62), a top (64), a front (66), a back (68). The top (64), front (66) and back (68) are each provided with a curved keeper (70). The keeper (70) and catch (60) are preferably designed to fit into interlocking mating engagement with one another. In the preferred embodiment, no additional fasteners or adhesive are required to maintain the female member (48) and male member (50) in contact with one another but, of course, it should be known that fasteners or any other suitable connection means may be utilized to further secure the female member (48) to the male member (50).
As shown in FIG. 2, the female member (48) and male member (50) are preferably provided with a plurality of steel L-brackets (72) which are secured to the female member (48) and male member (50) by nuts (74) and bolts (76). Alternatively, the female member (48) and male member (50) may be molded with a fin (not shown) along the perimeter of the bottoms (78) and (80) of the female member (48) and male member (50). Alternatively, a fin (not shown) constructed of aluminum or any other suitable material, may be bolted or otherwise secured to the bottoms (78) and (80) of the female member (48) and male member (50).
Also, as shown in FIG. 3, the female member (48) and the male member (50) are each integrally formed with keyways (79) sized to receive the tongues (36), (37), (38), (39), (40) and (41) provided on the sides (20) and (22) of the set of shelves (12). The keyways (79) guide the set of shelves into and out of the enclosure (14). Stainless steel screws (94) and (96), such as those known in the art, extend through the threaded nuts (86) and (88) and holes (90) and (92) associated with the center tongues (37) and (40).
As shown in FIG. 1, the lift system (16) comprises an electric rotary motor (98) which may be of any suitable type known in the art. As shown in FIG. 1, the motor (98) is electronically coupled to a simple central processing unit (100) such as those known in the art to control the actuation/deactuation of the motor (98), and to process input from radio frequency remote control devices, photoelectric eyes, limit switches and the like.
Also as shown in FIG. 1, the motor (98) is drivably coupled to a gearbox (101) which, in turn, is drivably coupled to the screw (96). As shown in FIG. 1, the screw (96) extends through the threaded nut (86) of the set of shelves (12) and into the hole (92) provided through the center tongue (37). The gearbox (101) is a right angle gearbox, such as those known in the art, and is provided with a first output shaft (104) coupled to the screw (96) and a second output shaft (106) coupled to a driveshaft (108). The driveshaft (108), in turn, is coupled to an input shaft (110) of another gearbox (112) which is drivably coupled to the screw (94) by an output shaft (114). On its other end, the screw (94) is provided through the threaded nut (88) bolted to the second lip (32) of the set of shelves (12) and into the hole (90) provided through the center tongue (40).
As shown in FIG. 1, an actuation switch (116) is provided on the wall (118) and is hardwired or, more preferably, connected via remote control radio frequency transmission to the central processing unit (100) in a manner such as that known in the art. Also preferably, a secondary actuation switch (120) is provided on a battery-operated remote control (122) in a manner such as that known in the art. Also coupled to the central processing unit (100) is a lower limit switch (122) and upper limit switch (124) set to deactuate the motor (98) when triggered by contact with the lip (30) of the set of shelves (12). The lip (30) actuates the limit switches (122) and (124) when the set of shelves (12) has reached its lowermost or uppermost orientation respectively. Alternatively, a boss (not shown) may be provided on the set of shelves (12) to trigger the limit switches (122) and (124).
Also as shown in FIG. 1, the set of shelves (12) is provided with warning lights (126) which are coupled to the central processing unit (100). The central processing unit (100) triggers the warning light to strobe whenever the motor (98) is raising or lowering the set of shelves (12).
As shown in FIG. 1, provided on the floor (128) are a pair of reflective discs (130) and (132), which may be constructed of Mylar, glass or any other suitable material. Provided on the bottom (26) of the set of shelves (12) is a first photoelectric eye (134) and a second photoelectric eye (136), such as those known in the art. The photoelectric eyes (134) and (136) are wired to the central processing unit (100) which, in turn, cuts power to the motor (98) in the event that a user (not shown) or other object moves between one of the photoelectric eyes (134) and (136), ad the reflective discs (130) and (132), thereby obstructing photoelectric input into the photoelectric eyes (134) and (136). This operates as a warning system to prevent the set of shelves (12) from lowering into contact with something and causing damage either to the set of shelves (12) or to the object to which it comes in contact. Alternatively, a motion detector (not shown) or similar sensor, such as those known in the art, may be utilized.
Additionally, the first shelf (138), second shelf (140), third shelf (142) and fourth shelf (144) are each provided with a door sensor (146) to detect whether the hinged doors (44) (FIGS. 1-2) are closed. The door sensors (146) are coupled to the central processing unit (100) which prevents actuation of the motor (98) if one or more of the hinged doors (44) are not closed. The central processing unit (100) is also provided with a current sensor (148), such as those known in the art, preset to detect an overload condition to stop actuation of the motor (98) in the event something prevents the set of shelves (12) from retracting, or in the event the set of shelves (12) become overloaded. In the event where the current sensor (148) detects the predetermined overload condition associated with the motor (98) trying to lift the set of shelves (12) against an overloaded capacity, the central processing unit (100) signals warning lights (126) to flash to indicate the jammed or overloaded conditions. The screws (94) and (96) also hold the set of shelves (12) in position during a power outage or malfunction of the motor (98) to prevent the set of shelves (12) from moving quickly downward.
As shown in FIGS. 1 and 2, the female member (48) and male member (50) are provided with a plurality of hinged panels (150), to allow the L-brackets (72) to be secured to a ceiling (152) from inside the enclosure (14) without requiring access to the second floor. An additional hinged panel (154) is provided on the top (64) of the male member (50) to allow access to the motor (98), central processing unit (100) and current sensor (148), to make any necessary adjustments, conduct any necessary maintenance and to make any required replacements without requiring access to the second floor. Preferably, all of the hinged panels (150) and (154) are sufficiently insulated to prevent a substantial amount of moisture or heat passing across the hinged panels (150) and (154) when they are in their closed positions.
