Knape & Vogt Mfg. v. Design Ideas - Complaint

Case 1:20-cv-01216 ECF No. 1, PageID.
1 Filed 12/17/20 Page 1 of 26
UNITED STATES DISTRICT COURT
FOR THE WESTERN DISTRICT OF MICHIGAN
SOUTHERN DIVISION

KNAPE & VOGT MANUFACTURING
COMPANY,
a Michigan corporation,
Civil Action No.
Plaintiff,
Hon.
v.

DESIGN IDEAS, LTD.,

Defendant.

COMPLAINT FOR DECLARATORY JUDGMENT
Plaintiff, Knape & Vogt Manufacturing Company (hereinafter “Plaintiff” or “KV”), by and
through its undersigned attorneys, for its Declaratory Judgment Complaint against Defendant
Design Ideas, Ltd. (hereinafter “Defendant” or “Design Ideas”), alleges as follows:
THE PARTIES
1. Knape & Vogt is a corporation organized and existing under the laws of the State
of Michigan and has its principal place of business at 2700 Oak Industrial Drive, Grand Rapids,
Michigan 49505.
2. Upon information and belief, Design Ideas is an Illinois corporation and has its
principal place of business at 2521 Stockyard Road, Springfield, Illinois 62702.
NATURE OF ACTION
3 This is an action for declaratory judgment arising under the patent laws of the
United States, 35 U.S.C. § 101 et seq., for a declaration that U.S. Patent No. 7,428,976 (the ‘976
Case 1:20-cv-01216 ECF No. 1, PageID.2 Filed 12/17/20 Page 2 of 26
patent) (Ex. A); U.S. Design Patent No. D624,753 (the ‘753 patent) (Ex. B); U.S. Patent
No. 8,006,858 (the ‘858 patent) (Ex. C); U.S. Patent No. 8,584,889 (the ‘889 patent) (Ex. D); U.S.
Design Patent No. D847,510 (the ‘510 patent) (Ex. E); U.S. Design Patent No. D856,678 (the ‘678
patent) (Ex. F); U.S. Patent No. 10,524,569 (the ‘569 patent) (Ex. G); and U.S. Design Patent
No. D895,291 (the ‘291 patent) (Ex. H) (collectively, the “patents in suit”) are not infringed by any
product sold by KV and are invalid.
JURISDICTION AND VENUE
4. This Court has jurisdiction pursuant to 28 U.S.C. §§ 1331 and 1338 with respect to
the claims arising under the Patent Act, 35 U.S.C. § 101, et seq., and pursuant to the Declaratory
Judgment Act, 28 U.S.C. § 2201, et seq.
5. There is complete diversity between KV and Design Ideas and the amount in
controversy exceeds $75,000.00 exclusive of interest and costs. Therefore, this Court also has
subject matter jurisdiction over this action under 28 U.S.C. § 1332.
6. Venue is proper in this District pursuant to 28 U.S.C. §§ 1391 and 1400 because a
substantial part of the events giving rise in the claims occurred in this District, and Design Ideas
is subject to personal jurisdiction in this judicial District based upon, among other things, its
business transactions within this District.
7. Upon information and belief, there is personal jurisdiction over Design Ideas since
Design Ideas is doing business within this State and judicial District, transacts business within this
State and judicial District, derives substantial revenue from intra‐state and inter‐state commerce,
and is otherwise within the jurisdiction of this Court.
2
8. Upon information and belief, there is personal jurisdiction over Design Ideas by
reason of the assertions made against KV in this District, namely, the allegation that KV infringes
the patents in suit. While KV is not a party to the lawsuit, Design Ideas has instituted litigation
(Design Ideas, Ltd. v. Lowe’s Home Centers, LLC, 3:20‐cv‐03204 (C.D. Ill.)) against two of KV’s retail
customers alleging that a KV product infringes the patents in suit (Partial Customer Litigation).
9. Allegations that a KV product infringes the patents in suit shows that there has
been and now is an actual controversy between KV and Design Ideas regarding the non‐
infringement and invalidity of the patents in suit.
FACTUAL BACKGROUND
10. Beginning in 2016, KV developed a wire mesh basket under the internal product
designation 0335‐BSKT‐7CN and 0335‐BSKT‐7SG. An image of this wire basket is shown below
(the KV Basket):
11. Over the past several years, the KV Basket has been marketed to a number of
customers in the United States. Some of these customers are retailers that resell the KV Basket.
12. Design Ideas has sued two of KV’s many retail customers in the Central District of
Illinois, alleging that the KV Basket infringes the patents in suit.
3
COUNT I

DECLARATORY JUDGMENT OF NON‐INFRINGEMENT
OF U.S. PATENT NO. 7,428,976

13. KV repeats and re‐alleges each allegation in paragraphs 1‐12 of this Complaint as
if set forth fully herein.
14. An actual controversy has arisen and now exists between KV and Design Ideas
concerning whether the KV Basket infringe U.S. Patent No. 7,428,976 (the ‘976 patent).
15. KV has not infringed and does not infringe the claims of the ‘976 patent. In the
Partial Customer Litigation, Design Ideas has asserted that the KV Basket infringes at least claim 1.
However, multiple limitations of that claim and other claims are missing both literally and under
the Doctrine of Equivalents. For example, without limitation, the “rail,” “first and second sections
of said rail are generally parallel,” and “horizontally extending outwardly” limitations are missing
from the KV Basket.
16. In particular, the manufacture, importation, use, offer for sale, and/or sale in the
United States of the KV Basket does not infringe, either literally or under the doctrine of
equivalents, the claims of the ‘976 patent.
17. K&V does not contribute to the infringement of, or induce others to infringe, the
‘976 patent through distribution and/or sale of the K&V Basket.
18. By virtue of the foregoing, KV desires a judicial determination of the parties’ rights
and duties with respect to the ‘976 patent, namely, that the KV Basket does not infringe any claim
of the ‘976 patent.
19. A judicial declaration is necessary and appropriate at this time so that the parties
may proceed in accordance with their respective rights as determined by the Court.
4
20. This is an exceptional case which entitles KV to an award of reasonable attorney
fees under 35 U.S.C. § 285.
COUNT II

DECLARATORY JUDGMENT OF INVALIDITY OF U.S. PATENT NO. 7,428,976

concerning whether the ‘976 patent is invalid.
23. Upon information and belief, the claims the ‘976 patent are invalid for failing to
comply with one or more of the conditions and requirements of the patent laws, including, but
not limited to 35 U.S.C. §§ 102, 103, and/or 112 and/or the rules, regulations, and laws pertaining
thereto. For example, to the extent that the claims of the ‘976 patent are construed broadly to
cover the KV Basket, the claims are invalid under 35 U.S.C. § 112 for indefiniteness and failure to
meet the written description requirement. Moreover, the prior art would render such broadly
construed claims either anticipated and/or obvious. For example, claims of similar scope having
a similar priority claim were found unpatentable in Europe over Publication WO 03/047987; U.S.
Patent No. 1,445,259; and U.S. Patent No. 463,964A. These same references along with the other
prior art cited during the European prosecution render the asserted claim(s) invalid. Claims of
similar scope were also initially found unpatentable in Japan based upon Japanese Utility model
Application No. H4‐55867, Japanese Unexamined Patent Application Publication No. 2001‐
199439, Japanese Unexamined Patent Application Publication No. 2001‐270515, and Japanese
Utility Model No. H4‐11357. Not all of this prior art was provided to the United States Patent and
5
Trademark Office (USPTO) during prosecution. In addition, the art cited in related Re‐exam
90/014,233 includes prior art and patentability arguments not considered during prosecution of
this patent. Claims of similar scope were found to have a substantial new question of
patentability in that re‐exam. Moreover, in addition to the prior art of record, references
JP2002058555; U.S. Patent No. 5,465,901; U.S. Patent No. 6,491,173; U.S. Patent No. 6,467,860;
DE19842666; GB672538; JPH08322662; JPH09234131; and JP3070896U anticipate the claims
and/or render them obvious depending upon the breadth of the claim construction. For example,
without limitation, at least the limitations of claim 1 are disclosed in JP202058555.
and duties with respect to the ‘976 patent, namely, that the claims of the ‘976 patent are invalid.
26. This is an exceptional case which entitled KV to an award of reasonable attorney
COUNT III

OF U.S. PATENT NO. D624,753

concerning whether the KV Basket infringe U.S. Patent No. D624,753 (the ‘753 patent).
29. KV has not infringed and does not infringe the single claim of the ‘753 patent. Any
similarities between the articles relate to mere concepts of the designs or the functional aspects
6
of the comparative features, neither of which are to be considered in assessing infringement of
design patents. In appropriately considering the claimed design as a whole, an ordinary observer
would not find any substantial similarity to the whole of the corresponding portion of the KV
Basket. For example, without limitation, the prominent cutout feature of the claimed design has
a much wider appearance than the cutout of the KV Basket. The claimed design also includes a
curved bottom side along the cutout, as compared to a straight bottom side of the KV Basket.
The claimed design also has a flat rim profile, as compared to the non‐flat rim provided in the KV
Basket. At least these notable differences contribute to the articles having overall appearances
that are not substantially the same.
equivalents, the single claim of the ‘753 patent.
and duties with respect to the ‘753 patent, namely, that the KV Basket does not infringe the ‘753
patent.
7
COUNT IV

DECLARATORY JUDGMENT OF INVALIDITY OF U.S. PATENT NO. D624,753

37. Upon information and belief, the single claim of the ‘753 patent is invalid for failing
to comply with one or more of the conditions and requirements of the patent laws, including,
but not limited to 35 U.S.C. §§ 102, 103, 112, and/or 171 and/or the rules, regulations, and laws
pertaining thereto. For example, the entire design of the ‘753 patent is dictated solely by its
function. To the extent that any aspect of the design is not dictated solely by function, the design
as a whole is anticipated or obvious to a designer of ordinary skill who designs baskets.
38. There is also no support in the written description of the parent D653,063 patent
for the boundary line introduced in the application that led to the ‘753 patent. The continuity
claim for the ‘753 patent is, therefore, invalid such that the application priority date is the
application filing date of June 25, 2008. Accordingly, the basket design disclosed in the Appendix
of U.S. Patent No. D481,232, publically available at least as early as February 27, 2003, and the
basket described as being on sale at least as early as October 2003, per the Declaration included
in the file history for U.S. Patent No. D567,553, are available as prior art with respect to the ‘753
patent. Each of these prior basket designs either anticipates and/or renders obvious the claimed
design.
8
and duties with respect to the ‘753 patent, namely, that it is invalid.
COUNT V


Partial Customer Litigation, Design Ideas has asserted that the KV Basket infringes at least claim 1.
However, multiple limitations of that claim and the other claims are missing from the KV Basket,
both literally and under the Doctrine of Equivalents. For example, without limitation, the “rail,”
“joined,” and “joining” limitations are not present in the KV Basket.
9
and duties with respect to the ‘858 patent, namely that the KV Basket does not infringe any claim
COUNT VI


10
11
COUNT VII


Partial Customer Litigation, Design Ideas has asserted that at least claim 3 of the ‘889 patent is
infringed. However, multiple limitations of that claim and other claims are missing both literally
and under the Doctrine of Equivalents. For example, without limitation, the “rail,” “generally
parallel,” and “horizontally extending outwardly” limitations are missing from the KV Basket.
12
COUNT VIII


13
COUNT IX


14
Basket. For example, without limitation, the cutout area in the claimed design is much larger in
comparison to the claimed width of the basket. The claimed design also has a flat ridge which
protrudes outwardly that is lacking the KV Basket. The claimed design also has a flat rim profile
which is lacking in the KV Basket. At least these notable differences contribute to the articles
having overall appearances that are not substantially the same.
and duties with respect to the ‘510 patent, namely that the KV Basket does not infringe the ‘510
patent.
15
COUNT X


function. To the extent that any aspect of the design is not solely dictated by function, the design
81. The claimed design only claims the front portion of the rim, stopping arbitrarily
after the corners. There is no support in the written description of the parent D773,815 patent
for such a claim. Accordingly, the continuity claim is invalid and the patent is only entitled, at
best, to a priority date based on the August 16, 2016 filing date of the application. The claimed
design is invalid as anticipated by or obvious over the disclosure in the Appendix of U.S. Patent
No. D481,233 publically available at least as early as February 27, 2003, and a related on‐sale bar
at least as early as October 2003, as set forth in the Declaration included in the file history for
U.S. Patent No. D567,553.
and duties with respect to the ‘510 patent.
16
COUNT XI


would not find any substantial similarity to the whole of the KV Basket. Arguments made in the
file history limit the scope of what could be considered substantially similar to the claimed design,
particularly with respect to the length, width, and height ratios of various features that contribute
significantly to the overall appearance of the design. In this respect, and without limitation, the
width‐to‐height ratio of the prominent front cutout is greater in the KV Basket than in the claimed
design, the cutout of the KV Basket is wider relative to the overall width of the basket than in the
claimed design, and the KV Basket cutout is more tapered and has more squared corners than in
the claimed design. In addition, the claimed design has a flat rim profile which is lacking in the KV
17
Basket. Additionally, the claimed design has diamond shaped holes in the mesh which has the
longer dimension horizontally. In contrast, the longer dimension of the openings in the mesh for
the KV Basket are vertical. At least these noticeable differences contribute to the articles having
overall appearances that are not substantially the same.
and duties with respect to the ‘678 patent, namely that the KV Basket does not infringe the ‘678
patent.
COUNT XII


18
96. The earliest priority date for the ‘678 patent is October 31, 2008. The publically
available Appendices from the ‘753 patent and the ‘510 patent were available at least as early as
October 28, 2003, and anticipate and/or render obvious the claimed design.
COUNT XIII


19
Partial Customer Litigation, Design Ideas has asserted that the KV Basket infringes at least
claim 11. However, multiple limitations of that claim and other claims are missing both literally
and under the Doctrine of Equivalents. For example, without limitation, the “rail,” “substantially
right‐angled junction,” “U‐shaped connecting section,” and “horizontally extending outwardly”
limitations are missing from the KV Basket.
COUNT XIV


20
construed claims either anticipated and/or obvious. In addition to the prior art of record,
references JP2002058555; U.S. Patent No. 5,465,901; U.S. Patent No. 6,491,173; U.S. Patent
No. 6,467,860; DE19842666; GB672538; JPH08322662; JPH09234131; and JP3070896U
anticipate the claims and/or render them obvious depending upon the breadth of the claim
construction. For example, without limitation, at least the limitations of claim 1 are disclosed in
JP202058555.
21
COUNT XV


Basket. For example, without limitation, during prosecution of the '291 patent family, arguments
were made asserting the significance of certain proportions in differentiating claimed designs
from the prior art. The KV Basket exhibits comparable differences in the same proportions, as
compared to the design claimed in the '291 patent. In addition, the claimed design has a flat rim
profile which is lacking in the KV Basket. Additionally, the claimed design has diamond shaped
holes in the mesh which have long dimensions horizontally. In contrast, the longer dimensions of
the openings in the mesh for the KV Basket are vertical. At least these noticeable differences
contribute to the articles having overall appearances that are not substantially the same.
22
and duties with respect to the ‘291 patent, namely, the KV Basket does not infringe the ‘291
patent.
COUNT XVI


23
125. There is no support in the written description of the parent U.S. Patent App.
No. 29/718,845 for the way the handle opening is disclaimed in the '291 patent. The handle
cutout is bounded by new lines not present in the photographs in any of the parent applications
included in claimed chain of priority. The continuity claim for the ‘291 patent is, therefore, invalid
such that the application priority date is the application filing date of March 13, 2020.
Accordingly, the basket designs disclosed in the Appendix of U.S. Patent No. D759,976, publically
available at least as early as June 28, 2016 are available as prior art with respect to the ‘291
patent. The prior basket designs either anticipate, or renders obvious, the claimed design.
126. The earliest claimed priority date for the ‘291 patent is October 31, 2008. The
publically available Appendices from the ‘753 patent and the ‘510 patent were available at least
as early as October 28, 2003, and anticipate and/or render obvious the claimed design. The
Appendices show cutouts on the long sides of various basket designs, as well as various baskets
designs with similar proportions to those of the claimed design.
WHEREFORE, KV prays for the following relief against Design Ideas:
A. for a declaration and judgment declaring that the ‘976 patent is not infringed by
the KV Basket;
24
B. for a declaration and judgment declaring that asserted claims of the ‘976 patent
are invalid;
C. for a declaration and judgment declaring that the ‘753 patent is not infringed by
the KV Basket;
D. for a declaration and judgment declaring that the ‘753 patent is invalid;
E. for a declaration and judgment declaring that the ‘858 patent is not infringed by
the KV Basket;
F. for a declaration and judgment declaring that the asserted claims of the ‘858
patent are invalid;
G. for a declaration and judgment declaring that the ‘889 patent is not infringed by
the KV Basket;
H. for a declaration and judgment declaring that the asserted claims of the ‘889
patent are invalid;
I. for a declaration and judgment declaring that the ‘510 patent is not infringed by
the KV Basket;
J. for a declaration and judgment declaring that the ‘510 patent is invalid;
K. for a declaration and judgment declaring that the ‘678 patent is not infringed by
the KV Basket;
L. for a declaration and judgment declaring that the ‘678 patent is invalid;
M. for a declaration and judgment declaring that the ‘569 patent is not infringed by
the KV Basket;
25
N. for a declaration and judgment declaring that the asserted claims of the ‘569
patent are invalid;
O. for a declaration and judgment declaring that the ‘291 patent is not infringed by
the KV Basket;
P. for a declaration and judgment declaring that the ‘291 patent is invalid;
Q. for a declaration and judgment declaring this case to be exceptional under 35
U.S.C. § 285;
R. for an award to KV of its costs, expenses, and reasonable attorney fees as
permitted by law; and
S. for an award to KV for such other and further relief as the Court may deem just
and proper.
Respectfully submitted,

Dated: December 17, 20202 s/Matthew J. Gipson
Matthew J. Gipson (P60169)
mgipson@priceheneveld.com
PRICE HENEVELD LLP
695 Kenmoor S.E. | P.O. Box 2567
Grand Rapids, MI 49501
T: 616.949.9610 | F: 616.957.8196
26
Case 1:20-cv-01216 ECF No. 1-1, PageID.27 Filed 12/17/20 Page 1 of 39
Exhibit A
USOO7428976B2
(12) United States Patent (10) Patent No.: US 7428,976 B2

Cheng et al. (45) Date of Patent: Sep. 30, 2008
(54) METHOD FOR MAKING MESH (56) References Cited
CONTAINERS WITH ARAL AND MESH U.S. PATENT DOCUMENTS
CONTAINER FORMED THEREFROM
171,032 A 12/1875 Meyers
(75) Inventors: Hsi-Ming Cheng, Chung-Hua Hsien
(TW); R. Neal Post, Springfield, IL
(US); Christopher Hardy, Springfield, (Continued)
IL (US) FOREIGN PATENT DOCUMENTS
(73) Assignee: Design Ideas, Ltd., Springfield, IL (US) DE 1083999 6, 1960
(*) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35
U.S.C. 154(b) by 152 days. (Continued)
(21) Appl. No.: 11/000,295 OTHER PUBLICATIONS
Millers Office Products, p. 442, 1995.
(22) Filed: Nov.30, 2004
(Continued)
(65) Prior Publication Data
Primary Examiner—Anthony D Stashick
US 2005/0077299 A1 Apr. 14, 2005 Assistant Examiner NIki M. Eloshway
(74) Attorney, Agent, or Firm—Saidman DesignLaw Group
Related U.S. Application Data
(57) ABSTRACT
(63) Continuation-in-part of application No. 10/972,308,
filed on Oct. 22, 2004, now Pat. No. 7,270,245, which
is a continuation of application No. 10/308.699, filed The present invention is directed to a method of forming a
on Dec. 3, 2002, now abandoned. container comprising forming a basket portion of metal mesh
material and a rail connected to the basket portion. The rail
(51) Int. Cl. extends substantially outwardly from the outer surface of the
B65D 6/08 (2006.01) basket portion and the rail extends continuously around the
B65D 6/32 (2006.01) outer Surface of the basket portion. In one example, the
B65D 6/36 (2006.01) method includes forming the rail so that it does not contain or
B65D 25/OO (2006.01) Surround a free edge of the basket portion. In another
example, the method includes forming the rail so that it
(52) U.S. Cl. ......................... 220/642: 220/62: 220/485; includes an opening for containing or Surrounding a free edge
220/607; 220/676; 29/509 of the basket portion. The method may also include forming
(58) Field of Classification Search ................. 220/491, a lower rail. The present invention is also directed to a con
220/492, 494, 485, 640–642, 646, 648, 62, tainer formed by such method.
220/607, 676; 29/509, 512
See application file for complete search history. 3 Claims, 27 Drawing Sheets
US 7428.976 B2
Page 2
U.S. PATENT DOCUMENTS 3,563,292 A 2f1971 Gordon