When it is desired to utilize the retractable storage system (10) of the present invention, a hole (156) is cut into the ceiling (152) as shown in FIG. 4. As shown, the hole (156) is preferably cut parallel to the ceiling joists (158) and (160). Alternatively, the male member (50) and female member (48) may be installed from the second floor, whereafter additional insulation, such as batting, may be applied to the outside of the male member (50) and female member (48). The hole (156) is preferably cut close enough to the joist (158) and (160) to maximize the area available for the set of shelves (12), allowing the utilization of the joists (158) and (160) for support of the enclosure (14). Once the hole (156) has been cut into the ceiling, the female member (48) and male member (50) are provided through the hole (156) in the ceiling (152). The female member (48) and male member (50) may be slightly compressed to pass them by the joists (158) and (160). Once the female member (48) and male member (50) are past the joists (158) and (160), they are positioned on top of the joists (158) and (160) as shown in FIG. 4. If desired, the L-brackets (72) associated with the male member (50) may secured to the male member (50) and the joists (158) and (160). Thereafter, the female member (48) may be secured to the male member (50), utilizing the keeper (70) and catch (60) described above. The hinged panel (150) may then be utilized to reach through the enclosure and secure the female member (48) to the joist (158), utilizing the L-brackets (72). Thereafter, the screws (94) and (96) are coupled to the output shafts (104) and (114).
The set of shelves (12) is thereafter lifted into the enclosure (14) and hinged panels (162) may be utilized to route the screws (94) and (96) through the collars (36) provided in the lips (30) and (32) of the top (28) of the set of shelves (12) and into the bushings (90) and (92). Thereafter, the motor (98) may be hardwired or otherwise coupled to an electrical power outlet (164) which, in the preferred embodiment, is a 120-volt alternating current source. The actuation switch (116) may be provided on a wall plate (166) and secured to the wall (118) in a manner such as that known in the art.
Thereafter, when it is desired to lower the set of shelves (12), the actuation switch (116) or secondary actuation switch (120) is actuated in a first direction to cause the motor (98) to rotate the screws (94) and (96) and lower the set of shelves (12). As the set of shelves (12) is being lowered, the central processing unit (100) actuates the warning lights (126) to strobe and warn of the descent of the set of shelves (12). Once the set of shelves (12) has been fully lowered, the lip (30) contacts the lower limit switch (122), causing the central processing unit (100) to cut power to the motor (98). The hinged doors (44) may then be opened and the set of shelves (12) accessed and filled with material. When it is desired to retract the set of shelves (12), the actuation switch (116), or secondary actuation switch (120) is actuated in the opposite direction. If an overload condition exists, the current sensor (148) causes the central processing unit (100) to cut power to the motor (98) and flash the warning lights (126). If no overload condition is present, the central processing unit (100) causes the motor (98) to turn the screws (94) and (96) in the opposite direction and lift the set of shelves (12) into the enclosure (14). If the motor (98) encounters an overload condition during the lifting process, again the current sensor (148) causes the central processing unit (100) to cut power to the motor (98) until the overload condition can be corrected. Once the set of shelves (12) has fully retracted into the enclosure (14) to the point where the bottom (26) of the set of shelves (12) is flush with the ceiling (152), the lift (30) contacts the upper limit switch (124), causing the central processing unit (100) to cut power to the motor (98), as shown in FIGS. 1, 2 and 4.
Shown in FIG. 6 is an alternative embodiment of the present invention, utilizing a motor (168) coupled to a shaft (170) which, in turn, is journaled to a bushing (172) provided on the interior of the enclosure (174). A support bushing (176) may also be coupled to the enclosure (174) to prevent bowing of the shaft (170) and allowing for the utilization of a smaller diameter shaft. Coupled to the shaft (170) are a pair of cables (178) and (180), or webbing straps such as those known in the art, which, in turn, are coupled to the top (182) of the set of shelves (184). As the central processing unit (186) causes the motor (168) to rotate in a first direction, the cables (178) and (180) wind around the shaft (170), thereby lifting the set of shelves (184) into the enclosure (174). Conversely, when the central processing unit (186) actuates the motor (168) to reverse the motion of the shaft (170), the cables (178) and (180) unwind from the shaft (170) and lower the set of shelves (184) out of the enclosure (174).
Yet another alternative embodiment of the present invention is shown in FIG. 7, which utilizes a rotary motor (188), drivably coupled to a drive shaft (190) which, in turn, is drivably coupled to a pulley (192). The pulley (192) is coupled to a pair of cables (194) and (196), or webbing straps such as those known in the art, which, in turn, are coupled to the top (198) of the set of shelves (200). The cables (194) and (196) pass through the top (202) of the enclosure (204) and are directed around pulleys (206) and (208), coupled to the top (202) of the enclosure (204) by brackets (210) and (212) in a manner such as that known in the art. Accordingly, as the central processing unit (214) causes the rotary motor (188) to actuate, the cables (194) and (196) move around the pulleys (206) and (208) to wind on the pulley (192), thereby lifting the set of shelves (200) into the enclosure (204). Conversely, when the central processing unit (214) causes the rotary motor (128) to reverse, the cables (194) and (196) to unwind from the pulley (192), thereby lowering the set of shelves (200) out of the enclosure (204).
Still another alternative embodiment of the present invention is shown generally as (216) in FIG. 8. In this embodiment, the male member (218) and female member (220) divide the enclosure (222) along an alternative axis.
Although the invention has been described with respect to a preferred embodiment thereof it is also to be understood that it is not to be so limited, since changes and modifications can be made therein which are within the full, intended scope of this invention as defined by the appended claims. As an example, the motor (98) may be located in any desired position, including, but not limited to, either side of the interior of the enclosure or on the underside of the ceiling, with cables, pulleys or the like, directing the power of the motor upward to the top of the enclosure. It is additionally anticipated that the enclosure may be provided with additional openings to allow egress to maintain the exterior of the enclosure, or to route cabling or the like from the exterior of the enclosure to the interior of the enclosure, and/or to a point below the ceiling.

Claims

1. A retractable storage system comprising:

(a) a rack comprising:

(i) a storage area;

(ii) a second storage area located above said first storage area;

(b) a supportive ceiling defining an opening;

(c) means for moving at least a part of said rack from a first position below said supportive ceiling to a second position above said supportive ceiling.

2. The retractable storage system of claim 1, further comprising means positioned above said supportive ceiling for insulating said rack.

3. The retractable storage system of claim 1, further comprising an enclosure secured to said supportive ceiling.

4. The retractable storage system of claim 3, wherein said enclosure is coupled to said supportive ceiling over said opening in a manner which substantially seals said opening.

5. The retractable storage system of claim 1, wherein said moving means comprises:

(a) first means coupled to a first part of said container for lifting said rack; and

(b) second means coupled to a second part of said container for lifting said rack.

6. The retractable storage system of claim 5, wherein said first means is secured to said container above said second storage area and wherein said second means is secured to said container above said second storage area.

7. The retractable storage system of claim 1, wherein said rack further comprises a door.

8. The retractable storage system of claim 7, wherein said rack further comprises:

(a) a back provided between said first storage area and said second storage area;

(b) a first side provided between said first storage area and said second storage area; and

(c) a second side provided between said first storage area and said second storage area.

9. The retractable storage system of claim 1, wherein said moving means comprises a motor provided above said supportive ceiling.

10. The retractable storage system of claim 9, further comprising an actuator coupled to said motor, wherein said motor is provided above said supportive ceiling.

11. The retractable storage system of claim 10, further comprising an enclosure secured to said supportive ceiling.

12. The retractable storage system of claim 1, further comprising means coupled to said moving means for attenuating said moving means in response to an object being in the path of said rack.

13. The retractable storage system of claim 1, wherein said moving means is a motorized screw coupled to said rack.

14. The retractable storage system of claim 13, further comprising a slave screw operably coupled to said motorized screw and to said rack.

15. The retractable storage system of claim 1, wherein said rack comprises a set of drawers.

16. A retractable storage system for moving a rack from a first point below a ceiling to a second point above the ceiling, the retractable storage system comprising:

(a) a rack comprising:

(i) a first storage area;

(ii) a second storage area located above said first storage area.

(b) an enclosure, at least a portion of which is located above the ceiling; and

(c) means for moving at least a portion of said rack into said enclosure.

17. The retractable storage system of claim 16, wherein the ceiling defines an opening and wherein said enclosure is secured over said opening in a manner which substantially seals said opening.

18. The retractable storage system of claim 16, wherein said rack is a set of shelves.

19. A method for storing material comprising:

(a) providing a ceiling defining a lower space and an upper space;

(b) providing an opening in said ceiling;

(c) providing an enclosure from said lower space, through said opening, into said upper space;

(d) securing said enclosure to said ceiling over said opening;

(e) providing a rack comprising:

(i) a first storage area;

(ii) a second storage area located above said first storage area.

(f) providing material on said first storage area; and

(g) moving at least a portion of said rack into said enclosure.

20. The method for storing material of claim 19, further comprising moving said rack into said enclosure sufficiently so that a bottom of said rack is substantially flush with said ceiling.