3,923, 187 A 12, 1975 Johansson et al.
201959 A 4, 1878 Stockwell et al. 4,173,289 A 11, 1979 Nest
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900,162. A 10, 1908 Goodwin D298.403 S 11/1988 Magberg et al.
920,313 A 5/1909 Franklin 4,903,853 A 2, 1990 Lin ............................... 220/6
933,517 A 9, 1909 Worcester D328,993 S 9, 1992 Rosenthal
981,205 A 1/1911 Loetzer D341,459 S 1 1/1993 Yang
994.984 A 6, 1911 Dennis D373,039 S 8, 1996 Cohen et al.
1,098,053 A 5, 1914 Porter D383,283 S 9/1997 Hankins, III
1,138,496 A 5, 1915 Martin D393,766 S 4/1998 MaZZola et al.
1,224,234 A 5, 1917 Taber 5,810,179 A 9, 1998 Kleiman
1,305,148 A 5, 1919 Montain 5,851,393 A * 12/1998 Carr et al. ................... 210,489
1,382,592 A 6, 1921 Ames D416, 165 S 11/1999 Zemel
1,384,755 A T. 1921 Hall D419,302 S 1/2000 Hardy et al.
1,389,908 A 9, 1921 ShultSet al. D433,709 S 1 1/2000 Hardy
1445,259 A 2, 1923 Wiselogel D437,984 S 2/2001 Weiss et al.
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1484,696 A 2/1924 Wulftange D444,927 S 7, 2001 Lin
1,660,410 A 2, 1928 Beckman D451,675 S 12/2001 Hardy et al.
1,688,846 A 10/1928 Andrews D453,027 S 1/2002 Andujar
1,840,561 A 1/1932 Miller D455,029 S 4/2002 Gusdorf
1,890,983. A 12/1932 Griffith 6,461,501 B1 10/2002 Porter
1,950,921 A 3/1934 Gray et al. 6,718,635 B2 * 4/2004 Cheng et al. ............... 29,896.6
2009,527 A 7, 1935 Shelton 7,228,985 B2 6, 2007 Yeh
2,050,980 A 8, 1936 Buhl .......................... 220/640
2,502,781 A 4, 1950 Erickson FOREIGN PATENT DOCUMENTS
2,507,152 A 5, 1950 Garofalo
2,574,998 A * 1 1/1951 Bangert, Jr. .................. 220/62 FR
GB
826876
228338
4,2, 1925
1938
2,658,444. A 1 1/1953 Wheeler GB 730785 6, 1955
2,706,064 A 4, 1955 Vitols JP 2001-270515 2, 2001
2,721,671. A 10/1955 Averill TW O862O2707 2, 1998
2,768,022 A 10/1956 Pope
2,826,329 A 3, 1958 Beckner OTHER PUBLICATIONS
2,898,122 A 8, 1959 Beckner
D194,513 S 2, 1963 Sparling Hong Kong Enterprise, Oct. 1999, p. 98.
3,120,323 A 2, 1964 Sparling Hong Kong Enterprise, Oct. 1999, p. 1126.
3,138,281
3,250,430 A
A 6/1964
5, 1966 Schray
Cella Rela.
26 Ontainer Store, first
e Ultimate E. R".E.
Planning Guide, revise OW.
3,272,377 A 9/1966 Schray
3,436,044 A 4, 1969 Martinson * cited by examiner
U.S. Patent Sep. 30, 2008 Sheet 2 of 27 US 7428,976 B2
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1. 2
METHOD FOR MAKING MESH between the sidewalls of the liner may allow small objects to
CONTAINERS WITH A RAIL AND MESH fall out of the basket, which is undesirable.
CONTAINER FORMED THEREFROM Mesh material is typically formed by perforating or slitting
a piece of sheet metal and stretching it. A sheet of mesh
CROSS-REFERENCE TO RELATED material requires less raw sheet metal than a non-mesh piece
APPLICATIONS of sheet metal and a perforated piece of sheet metal. U.S. Pat.
No. 1,408,026 to Ochiltree discloses a desk tray or basket
This application is a continuation-in-part of our prior pend formed of “expanded metal' or mesh material. Similar to the
ing application Ser. No. 10/972,308, filed Oct. 22, 2004 now previous containers, the Ochiltree container is formed by a
U.S. Pat. No. 7,270,245, which is a continuation of Ser. No. 10 single blank of flat material that is cut out and folded.
10/308,699, filed Dec. 3, 2002 now abandoned, which claims ROC (Taiwan) Patent Application No. 086202709 to Chih
priority to the prior ROC (Taiwan) Patent Application No. Ming, Ko (in transliteration), filed Feb. 21, 1997, discloses a
090220946, filed Dec. 3, 2001; ROC (Taiwan) Patent Appli system of containers Supported by a frame. The containers are
cation No. 091202306, filed Apr. 16, 2002; and ROC (Tai formed of a single piece of mesh with a rim connected thereto.
wan) Patent Application No. 09 1214244, filed Sep. 11, 2002. 15 Additionally, the containers do not move with respect to the
This application also claims priority to the prior ROC (Tai frame so that the contents of the lower container are not easily
wan) Patent Application No. 0932.11506, filed Jul. 21, 2004; accessible.
China Patent Application No. 200420084938.8, filed Jul. 28, A number of mesh containers are made by Design Ideas,
2004; ROC (Taiwan) Patent Application No. 09321 1507, Ltd. One of these containers is the “Mesh Storage Nest.” This
filed Jul. 21, 2004; and China Patent Application No. container is formed using a first piece of mesh that has the
200420084546.1, filed Jul. 29, 2004. These applications are ends welded together to form a loop. A second piece of mesh
incorporated by reference herein in their entirety. 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
BACKGROUND OF THE INVENTION a bottom wall. The seam at the bottom of the container is
25 covered by a bottom rail. A top rail is connected to the upper
1. Field of the Invention edge of the container. The sidewalls can be shaped to include
The present invention relates to containers, a system using a plurality of corners.
Such containers, and a method of making Such containers. A need exists for a lightweight container that can be incor
More particularly, the present invention relates to rails for use porated into a system for storing objects. It is also desirable
with drawers made of mesh material. 30 that the contents of such a container be made easily accessible
2. Description of Related Art and be prevented from accidentally falling through holes in
Forming containers out of sheet metal is well known. U.S. the container. Furthermore, it is desirable that the container be
Pat. No. 903,848 to Donnelly and 1,107,014 to Avery disclose formed by an economical method in unlimited sizes.
Such containers. In order to make these containers, a single 35 SUMMARY OF THE INVENTION
blank of flat material is cut out and folded with overlapping
sections. Sheet metal does not provide desirable characteris The present invention is directed to a method of forming a
tics such as drainage and ventilation. container comprising the following step: forming a basket
In an effort to make a well-ventilated container, U.S. Pat. portion of metal mesh material into a bottom wall and
No. 645,344 to White discloses a container formed of perfo 40 upwardly extending first and second spaced apart sidewalls
rated sheet metal, wire-netting or another open-work mate and upwardly extending third and fourth spaced apart side
rial. The White container is intended to have a folded state and walls, the first, second, third and fourth sidewalls including an
a flat state. This container is designed to be readily knocked outer surface. The method further includes the following
down from its folded state to its flat state and to be easily steps: forming a rail; and joining the rail to the outer Surface
constructed without tools. 45 such that a substantial portion of the rail extends substantially
Other patents attempt to make lightweight, drainable and/ outwardly from the outer surface of the first, second, third and
or ventilated containers. U.S. Pat. No. 1,994,553 to Wolcott fourth sidewalls, and the rail extending Substantially continu
discloses one such container of finely woven wire Screening. ously around the outer surface of the basket portion.
U.S. Pat. No. 2,825,481 to Glenny discloses another such In one example, the step of joining further includes spacing
container offinely woven wire screening. In order to make the 50 the rail from a free edge of the basket portion so that an upper
White, Wolcott and Glenny containers, a single blank of flat section of the basket portion extends above the rail. In such a
woven wire is cut out and folded with overlapping sections. method, the method further includes the step of cutting the
Another wire container that is commercially available upper section of the basket portion from the remaining por
under the brand name ElfaR) is formed of a wire grid with a tion of the basket portion.
plurality of separately formed wires welded together. The 55 In another example of the method, the rail is generally
ElfaR, container includes a basket portion and a flat rail L-shaped and has a first portion joined to the basket portion
around the top edge of the basket portion. The ElfaR, baskets and a second outwardly-extending portion. In Such a method,
are designed for use in a frame having a plurality of pairs of the rail further includes a projecting connection portion that
runners. When the baskets are inserted in the frame, the flat becomes integral with the sidewalls after joining the rail to the
rail is supported by a pair of runners and is movable between 60 basket portion. Such method may further include forming a
retracted and extended positions. The wire grid used for the second rail having a L-shape and two connection portions.
ElfaR, basket has large holes measuring about 1 inch by 1 The second rail being joined to the sidewalls and the bottom
inch. The ElfaR, basket also has openings at its corners. If a wall such that the connection portions become integral there
user desires to store Small objects in these baskets, a plastic with.
liner can be used. The liner has a bottom wall and upwardly 65 In yet another example, the step of joining further includes
bendable sidewalls, with slits between the sidewalls to allow containing a free edge of the basket portion with the rail. In
for such bending. The open corners of the basket and the slits Such an example, the step of forming the rail further includes
US 7,428,976 B2
3 4
forming the rail with a curved portion having an opening and and the second extension is joined to an inner Surface of the
a curved section joining first and second sections of the rail. first, second, third and fourth sidewalls.
The method further including the step of inserting the free According to one feature of the present invention, the rail is
edge of said basket portion within the opening. a Substantially continuous piece of material.
According to one aspect of the present invention, the step According to one feature of the present invention, the bas
of forming said rail further includes forming said rail with a ketportion includes open corners between the first and second
first extension coupled to and angularly offset from the first sidewalls and the third and fourth sidewalls. According to
section. another feature of the present invention, the basket portion
According to another aspect of the present invention, the includes closed corners between the first and second side
step of forming said rail further includes forming said rail 10 walls and the third and fourth sidewalls.
with a second extension coupled to and angularly offset from The present invention is also directed to a container com
the second section. prising a basket portion and first and second rails. The basket
The present invention is directed to a method of forming a portion is formed of metal mesh material and includes a
container comprising the following step: forming a basket bottom wall and upwardly extending first and second spaced
portion of metal mesh material into a bottom wall and 15 apart sidewalls and upwardly extending third and fourth
upwardly extending first and second spaced apart sidewalls spaced apart sidewalls. The first rail has a L-shape and is
and upwardly extending third and fourth spaced apart side joined to the first, second, third and fourth sidewalls. The
walls. The method further includes the following steps: bend second rail has a L-shape and is joined to the sidewalls and the
ing an upper section of the first, second, third and fourth bottom wall.
sidewalls outwardly; forming a rail including an opening; In an alternative example, the first rail further includes a
inserting the uppersection of the first, second, third and fourth first projecting connection portion that contacts the sidewalls
sidewalls into the opening; and compressing the rail to engage and becomes integral therewith, when the first rail is joined to
the upper section of the first, second, third and fourth side the basket portion. In yet another alternative example, the
walls. second rail further includes at least one second projecting
According to one example of the inventive method, the rail 25 connection portion. The second projecting connection por
tion contacts the sidewalls or bottom wall and becomes inte
forming step further includes forming a curved portion hav
ing the opening and the rail forming step further includes an gral therewith, when the second rail is joined to the basket
extension angularly offset from the curved portion. In addi portion.
tion, the inserting step further includes locating the extension Alternatively, the present invention is directed to a con
30 tainer with a first rail or a second rail.
adjacent the basket portion; and the method further includes
welding the extension to the first, second, third and fourth BRIEF DESCRIPTION OF THE DRAWINGS
sidewalls.
According to another aspect of the present invention, the The present invention will be more fully appreciated as the
rail forming step further includes forming the rail with a 35 same becomes understood from the following detailed
curved portion and a curved section joining first and second description of the best mode presently contemplated for car
sections of the rail and the curved portion forms the opening, rying out the present invention when viewed in conjunction
and the method further includes forming the rail with first and with the accompanying drawings, in which:
second extensions angularly offset from the curved portion. FIG. 1 is front, perspective view of a first example of a
Additionally, the compression step further includes locating 40 system of drawers of the present invention, where the drawers
the first extension adjacent an outer Surface of the first, sec are in a retracted position;
ond, third and fourth sidewalls and locating the second exten FIG. 2A is an enlarged, perspective view of an L-connector
sion adjacent an inner Surface of the first, second, third and for use with the system of FIG. 1;
fourth sidewalls. The method further includes welding the FIG. 2B is an enlarged, end view of the L-connector shown
first extension to the outer surface of the first, second, third 45 in FIG. 2A;
and fourth sidewalls and welding the second extension to the FIG. 2C is an enlarged, perspective view of a T-connector
inner surface of the first, second, third and fourth sidewalls. for use with the system of FIG. 1;
The present invention is also directed to a container com FIG. 2D is an enlarged, end view of the T-connector shown
prising a basket portion and a rail. The basket portion is in FIG. 2C;
formed of metal mesh material that includes a bottom wall 50 FIG. 3 is an enlarged, rear, perspective view of the first
and upwardly extending first and second spaced apart side example of a drawer shown in FIG. 1;
walls and upwardly extending third and fourth spaced apart FIG.3A is an enlarged, perspective view of a portion of the
sidewalls. The basket portion further includes an outwardly drawer shown in FIG. 3;
extending upper section of the first, second, third and fourth FIG. 4 is an exploded, rear, perspective view of the drawer
sidewalls. The rail includes an opening for receiving the 55 shown in FIG. 3;
upper section of the first, second, third and fourth sidewalls. FIG. 5 is an exploded, rear, perspective view of a portion of
The opening is sized so that the rail contacts opposing Sur the drawer shown in FIG. 3, wherein all of the mesh pieces
faces of said upper section. have been bent;
According to one aspect of the present invention, the rail FIG. 5A is a partially-exploded, rear, perspective view of
further includes a curved portion and an extension angularly 60 the drawer shown in FIG. 4, wherein three pieces of mesh
offset from the curved portion. The curved portion defines the material have been joined together,
opening and the extension is joined to the first, second, third FIG. 6 is a schematic representation of some of the mesh
and fourth sidewalls. pieces of FIG. 5 and a portion of a welding machine for
According to another aspect of the present invention, the joining Such pieces:
rail further includes first and second extensions angularly 65 FIG. 7 is a schematic representation of some of the mesh
offset from a curved portion. The first extension is joined to an pieces of FIG. 5 and a portion of the welding machine of FIG.
outer surface of the first, second, third and fourth sidewalls 6;
US 7,428,976 B2
5 6
FIG. 8 is a partial, elevational view of a first example of an FIG. 36 is a partial, elevational view of the upper rail of
upper rail joined to one of the mesh pieces shown in FIG. 5, FIG. 34 supported by a mesh piece, wherein welding has not
wherein an upper portion of the mesh piece is uncropped; occurred;
FIG. 9 is a partial, elevational view of the upper rail joined FIG.37 is a partial, elevational view of the upper rail joined
to the mesh piece of FIG. 8, wherein the upper portion of the 5 to the mesh piece of FIG. 36, wherein welding has occurred;
mesh piece is cropped; FIG.38 is a partial, elevational view of a tenth example of
FIG.10 is a partial, elevational view of a second example of an upper rail Supported by a mesh piece, wherein welding has
an upper rail separated from a mesh piece; not occurred;
FIG.11 is a partial, elevational view of the upper rail joined FIG.39 is a partial, elevational view of the upper rail joined
to the mesh piece of FIG. 10; 10 to the mesh piece of FIG. 38, wherein welding has occurred;
FIG. 12 is an exploded, rear, perspective view of a second FIG. 40 is an exploded, perspective view of an alternative
example of a drawer using the upper rail and mesh piece drawer example with an upper rail of FIG. 36 and a first
shown in FIGS. 10 and 11: example of a lower rail;
FIG. 13 is an exploded, rear, perspective view of a third FIG. 41 is a perspective view of the drawer and rails of FIG.
example of a drawer for use in the system of FIG. 1, wherein 15 40, wherein the rails are coupled to the basket portion;
an alternative example of two side pieces of mesh material are FIG. 42 is a partial, elevational view of the upper and lower
used; rails of FIG. 40 engaged with a mesh piece, wherein welding
FIG. 14 is a partially-exploded, rear, perspective view of has not occurred;
the drawer shown in FIG. 13, wherein three pieces of mesh FIG. 43 is a partial, elevational view of the upper and lower
material have been joined together, rails joined to the mesh piece of FIG. 42, wherein welding has
FIG. 15 is an enlarged, rear, perspective view of a fourth occurred;
example of a drawer useful in the system of FIG. 1; FIG. 44 is a partial, elevational view of the upper rail of
FIG.16 is an exploded, rear, perspective view of the drawer FIG.38 supported by a mesh piece and a second example of
shown in FIG. 15: a lower rail, wherein welding has not occurred; and
FIG. 17 is a partially-exploded, rear, perspective view of 25 FIG. 45 is a partial, elevational view of the upper and lower
the drawer shown in FIG. 15, wherein three pieces of mesh has rails joined to the mesh pieces of FIG. 44, wherein welding
occurred.
material have been joined together,
FIG. 18 is front, perspective view of a second example of a DETAILED DESCRIPTION OF EXAMPLES OF
system of drawers of the present invention, where the drawers 30 THE PRESENT INVENTION
are shown in a retracted position;
FIG. 19 is an exploded, perspective view of an exemplary Referring to FIG. 1, a first example of drawer system 10 is
drawer with a third example of an upper rail; shown. This drawer system 10 may be used to store a variety
FIG. 20 is a perspective view of the drawer and rail of FIG. of housewares, such as kitchen items, clothing, accessories,
19, wherein the rail is coupled to the drawer; 35 sports equipment, shoes, bathroom Supplies, tools, appli
FIG. 21 is an enlarged, partial, perspective view of the ances, and the like. Additionally, system 10 can be used to
upper rail of FIG. 19, wherein the rail is uncompressed; store a variety of other items, for example food, office Sup
FIG. 22 is a partial, elevational view of the upper rail of plies, office equipment, file folders, papers/documents, bags,
FIG. 19 disposed upon a mesh piece, wherein the rail is boxes, cans, bottles, etc.
uncompressed; 40 Drawer system 10 includes frame 12 and a plurality of
FIG.23 is a partial, elevational view of the upper rail joined containers or drawers 14a-d Drawer 14a is smaller than
to the mesh piece of FIG. 22, wherein the rail is compressed; drawers 14b-c so drawer 14a can hold a smaller volume than
FIG. 24 is a partial, elevational view of a fourth example of other drawers 14b-d. Drawers 14a-daremovable with respect
an upper rail separated from a mesh piece; to frame 12 between a retracted position (shown in FIG. 1)
FIG.25 is a partial, elevational view of the upper rail joined 45 and an extended position. In the retracted position, the con
to the mesh piece of FIG. 24; tents of lower drawers 14b-d is difficult to access. In the
FIG. 26 is a partial, elevational view of a fifth example of an extended position, the contents of the extended drawer are
upper rail separated from a mesh piece; easily accessible; the extended drawer may be fully with
FIG.27 is a partial, elevational view of the upper rail joined drawn from frame 12 if desired.
to the mesh piece of FIG. 26: 50 With reference to FIG. 1, frame 12 includes two side frame
FIG. 28 is a partial, elevational view of a sixth example of members or ladders 16 that are spaced apart and joined by
an upper rail separated from a mesh piece; pairs of upper and lower cross members 18a, b, respectively.
Side frame members 16 and pairs of upper and lower cross
FIG.29 is a partial, elevational view of the upper rail joined members
to the mesh piece of FIG. 28; 18a, b are formed to give frame 12 a rectangular
55 shape. The present invention is not limited to this frame
FIG. 30 is a partial, elevational view of a seventh example shape.
of an upper rail separated from a mesh piece; Frame 12 further includes L-connectors 20 (as best seen in
FIG.31 is a partial, elevational view of the upper rail joined FIG. 2A) and T-connectors 22 (as best seen in FIG. 2B) for
to the mesh piece of FIG.30; joining side frame members 16 to cross frame members 18a,
FIG. 32 is a partial, elevational view of an eighth example 60 b. For example, L-connectors 20 connect upper cross member
of an upper rail separated from a mesh piece; 18a to side frame members 16, if no additional frames are to
FIG.33 is a partial, elevational view of the upper rail joined be added above the one illustrated in FIG.1. If an additional
to the mesh piece of FIG. 32: frame is to be added above frame 12 shown in FIG. 1, T-con
FIG. 34 is an exploded, perspective view of a drawer with nectors 22 are used to join upper cross members 18a to frame
a ninth example of an upper rail; 65 members 16. For example, T-connectors 22 also connect
FIG.35 is a perspective view of the drawer and rail of FIG. lower cross members 18b to side frame members 16. Alter
34, wherein the rail is coupled to the drawer; natively, T-connectors 22 joined to lower cross members 18b
US 7,428,976 B2
7 8
can be replaced with plugs with casters (not shown) thereonto form closed curved corners 64. Sidewalls 58, 60 and 62
make system 10 movable, as is apparent to those of ordinary extend upwardly from bottom wall 56 to form upwardly
skill in the art. facing opening 66.
Referring again to FIG. 1, each side frame member 16 As shown in FIG. 3, corners 64 are curved so that they
includes a pair of spaced apart vertical rods 24 coupled by 5 deviate from Straightness in a smooth, continuous fashion.
Vertically spaced apart horizontally-extending runners 26a-g. The present invention, however, is not limited to drawers with
Each side frame member 16 is formed so that runners 26a-g of curved corners and drawers with more angular corners are
each side frame member 16 are aligned with runners 26a-g of also considered inventive. The present invention is also not
other side frame member 16 to form a plurality of pairs of limited to drawers with a radius of curvature greater at the top
runners. Each runner 26a-g is a generally U-shaped member 10 of the drawer (adjacent the rail 54) than at the bottom. Thus,
with inwardly extending gap 28 defined therein. Runners drawers with, for example, a constant radius of curvature are
26a-g may include a bore (not shown) in the rear end for also considered inventive.
receiving a pin (not shown) for preventing rearward move In this example, sidewall 58 forms a front end wall that
ment of drawers 14a-d out of frame 12. To make frame 12 includes curved cutout 68 bordered by handle rail 70. Cutout
independent of direction the bore (not shown) may beformed 15 68 forms a place where a user can easily grasp drawer 14b to
at both ends of each runner and the pin (not shown) disposed move it between the retracted and extended positions. In an
in the desired end for use. alternative example, cutout 68 can be replaced with other
Frame 12 is, for example, formed of any metal with suffi methods to aid the user in moving drawer 14b, Such as a
cient rigidity and formability, for example mild sheet steel, protruding handle connected to wall 58. Handle rail 70 may
stainless steel, aluminum, copper or the like can be used. have a circular cross-sectional shape and be cut and formed to
Vertical rods 24 and runners 26a-gare, for example, welded extend along the edge of cutout 68. In the present example,
together using conventional welding techniques. Frame 12 rail 70 is of the same material as upper rail 54 and is spot
may be subjected to a powder painting treatment, similar to welded to basket portion 55. In this example, sidewall 60
that discussed below for drawers 14a-d. forms a rear end wall.
Referring to FIGS. 1, 2A and 2B, L-connector 20 includes 25 Referring to FIG.4, drawer 14b is shown in a disassembled
central body 30 and first and second generally perpendicular state. Basket portion 55 is formed by first piece of mesh 72,
legs 32 and 34 extending therefrom. For example, pairs of second piece of mesh 74 and third piece of mesh 76. First,
cross members 18a, b and vertical rods 24 are hollow so that second, and third pieces of mesh 72, 74, 76 are formed sepa
legs 32 and 34 are received therein to join these components rately from one another. First piece of mesh 72 is bent along
together. Referring to FIGS. 1, 2C and 2D, T-connector 22 30 lines 72a, b to form edges as shown in FIG.5 to define bottom
includes central body 36 and first, second, and third legs 38. wall 56 and sidewalls 62. The angle between bottom wall 56
40, and 42, respectively, extending therefrom. First and sec and sidewalls 62 is greater than about 90°, but the present
ond legs 38 and 40 are generally perpendicular to one another invention is not limited to this configuration.
similar to L-connector 20. Third and second legs 40 and 42 Second piece of mesh 74 includes outer edge 74a, inner
are also generally perpendicular to one another. For example, 35 edge 74b, central portion 74c, side extensions 74d, and lower
first leg 38 and third leg 42 may be inserted into hollow extension 74e. Central portion 74c is between outer edge 74a
vertical rods 24, and second leg 40 is inserted in hollow and lower extension 74e and between side extensions 74d.
associated cross members 18a, b. Side extensions 74d have a trapezoidal shape so that they
L-connectors 20 and T-connectors 22 are, for example, taper downward from outer edge 74a to lower edge 74b.
formed of any metal with sufficient rigidity and formability. 40 Second piece of mesh 74 is bent to form front end wall 58,
For example, connectors 20 and 22 can be cast of die-cast curved corners 64, and lower extension 74e that is generally
aluminum or any alloy, using conventional techniques known perpendicular to front end wall 58 (see FIGS. 3 and 5). Third
to those of ordinary skill in the art. Connectors 20 and 22. piece of mesh 76 is formed similarly to second piece of mesh
however, can also be formed of another material like injection 74 to include upper edge 76a, lower edge 76 b, central portion
molded plastic. 45 76c, side extensions 76d, and lower extension 76e.
Now, with reference to FIGS. 1, 3, and 3A, the details of In an alternative example, pieces of mesh 74 and 76 can be
drawer 14b will be discussed. Drawer 14b includes a runner formed of a single piece of material separate from first piece
portion that comprises upper rail 54 and basket portion 55. of mesh 72. In such event, the two pieces of mesh 74 and 76
Basket portion 55 is coupled to upper rail 54. In the present would be joined by another mesh segment (not shown) that
example, basket portion 55 is formed of expanded metal plate 50 would be shaped similar to bottom wall portion 56. As a
(i.e., sheet metal) or “mesh' and has small openings 55a result, bottom wall of basket 55 would be formed of two
therein. In the present specification and appended claims layers of mesh material that overlap.
"mesh' means flat metal that is pierced and stretched so that Referring to FIG. 5A, first, second, and third pieces of
no material is separated from the original raw material, as mesh 72, 74, and 76 have been joined together so that bottom
known by those of ordinary skill in the art. On the other hand, 55 seams 78 are formed. Seams 78 are where the material of
unlike mesh, punching portions of waste material out of sheet bottom wall 56 of first piece of mesh 72 overlaps with lower
metal material forms perforated metal. For example, open extension 74e of second and third pieces of mesh 74 and 76
ings 55a (see FIG.3A) in the mesh have an area less than 25.4 (see FIG. 4). When corners 64 are formed, side seams 80 (as
mm by 25.4 mm. In another example, openings 55a (see FIG. shown in FIG. 3) are formed adjacent each corner 64. Seams
3) in the mesh have an area less than 20 mm by 10 mm. In yet 60 80 are where the material of sidewalls 62 offirst piece of mesh
another example. In another example, openings 55a (see FIG. 72 overlaps with side extensions 74d and 76d of second and
3) in the mesh have an area less than 6 mm by 3 mm. third pieces of mesh 74 and 76, respectively. Seams 80 are
Basket portion 55, for example, is formed of any metal generally vertically extending side seams.
Such as copper, steel, stainless steel or aluminum, and the like. The method of making drawer 14b will now be discussed.
Basket portion 55 includes bottom wall 56, a pair of spaced 65 Referring to FIGS. 4 and 5, first piece of mesh 72 is formed
apart sidewalls 58 and 60, and another pair of sidewalls 62. and shaped as shown. This involves cutting piece of mesh 72
For example, sidewalls 58, 60 and 62 are joined together to with the desired dimensions from a roll of mesh using a
US 7,428,976 B2
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conventional press machine. Then, first piece of mesh 72 is As a result, second and third pieces 74 and 76 can, for
bent into a U-shape that includes bottom wall 56 and end example, be simultaneously welded to first piece 72.
walls 62 (as shown in FIG. 5). A conventional hydraulic press Another spot-welding machine similar to machine 84 is
machine is used to bend mesh piece 72. The hydraulic press used to weld pieces 74 and 76 to piece 72 adjacent the corners
machine includes a mold for achieving the desired bent shape, 5 64 to form seams 80. This spot-welding machine for forming
as is known by those of ordinary skill in the art. seams 80 has an appropriately sized fixture including
Second and third pieces of mesh 74 and 76 are formed and clamp(s), elongated member(s) and cathode electrode(s) for
shaped as shown in FIG. 4. This involves cutting pieces of smaller pieces 74 and 76. For example, the cathode
mesh 74 and 76 with the desired dimensions and shape from electrode(s) may be tapered to match trapezoidal extensions
a roll of mesh using a conventional press machine. Then, 10 74d,76d so that pieces 74 and 76 are suitably clamped to end
mesh piece 74 is bent using a conventional hydraulic press walls 58 and 60 during welding.
machine so that side extensions 74d are curved and lower With reference to FIG. 3, upper rail 54 is subsequently
extension 74e is angularly offset from centersection 74c. The connected to upper section of end walls 58 and 60 and side
hydraulic press machine includes a mold, as is known by walls 62 by spot-welding. Referring to FIGS. 3 and 8-9, the
those of ordinary skill in the art. Third piece of mesh 76 is bent 15 step of connecting upper rail 54 to basket portion 55 further,
similarly to second piece 74 (as shown in FIG. 5). Handle rail for example, includes the steps of forming generally flat
70 may be welded to mesh piece 74 at this point or later, when upper rail 54; contacting rail 54 to basket portion 55 on
upper rail 54 is joined to basket portion 55. contact surface 54a so that upper section 55a of basket por
Next, lower extensions 74e, 76e of each piece 74.76 are tion 55 extends above rail 54; and spot-welding contact sur
connected by welding to the side edge of bottom wall 56 of face 54a to outer surface of basket portion 55.
first piece 72 (as shown in FIG. 5A) to form seams 78. Then, Upper rail 54 is, for example, formed of the same material
curved side extensions 74d,76d of pieces 74.76 are connected as basket portion 55 so that these components can be welded
by welding to sidewalls 62 of first piece 72 to form seams 80 together. Thus, for example, rail 54 is formed of any metal
(as shown in FIG. 3). Such as copper, Steel, stainless steel, mild sheet steel or alu
After drawer 14b is completely formed (including attach 25 minum, and the like. In an example using sheet steel, a roll of
ing rail 54), a process of powderpainting may be used to coat sheet steel strip material with a circular cross-section is used.
drawer 14b, as is known by those of ordinary skill in the art. This material is passed through a conventional roll forming
One exemplary paint is an epoxy coat. The painting may machine with a number of pairs of rollers using a predeter
provide a decorative (colored and/or metallic) finish to mined compression pressure to continuously and gradually
drawer 14b, if desired, and will also provide some protection 30 change the circular cross-section into a generally flat rectan
for the drawer 14b from water and other corrosive elements. gular cross-section, as is known by those of ordinary skill in
Referring to FIGS. 5, 6, and 7, the equipment used to the art.
connect first, second and third pieces of mesh 72, 74, and 76 The material with the flat rectangular cross-section is then
together will now be discussed. The equipment, for example, fed into a bending machine that includes spaced apart pairs of
comprises spot-welding machine 84 including base 86, clamp 35 guide rollers for guiding the material through the machine
88 supported on base 86, movable elongated member 90 and bending the material into four spaced apart right angles to
movable by clamp 88 to provide clamping force F, and a pair form a rectangular ring. Hydraulic power can be used to
of anode electrodes 92a and a pair of cathode electrodes 92b. provide the bending force to the associated pairs of guide
Base 86, clamp 88, member 90, and cathode electrodes 92b rollers. Where the bending pairs of guide rollers are located,
form a fixture for supporting mesh pieces 72, 74, and 76 40 the machine further includes rollers for preventing vertical
during welding. As shown, for example, cathode electrodes expansion of the material. Once the rectangular ring is
92b are, for example, bar-like and parallel to one another to formed, the free ends of the ring are joined by welding to form
properly support and clamp mesh pieces 72, 74, and 76. In an upper rail 54.
alternative example, the spot-welder can be used without Rail 54 is not limited to the above configuration, shape and
clamp 88 and elongated member 90, where the pieces may be 45 materials. For example, it can be hollow with various shapes,
manually held during welding. such as a circular cross-section. Rail 54 can also be solid with
In order to join lower extension 74e of second piece 74 to various shapes, such as a circular cross-section. Rail 54 can
bottom wall 56 of first piece 72, already-bent first piece 72 is also be formed of a plastic that is connected to basket portion
disposed on cathode electrodes 92b so that sidewalls 62 55 by glue or adhesive, for example.
extend downward (as shown in FIG. 6) toward the floor. Bent 50 Referring to FIGS. 8 and 9, the step of contacting rail 54 to
second piece 74 is disposed between member 90 and cathode basket portion 55 on contact surface 54a may, for example,
electrode 92b, as shown in FIG. 7. Next, clamp 88 is actuated further include the step of using spot-welding machine with
so that clamping force F moves member 90 from a retracted fixture F for supporting rail 54 at a sufficient elevation above
position (shown in FIG. 6) into a clamping position (shown in a table (not shown) so that upper section 55a of basket portion
FIG. 7). In the clamping position, mesh piece 74 is com 55 55 extends above rail 54. Fixture F may also provide a clamp
pressed between member 90 and cathode electrode 92b. ing force for assuring Surface 54a is in Solid contact with
Clamping force F must be sufficient to hold mesh piece 74 basket portion 55 or this force may be provided by movable
into contact with mesh piece 72 for the welding operation. anode and cathode electrodes AE and CE, respectively. For
Then, anode electrode 92a moves in direction D1 into example, electrodes AE and CE are circular welding wheels.
contact with pieces 72.74 adjacent extension 74e. Pieces 60 Anode electrode AE contacts outer surface of rail 54 and
72.74 are tightly compressed between electrodes 92a and cathode electrode CE contacts inner surface of basket portion
92b. Electrodes 92a, b then discharge electric welding current 55 adjacent surface 54a, as shown in FIG. 9. An electric
through the place to be welded and seam 78 (see FIG.5A) is current is discharged through electrodes AE and CE, rail 54
formed. Third piece 76, as shown in FIG. 5, is similarly joined and basket portion 55 to spot-weld rail 54 to basket portion
to first piece 72. In the present example, welding machine 84 65 55. For example, sufficient electrodes AE and CE are pro
is properly configured so that the fixture includes two clamps, vided to make the welding of rail 54 to basket portion 55
two elongated members 90 and two pairs of electrodes 92a, b. efficient. Since electrodes AE and CE are movable vertically
US 7,428,976 B2
11 12
in directions V and horizontally in directions H, the spot larly, upper section 55a' is formed on pieces 74 and 76, when
welder can be used to weld variously size rails and baskets edges 74d and 74e and edges 76e and 76d, respectively, are
together. formed. Then, pieces 72, 74, 76 are welded together.
The step of connecting upper rail 54 may further include Bent upper section 55a' is inserted into opening 54b' of
cutting and grinding steps. In the cutting step, upper section upper rail 54 (as shown in FIG. 11). Curved portion 54a' is
55a (as shown in FIG. 8) of basket portion 55 is severed using then compressed by a conventional press machine so that
a conventional severing apparatus, such as one including a opening 54b' is minimized and curved portion 54a' tightly
reciprocating saw blade. In the grinding step, exposed upper engages basket portion 55a' so that inner surfaces of curved
edge 55b (FIG. 9) of basket portion 55 is worked using a portion 54a' contact basket portion 55a'. This step also results
conventional grinding machine so that upper edge 55b 10 in front curved tip or portion 54d of rail 54 engaging angled
becomes smooth. Rail 54 aids in providing structural rigidity corner 55b' of basket portion 55'. Then, vertically-extending
to basket portion 55 and is the only rail circumscribing each extension 54c is welded to the basket using a spot-welding
drawer's perimeter. machine and fixture similar to the method used for rail 54
Once rail 54 is joined to the outer surface of the basket (shown in FIGS. 8 and 9).
portion, a substantial portion of rail 54 extends substantially 15 Once upper rail 54" is joined to basket portion 55' in this
outwardly from the outer surface of first, second, third and manner, it provides additional structural rigidity to basket
fourth sidewalls of basket portion 55 and rail 54 extends portion 55'. Using rail 54 eliminates the need to cut upper
continuously around the outer surface of basket portion 55 (as section 55a of basket portion 55, as when using rail 54, as
shown in FIG. 3). shown in FIGS. 8 and 9. Consequently, rail 54 eliminates the
Referring to FIGS. 1 and 3, in use drawer 14b is inserted need to deburr or grind basket portion 55'.
into system 10 by disposing upper rail 54 within gap 28 of In an alternative exemplary method, pieces 72, 74, 76 (see
opposed, aligned pair of runners 26b. Rail 54 and gap 28 are FIG. 5) are bent to form edges 72a and 72b in piece 72, edges
sized to allow free sliding movement of drawer 14b with 74d and 74e in piece 74, and edges 76e and 76d in piece 76.
respect to frame 12 between the retracted and extended posi Then, pieces 72, 74, 76 are welded together. Next, joined
tions. 25 pieces 72, 74, and 76 are placed in a conventional hydraulic
Since drawer 14b is formed of mesh with very small open press machine with a mold and bent to create outwardly bent
ings 55a (see FIG. 3), Small objects, such as pens, paper clips, upper section 55a' on each piece 72, 74,76. Subsequently, rail
and the like, can be stored in drawer 14b without a liner and 54 is coupled to basket 55' as previously discussed.
will not fall through openings 55a. In addition, since drawer Referring back to FIG. 1, basket 14a includes a rectangular
14b has closed corners 64, small objects also cannot fall out of 30 cutout 68 on front of wall 58'. Metal handle rail 70' covers the
this area of drawer 14b. free end of the mesh within cutout 68. Handle rail 70' is, for
As shown in FIG. 1, drawers 14b-14d are of medium size example, formed similar to rail 54 (ee FIG. 10) with an
and vertically extend across two sets of Vertically spaced opening that is compressed about the mesh, once the mesh is
runners. Drawer 14a is a Small size and consequently extends inserted therein. For example, handle rail 70' also includes an
across only one set of vertically spaced runners. The drawers 35 extension, similar to extension 54c of rail 54, that can be
may be sized differently, see FIG.4, particularly by changing spot-welded to securely attach rail 70' to the mesh. In such an
the length L of first piece of mesh 72 and the height H of example, opening in rail 70' extends vertically along with its
second and third pieces of mesh 74 and 76. This allows extension similar to extension 54c'. In an example of handle
containers of a variety of sizes to be formed without excess rail 70' without such an extension, rail 70' may still be spot
machinery costs, particularly large containers having depth D 40 welded to the mesh.
from bottom wall 56 to top surface oftop rail 54 (see FIG. 3) Referring to FIGS. 13-14, third drawer example 114b is
equal to or greater than about 11 inches. If larger baskets are shown. Drawer 114b comprises runner portion or upper rail
desired, the basket material may need to be changed and/or 154 and basket portion 155. Upper rail 154 may be formed
thickened to provide more rigidity thereto. Width W of the like rail 54 or rail 54 previously discussed. Basket portion
mesh (FIG. 4) can be set by the machine forming the raw 45 155 includes bottom wall 156, end walls 158 and 160, and
materialso that the edges of piece 72 that will be connected to sidewalls 162. Bottom and end walls 156 and 158 are also
pieces 74 and 76 are Smooth and require no cutting or grind sidewalls. First piece of mesh 172 is bent to form bottom wall
1ng. 156 and end walls 158 and 160. Sidewalls 162 are formed of
FIGS. 10-12 illustrate an alternative example of upper rail separate second and third pieces of mesh 174 and 176, respec
54" for use with alternative example of basket portion 55'. To 50 tively. End wall 158 includes first piece of mesh 172 with
form upper rail 54 raw material is bent to include curved cutout 168 similar to end wall 58.
portion 54a' with opening 54b' and extension 54c' angularly For drawer 114b, different from drawer 14b, second piece
offset from curved portion 54a'using a roll forming machine. of mesh 174 includes central portion 174c, rectangular side
Curved portion 54a' further includes first section A, second extensions 174d and lower extension 174e. Third piece of
section B, and curved section C joining first and second 55 mesh 176 has a similar configuration. When pieces 172,174
sections A,B so that opening 54b' is located therein. Sections and 176 are connected using a method similar to that used in
A and B are generally horizontal sections. Extension 54c is forming drawer 14b, drawer 114b has closed smoothly
joined to first section. A via curved section 54d. The material curved corners similar to corners 64 (as shown in FIG.3), but
for rail 54 is bent into a closed rectangular loop and welded corners of drawer 114b will have a substantially constant
together, similar to rail 54 so that rail 54 is continuous. 60 radius. Drawer 114b also includes four side seams 80 at each
Basket portion 55 is formed similarly to basket portion 55 corner and two bottom seams 178.
except end walls 58, 60 and sidewalls 62 all have an out Referring to FIGS. 15-17, fourth drawer example 214b is
wardly bent upper section 55a'. Upper section 55a' is formed shown. Drawer 214b comprises runner portion or upper rail
by a conventional hydraulic press machine with a mold at the 254 and basket portion 255. Upper rail 254 may be formed
same time other bends are formed in pieces 72, 74, 76 (see 65 like rails 54,54, 154" or 254' discussed above. Basketportion
FIG. 5). That is when piece 72 is bent to form edges 72a and 255 includes bottom wall 256, end walls 258 and 260, and
72b, piece 72 is also bent to form upper section 55a'. Simi sidewalls 262. End walls 258 and 260 are also sidewalls. First
US 7,428,976 B2
13 14
piece of mesh 272 is bent to form bottom wall 256 and end welding machine and fixture similar to the method used for
walls 258 and 260. Sidewalls 262 are formed of separate rail 54 (shown in FIGS. 8 and 9).
second and third pieces of mesh 274 and 276. End wall 258 Rail 354 adds structural rigidity to basket portion 355 and
includes cutout 268 similar to end wall 58. eliminates the need to cut and deburr basket portion 355.
In drawer 214b, different from drawers 14b and 114b, FIGS. 24-25 illustrate an alternative fourth example of
second and third pieces of mesh 274 and 276 do not include upper rail 454 for use with basket portion 55 (shown in FIGS.
extensions. When pieces 272, 274 and 276 are connected 8 and 24). Rail 454 is similar to rail 54 as shown in FIG. 10
using the method of forming drawer 14b, pieces 274 and 276 except as discussed below. Upper rail 454 is bent to include
only overlap piece 272 on the bottom not on the sides. As a first portion 454a and angularly offset second portion 454b.
result, drawer 214b has open corners 264 (as shown in FIG. 10 Second portion 454b includes contact surface 454c.
15) and two bottom seams 278. Drawers configured like Second portion 454b of rail 454 is connected to basket
drawer 214b can be used in systems like system 10 (shown in portion 55 by spot-welding, similar to rail 54 shown in FIGS.
FIG. 1) and move between extended and retracted positions. 8 and 9. The step of connecting upper rail 454 to basket
Drawers similar to drawer 214b can come in a number of portion 55 further includes, for example, the steps of forming
sizes. Drawer 214b is formed similarly to drawer 14b by 15 generally L-shaped rail 454, contacting contact Surface 454c
bending and spot-welding the mesh pieces. of rail 454 to basket portion 55 so that upper section 55a of
Referring to FIG. 18, a second example of drawer system basket portion 55 extends above rail 454 and first portion
310 is shown. Drawer system 310 includes frame 312 and 454a is spaced from upper edge 55b, spot-welding contact
plurality of drawers 314a and 314b. Frame 312 includes four surface 454c to outer surface of basket portion 55 (as shown
pairs of runners 326a-d. This example illustrates that any in FIG. 25), and cutting upper section 55a of basket portion
number of pairs of runners can be used depending on how 55. A finishing or grinding step may be used to assure that
large a system is desired. Frame 312 is otherwise configured upper edge 55b of basket portion 55 is not sharp. Alterna
and formed similarly to frame 12 (shown in FIG. 1). System tively, rail 454 can be joined to basket portion 55 so that free
310 further may include solid table top or shelf 327 that is end of portion 454b is aligned with edge 55b. As a result, no
securely connected to the top of frame 312 by a press fit so that 25 additional cutting of basket portion is necessary. First portion
objects can be stored or displayed thereon. Alternatively, 454a of the rail is operatively associated with runners 26a-g
shelf 327 may be sized differently (larger or smaller than) of frame 12 (see FIG. 1) during use.
frame 312 and connected to frame 312 with conventional FIGS. 26-27 illustrate an alternative fifth example of upper
fasteners such as screws and L-brackets. Drawer 314a is rail 554 for use with basket portion 55 (shown in FIGS. 3 and
small and extends across one pair of runners 326a. Drawer 30 26). Upper rail 554 is similar to upper rail 454 except rail 554
314b is large and extends vertically across three pairs of is oriented differently when joined to basket portion 55. As
runners 326b-d. Drawers 314a and 314b are configured and shown in FIG.27, when rail 554 isjoined to basketportion55,
manufactured similar to drawer 14b (see FIG. 1), but drawers first portion 554a is aligned with upper edge 55b and second
configured like drawers 114b and 214b can also be used with portion 554b is coupled to basket portion 55. Rail 554 is
system 310. 35 joined to basket portion 55 as previously discussed with
FIGS. 19-23 illustrate an alternative third example of upper respect to rail 454. Rail portion 554a is operatively associated
rail354 for use with basket portion 355. As shown in FIG. 21, with runners 26a-g of frame 12 (see FIG. 1) during use.
upper rail 354 is formed similar to rail 54 to include curved FIGS. 28-29 illustrate an alternative sixth example of upper
portion 354a with opening 354b and first and second exten rail 654 for use with basket portion 55 (shown in FIGS. 3 and
sions 354c and 354e angularly offset from curved portion 40 28). Upper rail 654 is similar to upper rail 454 except as noted
354a. Curved portion 354a further includes first section A, below. Rail 654 includes first portion 654a angularly offset
second section B, and curved section C joining first and from second portion 654b which is offset from third portion
second sections A, B so that opening 354b is located therein. 654c to form recess 654d between second and third portions
In the present example, first section A has a length less than 654b, 654C. In the present example (as shown in FIG. 29), rail
second section B. First extension354c isjoined to first section 45 thickness to of second portion 654b is less than mesh thick
A. Second extension 354e is joined to second section B. Rail ness t of basket portion 55 so that upper edge 55b of basket
354 is bent so that curved portion 354a has a generally portion 55 is not fully received within recess 654b and must
V-shape form, as shown in FIG. 21. therefore be ground to ensure edge 55b is smooth. Alterna
Referring to FIGS. 22 and 23, bent upper section 355a of tively, the offset between second and third portions 654b,
basket portion 355, which is similar to basket portion 55", is 50 654c can be increased so that edge 55bis fully received within
inserted into opening 354b of upper rail 354'. As a result, first recess 654d. In yet another alternative, rail 754 (see FIGS.
and second extensions 354c and 354e are adjacent to outer 30-31) can be configured similar to rail 654, except rail thick
and inner surfaces, respectively, of basket portion 355. ness to of second portion 754b is greater than mesh thickness
Curved portion 354a is then compressed, as indicated by t of basket portion 55 so that upper edge 55b of basket
arrows F in FIG. 22, by a conventional press machine. As a 55 portion 55 is fully received within recess 754b and thus does
result, opening 354b is minimized (as shown in FIG. 23) and not require grinding.
curved portion 354a tightly engages basket portion 355a. Rails 654, 754 are joined to basket portions 55 as previ
This compression also result in extensions 354c and 354e ously discussed with respect to rail 454. Rail portions 654a,
sandwiching basket portion 355 therebetween. Additionally 754a are operatively associated with runners 26a-g of frame
after compression, extensions 354c, 354e are generally ver 60 12 (see FIG. 1) during use.
tically oriented and first and second sections A,B are gener FIGS. 32-33 illustrate an alternative eighth example of
ally horizontally oriented (as best shown in FIG. 23). In upper rail 854 for use with basket portion 55 (shown also in
addition, compression results in curved edge 354d of rail 354 FIG. 3). Rail 854 is similar to rail 454 shown in FIG. 24,
engaging angled corner 355b of basket portion 355 (see except second portion 854b of rail 854 is connected to curved
FIGS. 22-23). Then, the now generally vertically-extending 65 section 854C, which is connected to extension 854d. Curved
extensions 354c and 354e are welded to outer and inner portion 854e of rail 854 is formed by second portion 854b,
surfaces, respectively, of basket portion 355 using a spot curved section 854c and extension 854d and also defines
US 7,428,976 B2
15 16
opening 854f. Rail 854 is bent so that curved portion 854e has bottom wall 1155b and second portion 1154b and rib 1155d
a generally open V-shape (as shown in FIG. 32). contact sidewalls 1155a. After joining rail 1154 to basket
Upper edge 55b of basket portion 55 is inserted into open portion 1155, the use of electric welding (using heat collec
ing 854f so that when rail 854 is compressed by a conven tion and pressure) could allow the ribs 1154c, d and basket
tional press machine, as shown in FIG. 33, second portion portion 1155 contacting ribs 1154c,d to be fused into an
854b and extension 854e are adjacent to outer and inner integral structure (as shown in FIG. 43).
surfaces, respectively, of basket portion 55. Compression also FIGS. 44-45 illustrate basket portion 1155 with upper rail
minimizes opening 854f (as shown in FIG. 33) and causes 1054 and alternative lower rail 1254. Basket portion 1155 is
curved section 854c to tightly engage basket portion 55. previously described with reference to FIGS. 40-41. Upper
Additionally, after compression extension 854d is generally 10 rail 1054 previously described with reference to FIGS. 38-39
vertically-extending and second portion 854b and extension is joined to basket portion 1155 as previously discussed.
854d are welded to the outer and inner surfaces, respectively, Lower rail 1254 is similar to lower rail 1154 (shown in
of basket portion 55using a spot-welding machine and fixture FIGS. 42-43), except ribs 1154c, d have been replaced with
similar to the method used for rail 54 (shown in FIGS. 8 and inwardly extending or projecting connection portions
9). 15 1254c, d at the free end of first and second portions 1254a, b,
Once upper rail 854 is joined to basket portion 55 in this respectively. When rail 1254 is joined to basket portion 1155.
manner, it provides additional structural rigidity to the basket first portion 1254a and rib 1255c contact bottom wall 1155b
portion 55. Using rail 854 eliminates the need to cut upper and second portion 1254b and rib 1255d contact sidewalls
section 55a of basket portion 55 as when using rail 54, as 1155a. After joining rail 1254 to basket portion 1155, the use
shown in FIGS. 8 and 9. Consequently, rail 854 eliminates the of electric welding (using heat collection and pressure) could
need to deburr basket portion 55. allow connection portions 1254c, d and basket portion 1155
FIGS. 34-37 illustrate an alternative ninth example of contacting the connection portions 1254c,d to be fused into an
upper rail954 for use with basket portion 955. Upper rail954 integral structure (as shown in FIG. 43).
is similar to upper rail 454 (shown in FIGS. 26-27), except Rails 354, 454, 554, 654, 754, 854, 954, 1054, 1154 and
vertical second portion 954b of rail 954 includes an outwardly 25 1254 are generally rectangular rings that are continuous about
extending or projecting connection portion or rib 954c. The their respective basket portions. These rails are formed of
location of rib 954c along vertical portion 954b can be varied. materials similar to those discussed with respect to rails 54
As shown in FIG.37, when rail 954 is joined to basket portion and 54'.
955, horizontal first portion 954a covers upper edge 955b Those skilled in the art will appreciate that the conception,
(shown in FIG. 34) and second portion 954b and rib 954c 30 upon which this disclosure is based, may readily be utilized as
contact basket portion 955. After joining rail 954 to basket a basis for designing other products for carrying out the
portion 955, the use of electric welding could allow rib 954c several purposes of the present invention. It is important,
and basket portion 955 contacting rib 954c to be fused into an therefore, that the claims be regarded as including Such
integral structure (as shown in FIG.37). This is due to the heat equivalent constructions insofar as they do not depart from
collection and pressure of resistors used during welding. 35 the spirit and scope of the present invention as defined in the
Rail 954 adds structural rigidity to basket portion 955 and appended claims. Therefore, this invention is not to be limited
eliminates the need to cut and deburr basket portion 955. Rail to the specific examples depicted therein. For example, the
portion 954a is operatively associated with runners 26a-g of features of one example disclosed above can be used with the
frame 12 (see FIG. 1) during use. features of another example. Furthermore, the various rail
FIGS. 38-39 illustrate an alternative tenth example of 40 examples 54,54', 354, 454, 554, 654, 754, 854, 954, 1054,
upper rail 1054 for use with basket portion 955. Upper rail 1154 and 1254 can be used exclusively in different systems of
1054 is similar to upper rail 954 (shown in FIGS. 36-37), drawers to provide systems that cost different amounts, e.g., a
except rib 954c has been replaced with outwardly extending high-priced system and a lower priced system. Alternatively,
or projecting connection portion 1054c at the free end of one system can have drawers with various types of rails 54,
vertical second portion 1054b. When rail 1054 is joined to 45 54,354, 454,554, 654, 754, 854,954, 1054, 1154 and 1254.
basket portion 955, horizontal first portion 1054a covers Additionally, a system can use all closed-corner drawers or
upper edge 955b (shown in FIG. 34) and second portion combine closed-corner drawers with open-corner drawers in
1054b and connection portion 1054c contact basket portion one system. The system may be used with sliding drawers
955. After joining rail 1054 to basket portion 955, the use of and/or stationary and sliding shelves each Supported by a pair
electric welding could allow connection portion 1054c and 50 of runners. The system frame may also include a section for
basket portion 955 contacting connection portion 1054c to be holding hanging file folders and one or more of the inventive
fused into an integral structure (as shown in FIG. 39). drawers. The drawers of the present invention may be used
FIGS. 40-43 illustrate an alternative example of basket without a frame. In yet another alternative example, the con
portion 1155 with upper rail 954 and lower rail 1154. Basket tainers/drawers of the present invention may be retained
portion 1155 is formed by four sidewalls 1155a of mesh and 55 within a frame formed of wood, plastic, metal, or material
one bottom wall 1155b of mesh. Sidewalls 1155a are prefer with a wood finish, where the frame has components such as
ably joined by conventional methods such as welding. Bot runners and rollers thereon. The frame would cooperate with
tom wall 1155b can be joined to sidewalls 1155a by welding a stationary holder with runners and rollers thereon so that the
and/or by rail 1154. Upper rail 955 previously described with container does not move with respect to the holder, but when
reference to FIGS. 36-37 is joined to basket portion 1155 as 60 the holder moves between an extended and retracted position
previously discussed. by moving with respect to the stationary component, the
Lower rail 1154 includes horizontal first portion 1155a and container likewise moves. In such an example, the runner
vertical second portion 1155b. Horizontal first portion 1155a portion serves to connect the container to the holder without
includes inwardly projecting connection portion or rib 1154c. a sliding engagement therebetween. In addition, the container
Vertical second portion 1155b includes inwardly projecting 65 can be formed without upper rail 54 (see FIG. 3) by forming
connection portion or rib 1154d. When rail 1154 is joined to the runner portion in another way, Such as by folding the
basket portion 1155, first portion 1154a and rib 1155c contact upper edge of the basket portion upon itself to form a suffi
US 7,428,976 B2
17 18
ciently-rigid integral runner portion. Alternatively, the runner fourth spaced apart sidewalls, and an upwardly extend
portion need not extend around the entire basket and may ing opening, said first, second, third and fourth sidewalls
extend only on the sides to work with the runners 26a-g (see including an outer Surface;
FIG. 1). In such an example, the end walls without the runner bending an upper section of said first, second, third and
portions may have upper edges finished with portions of 5 fourth sidewalls generally horizontally outwardly away
metal, wood, plastic or some other Suitable material. Exem from said upwardly-extending opening;
plary rails shown and described above with one basket con forming a rail including a first section, a second section,
struction can be used with basket constructions shown in and a curved section joining said first and second sec
other examples or with conventional basket constructions. tions so that an opening is located therein;
For example, the exemplary rails shown and described above 10 inserting said upper section of said first, second, third and
can be used with baskets that include sidewalls formed from fourth sidewalls into said opening; and
a single loop of mesh material joined to a separate piece of joining said rail to said first, second, third and fourth side
bottom wall mesh material. Thus, the details of the present walls by compressing said rail to engage said upper
invention as set forth in the above-described examples should section of said first, second, third and fourth sidewalls
not limit the scope of the present invention. 15 Such that said first and second sections of said rail are
Further, the purpose of the Abstract is to enable the U.S. generally parallel and horizontally extending outwardly
Patent and Trademark Office, and the public generally, and away from said upwardly-extending opening, such that a
especially the designers and practitioners in the art who are Substantial portion of said rail extends generally hori
not familiar with patent or legal terms or phraseology, to Zontally away from said upwardly-extending opening
determine quickly from a cursory inspection the nature and Substantially outwardly from and Substantially continu
essence of the technical disclosure of the application. The ously around said outer Surface of said first, second, third
Abstract is neither intended to define the invention of the and fourth sidewalls of said basket portion.
application, which is measured solely by the claims, nor is 3. A method of forming a container comprising the follow
intended to be limiting as to the scope of the invention in any ing steps:
way. 25 forming a basket portion of metal mesh material into a
bottom wall and upwardly extending first and second
We claim as our invention: spaced apart sidewalls and upwardly extending third and
1. A container, comprising: fourth spaced apart sidewalls, said first, second, third
and fourth sidewalls including an outer Surface;
a basket portion of metal mesh material having a bottom 30 forming a rail;
wall, upwardly extending first and second spaced apart joining said rail to said first, second, third and fourth side
sidewalls, upwardly extending third and fourth spaced walls such that a substantial portion of said rail extends
apart sidewalls, and an upwardly extending opening, substantially outwardly from said outer surface of said
said first, second, third and fourth sidewalls including an first, second, third and fourth sidewalls, and said rail
outer Surface; 35 extends Substantially continuously around said outer
an upper section of said first, second, third and fourth Surface of said basket portion;
sidewalls extending generally horizontally outwardly forming said basket portion with an upwardly-extending
away from said upwardly-extending opening; opening, where said step of joining said rail further
a rail including a first section, a second section, and a includes joining said rail to said first, second, third and
curved section joining said first and second sections to 40 fourth sidewalls such that said substantial portion of said
define an opening therein; rail extends substantially outwardly from said outer sur
said upper section of said first, second, third and fourth face of said first, second third and fourth sidewalls away
sidewalls positioned in said opening; and from said upwardly-extending opening and generally
said upper sections of said first, second, third and fourth horizontally; and
sidewalls being compressed within said opening Such 45 bending an upper section of said first, second, third and
that said first and second sections of said rail are gener fourth sidewalls generally horizontally outwardly away
ally parallel and horizontally extending outwardly away from said upwardly-extending opening;
from said upwardly-extending opening and a Substantial said rail including a first section, a second section, and a
portion of said rail extends generally horizontally away curved section joining said first and second sections so
from said upwardly-extending opening Substantially 50 that an opening is located therein;
outwardly from and Substantially continuously around inserting said upper section of said first, second, third and
said outer surface of said first, second, third and fourth fourth sidewalls into said opening; and
sidewalls of said basket portion. compressing said rail to engage said upper section of said
2. A method of forming a container comprising the follow first, second, third and fourth sidewalls such that said
ing steps: 55 first and second sections of said rail are generally paral
forming a basket portion of metal mesh material into a leland horizontally extending outwardly away from said
bottom wall, upwardly extending first and second upwardly-extending opening.
spaced apart sidewalls, upwardly extending third and k k k k k
Exhibit B
USOOD624753S
(12) United States Design Patent (10) Patent No.: USD624,753 S

Post et al. (45) Date of Patent: Oct. 5, 2010
(54) HANDLE FOR MESH BASKET TW O862O2707 2, 1998
(75) Inventors: R. Neal Post, Springfield, IL (US); OTHER PUBLICATIONS
Christopher Hardy, Springfield, IL
(US) The Container Store. The Ultimate Planning Guide, revised Nov.
(73) Assignee: Design Ideas, Ltd., Springfield, IL (US) 2001.
(**) Term: 14 Years (Continued)
(21) Appl. No. 29/308,601 Primary Examiner T. Chase Nelson
Assistant Examiner—Eric L. Goodman
(22) Filed: Jun. 25, 2008 (74) Attorney, Agent, or Firm—Saidman DesignLaw Group
(57) CLAM
(60) Continuation of application No. 29/307,556, filed on
Apr. 25, 2008, which is a division of application No. The ornamental design for a handle for mesh basket, as shown
29/238,378, filed on Sep. 14, 2005, now Pat. No. Des. and described.
567,553, which is a division of application No. 29/216,
533, filed on Nov. 4, 2004, now abandoned, which is a DESCRIPTION
division of application No. 29/190.480, filed on Sep.
22, 2003, now Pat. No. Des. 501,105, which is a divi- FIG. 1 is a front perspective view of a first embodiment of a
sion of application No. 29/176,610, filed on Feb. 27, handle for mesh basket showing our new design,
2003, now Pat. No. Des. 481.233, which is a continu- FIG. 2 is a front view thereof;
ation-in-part of application No. 29/148,906, filed on FIG.3 is a left-side view thereof, the right-side being a mirror
Sep. 28, 2001, now abandoned. image;
(51) LOC (9) Cl. .................................................. 03-01 FIG. 4 is a front perspective view of a second embodiment
(52) U.S. Cl. ....................................................... D3A306 therof:
(58) Field of Classification Search .................... D3/20, FIG. 5 is a front view thereof;
D3/201-202, 203.1, 203.3, 205-206, 273, - 0 - - - -
D3/276,304–315; D6/475 476,525,449, FIG. 6 is a left-side view thereof, the right-side being a mirror
D6/553,567; D19/75, 77, 86, 90,92, 100: 1mage:
206/203, 214, 215,822, 307.1, 100, 915, FIG. 7 is a front perspective view of a third embodiment
206/406, 503, 506,507,518,540, 557,519, thereof;
206/676, 224, 371; D12/425; D9/424 425; FIG. 8 is a front view thereof, and,
211 (69.1-69.9, 88.01, 42.45, 46. 10-11
s 2150 FIG.9 is a left-side view thereof, the right-side being a mirror
See application file for complete search history. image.
The broken line showing of structural lines is included for the
(56) References Cited purpose of illustrating non-claimed Subject matter and forms
U.S. PATENT DOCUMENTS no part of the claimed design. The dash-dot broken lines
represent an artificial boundary and form no part of the
297,382 A 4. 8, ES5 claimed design. The mesh material that may be visible
through the holes in the mesh has been removed for clarity.
FOREIGN PATENT DOCUMENTS
GB 228338 2, 1925 1 Claim, 6 Drawing Sheets
SS
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s8
8
USD624,753 S
Page 2
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1,098,053 A 5, 1914 Porter D425,562 S * 5/2000 Conley et al. ................ D19,90
RE 16.431 E 9, 1926 Kratzer D430,375 S 8, 2000 Tezak
D152,141 S 12/1948 Crawford et al. D432,752 S 10/2000 Andujar et al.
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2,825,481 A 3/1958 Glenny D436,239 S 1, 2001 Walsh
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D340,369 S 10/1993 Dokoupil et al. D514,318 S 2/2006 Post et al.
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D365,226 S 12/1995 Goebel
D370,144 S 5/1996 Insalaco et al. OTHER PUBLICATIONS
D373,039 S 8, 1996 Cohen et al. The Container Store Catalog, Elfa Drawer Units, 1999, pp.
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5,673,984 A 10, 1997Insalaco et al. 4,5,8,10,16, 17, and 31.
5,685,442 A 11/1997 Yoshino et al. Design Ideas Catalogue, 1995, pp. cover p. 24, 26, 27, and 29.
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5,810,179 A 9, 1998Kleiman HK Enterprise. Oct. 1999, p. 98. Item NH-11
D408,175 S 4/1999 Daniels et al. rprise, Uc. 1999, p. 98,
D409,866 S 5, 1999 West * cited by examiner
Exhibit C
US008.006858B2
(12) United States Patent (10) Patent No.: US 8,006,858 B2

Cheng et al. (45) Date of Patent: Aug. 30, 2011
(54) METHOD FOR MAKING MESH (56) References Cited
CONTAINERS WITH ARAL AND MESH
CONTAINER FORMED THEREFROM U.S. PATENT DOCUMENTS
171,032 A 12/1875 Meyers
(75) Inventors: Hsi-Ming Cheng, Chung-Hua Hsien 201959 A 4, 1878 Stockwell et al.
(TW); R. Neal Post, Springfield, IL 463,964 A 11 1891 Gates
(US); Christopher Hardy, Springfield, 900, 162 A 10, 1908 Goodwin
IL (US) (Continued)
(73) Assignee: Design Ideas, Ltd., Springfield, IL (US) FOREIGN PATENT DOCUMENTS
DE 1083999 6, 1960
(*) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 (Continued)
U.S.C. 154(b) by 160 days.
OTHER PUBLICATIONS
(21) Appl. No.: 12/237,926
Millers Office Products, p. 442, 1995.
(22) Filed: Sep. 25, 2008 (Continued)
(65) Prior Publication Data
Primary Examiner — Anthony Stashick
US 2009/OO452O1 A1 Feb. 19, 2009 Assistant Examiner — Madison L Wright
Related U.S. Application Data (74) Attorney, Agent, or Firm — SAIDMAN Design aw
Group
(63) Continuation of application No. 11/000,295, filed on
Nov. 30, 2004, now Pat. No. 7,428,976, which is a (57) ABSTRACT
continuation-in-part of application No. 10/972,308,
filed on Oct. 22, 2004, now Pat. No. 7,270,245, which The present invention is directed to a method of forming a
is a continuation of application No. 10/308.699, filed container comprising forming a basket portion of metal mesh
on Dec. 3, 2002, now abandoned. material and a rail connected to the basket portion. The rail
extends substantially outwardly from the outer surface of the
(51) Int. Cl. basket portion and the rail extends continuously around the
B65D 25/00 (2006.01) outer Surface of the basket portion. In one example, the
B65D 6/08 (2006.01) method includes forming the rail so that it does not contain or
B65D 8/04 (2006.01) Surround a free edge of the basket portion. In another
B65D L/42 (2006.01) example, the method includes forming the rail so that it
B65D 6/34 (2006.01) includes an opening for containing or Surrounding a free edge
(52) U.S. Cl. .......... 220/485; 220/62: 220/494; 220/607; of the basket portion. The method may also include forming
220/642; 29/509 a lower rail. The present invention is also directed to a con
(58) Field of Classification Search .................... 220/62, tainer formed by such method.
220/485, 494, 607, 642, 676; 29/509, 512
See application file for complete search history. 25 Claims, 29 Drawing Sheets
US 8,006,858 B2
Page 2
U.S. PATENT DOCUMENTS D298.403 S 1 1/1988 Magbert et al.

920,313 A 5, 1909 Franklin 4,795,041 A 1, 1989 Remmers
4,903,853. A 2, 1990 Lin
933,517 A 9, 1909 Worcester D328,993 S 9, 1992 Rosenthal
981,205 A 1/1911 Loetzer D341,459 S 1 1/1993 Yang
994.984 A 6, 1911 Dennis D373,039 S 8, 1996 Cohen et al.
1,098,053 A 5, 1914 Porter D383,283 S 9/1997 Hankins, III
1,138,496 A 5, 1915 Martin D393,766 S 4/1998 MaZZola et al.
1,224,234 A 5, 1917 Taber 5,810,179 A 9, 1998 Kleiman
1,305,148 A 5, 1919 Montain 5,842,789 A 12/1998 Derby et al.
1,382,592 A 6, 1921 Ames 5,851,393 A 12/1998 Carr et al.
1,384,755 A T. 1921 Hall D416, 165 S 11/1999 Zemel
1,389,908 A 9, 1921 ShultSet al. D419,302 S 1/2000 Hardy et al.
1408,026 A 2f1922 Ochiltree D433,709 S 1 1/2000 Hardy
1445,259 A 2, 1923 Wiselogel D437,984 S 2/2001 Weiss et al.
1463,098 A 7, 1923 Snyder D444,039 S 6/2001 Tong
1484,696 A 2/1924 Wulftange D444,927 S 7, 2001 Lin
RE 16.431 E 9, 1926 Kratzer D451,675 S 12/2001 Hardy et al.
1,660,410 A 2f1928 Beckman D453,027 S 1/2002 Andujar
1,688,846 A 10, 1928 Andrews D455,029 S 4/2002 Gusdorf
1,840,561 A 1, 1932 Miller 6,461,501 B1 10/2002 Porter
1,890,983 A 12, 1932 Griffith 6,508,376 B1 ck 1/2003 Chiang ......................... 220,485
1,950,921 A 3/1934 Gray et al. D476,155 S 6/2003 Post et al.
2009,527 A 7, 1935 Shelton D481.233 S 10/2003 Post et al.
2,050,980 A 8, 1936 Buhl 6,718,635 B2 4/2004 Cheng et al.
2,502,781 A 4, 1950 Erickson D501,105 S 1/2005 Post et al.
2,507,152 A 5, 1950 Garofalo D513,874 S 1/2006 Hardy et al.
2,574,998 A 11/1951 Bangert, Jr. T.228,985 B2 6, 2007 Yeh
2,658,444 A 11, 1953 Wheeler 4 4-w
2,706,064 A 4, 1955 Vitols FOREIGN PATENT DOCUMENTS
2,721.671 A 10, 1955 Averill
2,768,022 A 10/1956 Pope FR 826876 4, 1938
2,825,481 A 3/1958 Glenny GB 228338 2, 1925
2,826,329 A 3/1958 Beckner GB 730785 6, 1955
2.851,186 A 9, 1958 Rupe, Jr. ........................... 220/6 JP 2001-270515 2, 2001
2,898,122 A 8/1959 Beckner TW O862O2707 2, 1998
D194,513 S 2, 1963 Sparling OTHER PUBLICATIONS
3,120,323 A 2, 1964 Sparling
3,138,281 A 6/1964 Schray Hong Kong Enterprise, Oct. 1999, p. 98.
3,250,430 A 5, 1966 Cella Hong Kong Enterprise, Oct. 1999, p. 1126.
3,272,377 A 9/1966 Schray Baigelman & Co., Office Products Catalog, 2000, item A, p. 492.
3,436,044 A 4, 1969 Martinson The Container Store. The Ultimate Planning Guide, revised Nov.
3,563,292 A 2f1971 Gordon 2001.
3,923, 187 A 12/1975 Johansson et al. Design IdeasTM Product Catalogue, Design Ideas, Ltd., Copyright
4,173,289 A 1 1/1979 Nesti 1996, p. 47, product H. Mesh Pencil Cup in Black and 3 photographs
4,205,406 A 6/1980 Wangkeo et al. of Design Ideas' Mesh Pencil Cup in Silver.
D267,395 S 12/1982 Groenewold et al.
4,664,684 A 5, 1987 Dunn et al. * cited by examiner
U.S. Patent Aug. 30, 2011 Sheet 2 of 29 US 8,006,858 B2
FIG. 2A
3O
FIG 2B
(C) FIG. 2C
FIG. 2D
62
FIG. 3
FIG. 5A
C
&
FIG. 6
FIG. 7
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NN
N
N
N
FIG. 8
U.S. Patent Aug. 30, 2011 Sheet 9 Of 29 US 8,006,858 B2

54
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-55
FIG 10
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l 55a
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US 8,006,858 B2
1. 2
METHOD FOR MAKING MESH for such bending. The open corners of the basket and the slits
CONTAINERS WITH A RAIL AND MESH between the sidewalls of the liner may allow small objects to
CONTAINER FORMED THEREFROM fall out of the basket, which is undesirable.
Mesh material is typically formed by perforating or slitting
CROSS-REFERENCE TO RELATED a piece of sheet metal and stretching it. A sheet of mesh
APPLICATIONS material requires less raw sheet metal than a non-mesh piece
of sheet metal and a perforated piece of sheet metal. U.S. Pat.
This application is a continuation of our prior application No. 1,408,026 to Ochiltree discloses a desk tray or basket
Ser. No. 11/000,295, filed Nov.30, 2004, now U.S. Pat. No. formed of “expanded metal' or mesh material. Similar to the
7,428.976 which is a continuation-in-part of Ser. No. 10/972, 10 previous containers, the Ochiltree container is formed by a
308, filed Oct. 22, 2004, now U.S. Pat. No. 7,270,245 which single blank of flat material that is cut out and folded.
is a continuation of Ser. No. 10/308,699, filed Dec. 3, 2002, ROC (Taiwan) Patent Application No. 086202709 to Chih
now abandoned which claims priority to the prior ROC (Tai Ming, Ko (in transliteration), filed Feb. 21, 1997, discloses a
wan) Patent Application No. 090220946, filed Dec. 3, 2001; system of containers Supported by a frame. The containers are
ROC (Taiwan) Patent Application No. 091202306, filed Apr. 15 formed of a single piece of mesh with a rim connected thereto.
16, 2002; and ROC (Taiwan) Patent Application No. Additionally, the containers do not move with respect to the
091214244, filed Sep. 11, 2002. This application also claims frame so that the contents of the lower container are not easily
priority to the prior ROC (Taiwan) Patent Application No. accessible.
09321 1506, filed Jul. 21, 2004; China Patent Application No. A number of mesh containers are made by Design Ideas,
200420084938.8, filed Jul. 28, 2004; ROC (Taiwan) Patent Ltd. One of these containers is the “Mesh Storage Nest.” This
Application No. 09321 1507, filed Jul. 21, 2004; and China container is formed using a first piece of mesh that has the
Patent Application No. 200420084546.1, filed Jul. 29, 2004. ends welded together to form a loop. A second piece of mesh
These applications are incorporated by reference herein in is welded to the lower edge of the loop so that the first piece
their entirety. of mesh forms sidewalls and the second piece of mesh forms
25 a bottom wall. The seam at the bottom of the container is
BACKGROUND OF THE INVENTION covered by a bottom rail. A top rail is connected to the upper
edge of the container. The sidewalls can be shaped to include
1. Field of the Invention a plurality of corners.
The present invention relates to containers, a system using A need exists for a lightweight container that can be incor
Such containers, and a method of making Such containers. 30 porated into a system for storing objects. It is also desirable
More particularly, the present invention relates to rails for use that the contents of such a container be made easily accessible
with drawers made of mesh material. and be prevented from accidentally falling through holes in
2. Description of Related Art the container. Furthermore, it is desirable that the container be
Forming containers out of sheet metal is well known. U.S. formed by an economical method in unlimited sizes.
Pat. No. 903,848 to Donnelly and U.S. Pat. No. 1,107,014 to 35
Avery disclose Such containers. In order to make these con SUMMARY OF THE INVENTION
tainers, a single blank of flat material is cut out and folded
with overlapping sections. Sheet metal does not provide The present invention is directed to a method of forming a
desirable characteristics Such as drainage and ventilation. container comprising the following step: forming a basket
In an effort to make a well-ventilated container, U.S. Pat. 40 portion of metal mesh material into a bottom wall and
No. 645,344 to White discloses a container formed of perfo upwardly extending first and second spaced apart sidewalls
down from its folded state to its flat state and to be easily 45 steps: forming a rail; and joining the rail to the outer Surface
constructed without tools. such that a substantial portion of the rail extends substantially
U.S. Pat. No. 2,825,481 to Glenny discloses another such 50 In one example, the step of joining further includes spacing
container offinely woven wire screening. In order to make the the rail from a free edge of the basket portion so that an upper
under the brand name ElfaR) is formed of a wire grid with a 55 tion of the basket portion.
plurality of separately formed wires welded together. The In another example of the method, the rail is generally
runners. When the baskets are inserted in the frame, the flat 60 becomes integral with the sidewalls after joining the rail to the
rail is supported by a pair of runners and is movable between basket portion. Such method may further include forming a
user desires to store Small objects in these baskets, a plastic 65 with.
liner can be used. The liner has a bottom wall and upwardly In yet another example, the step of joining further includes
US 8,006,858 B2
3 4
Such an example, the step of forming the rail further includes and the second extension is joined to an inner Surface of the
forming the rail with a curved portion having an opening and first, second, third and fourth sidewalls.
a curved section joining first and second sections of the rail. According to one feature of the present invention, the rail is
The method further including the step of inserting the free a Substantially continuous piece of material.
edge of said basket portion within the opening. According to one feature of the present invention, the bas
According to one aspect of the present invention, the step ketportion includes open corners between the first and second
of forming said rail further includes forming said rail with a sidewalls and the third and fourth sidewalls. According to
first extension coupled to and angularly offset from the first another feature of the present invention, the basket portion
section. includes closed corners between the first and second side
According to another aspect of the present invention, the 10 walls and the third and fourth sidewalls.
step of forming said rail further includes forming said rail The present invention is also directed to a container com
with a second extension coupled to and angularly offset from prising a basket portion and first and second rails. The basket
the second section. portion is formed of metal mesh material and includes a
The present invention is directed to a method of forming a bottom wall and upwardly extending first and second spaced
container comprising the following step: forming a basket 15 apart sidewalls and upwardly extending third and fourth
portion of metal mesh material into a bottom wall and spaced apart sidewalls. The first rail has a L-shape and is
upwardly extending first and second spaced apart sidewalls joined to the first, second, third and fourth sidewalls. The
and upwardly extending third and fourth spaced apart side second rail has a L-shape and is joined to the sidewalls and the
walls. The method further includes the following steps: bend bottom wall.
ing an upper section of the first, second, third and fourth In an alternative example, the first rail further includes a
sidewalls outwardly; forming a rail including an opening; first projecting connection portion that contacts the sidewalls
inserting the uppersection of the first, second, third and fourth and becomes integral therewith, when the first rail is joined to
sidewalls into the opening; and compressing the rail to engage the basket portion. In yet another alternative example, the
the upper section of the first, second, third and fourth side second rail further includes at least one second projecting
walls. 25 connection portion. The second projecting connection por
According to one example of the inventive method, the rail tion contacts the sidewalls or bottom wall and becomes inte
forming step further includes forming a curved portion hav gral therewith, when the second rail is joined to the basket
ing the opening and the rail forming step further includes an portion.
extension angularly offset from the curved portion. In addi Alternatively, the present invention is directed to a con
tion, the inserting step further includes locating the extension 30 tainer with a first rail or a second rail.
sidewalls.
US 8,006,858 B2
5 6
FIG.11 is a partial, elevational view of the upper rail joined 10 FIG.39 is a partial, elevational view of the upper rail joined
to the mesh piece of FIG. 10; to the mesh piece of FIG. 38, wherein welding has occurred;
example of a drawer using the upper rail and mesh piece drawer example
example with an upper rail of FIG. 36 and a first
of a lower rail;
shown in FIGS. 10 and 11:
FIG. 13 is an exploded, rear, perspective view of a third 15 40, whereinis the
FIG. 41 a perspective view of the drawer and rails of FIG.
rails are coupled to the basket portion;
example of a drawer for use in the system of FIG. 1, wherein FIG. 42 is a partial, elevational view of the upper and lower
an alternative example of two side pieces of mesh material are rails of FIG. 40 engaged with a mesh piece, wherein welding
used; has not occurred;
FIG. 14 is a partially-exploded, rear, perspective view of FIG. 43 is a partial, elevational view of the upper and lower
the drawer shown in FIG. 13, wherein three pieces of mesh rails joined to the mesh piece of FIG. 42, wherein welding has
material have been joined together, occurred;
FIG. 15 is an enlarged, rear, perspective view of a fourth FIG. 44 is a partial, elevational view of the upper rail of
example of a drawer useful in the system of FIG. 1; FIG.38 supported by a mesh piece and a second example of
FIG.16 is an exploded, rear, perspective view of the drawer a lower rail, wherein welding has not occurred; and
shown in FIG. 15: 25 FIG. 45 is a partial, elevational view of the upper and lower
FIG. 17 is a partially-exploded, rear, perspective view of rails joined to the mesh pieces of FIG. 44, wherein welding
the drawer shown in FIG. 15, wherein three pieces of mesh has occurred.
material have been joined together, DETAILED DESCRIPTION OF EXAMPLES OF
FIG. 18 is front, perspective view of a second example of a 30 THE PRESENT INVENTION
system of drawers of the present invention, where the drawers
are shown in a retracted position; Referring to FIG. 1, a first example of drawer system 10 is
FIG. 19 is an exploded, perspective view of an exemplary shown. This drawer system 10 may be used to store a variety
drawer with a third example of an upper rail; of housewares, such as kitchen items, clothing, accessories,
FIG. 20 is a perspective view of the drawer and rail of FIG. 35 sports equipment, shoes, bathroom Supplies, tools, appli
19, wherein the rail is coupled to the drawer; ances, and the like. Additionally, system 10 can be used to
FIG. 21 is an enlarged, partial, perspective view of the store a variety of other items, for example food, office Sup
upper rail of FIG. 19, wherein the rail is uncompressed; plies, office equipment, file folders, papers/documents, bags,
FIG. 22 is a partial, elevational view of the upper rail of boxes, cans, bottles, etc.
FIG. 19 disposed upon a mesh piece, wherein the rail is 40 Drawer system 10 includes frame 12 and a plurality of
uncompressed; containers or drawers 14a-d. Drawer 14a is smaller than
FIG.23 is a partial, elevational view of the upper rail joined drawers 14b-c so drawer 14a can hold a smaller volume than
to the mesh piece of FIG. 22, wherein the rail is compressed; other drawers 14b-d. Drawers 14a-daremovable with respect
FIG. 24 is a partial, elevational view of a fourth example of to frame 12 between a retracted position (shown in FIG. 1)
an upper rail separated from a mesh piece; 45 and an extended position. In the retracted position, the con
FIG.25 is a partial, elevational view of the upper rail joined tents of lower drawers 14b-d is difficult to access. In the
to the mesh piece of FIG. 24; extended position, the contents of the extended drawer are
FIG. 26 is a partial, elevational view of a fifth example of an easily accessible; the extended drawer may be fully with
upper rail separated from a mesh piece; drawn from frame 12 if desired.
FIG.27 is a partial, elevational view of the upper rail joined 50 With reference to FIG. 1, frame 12 includes two side frame
to the mesh piece of FIG. 26: members or ladders 16 that are spaced apart and joined by
FIG. 28 is a partial, elevational view of a sixth example of pairs of upper and lower cross members 18a, b, respectively.
an upper rail separated from a mesh piece; Side frame members 16 and pairs of upper and lower cross
FIG.29 is a partial, elevational view of the upper rail joined members 18a, b are formed to give frame 12 a rectangular
to the mesh piece of FIG. 28; 55 shape. The present invention is not limited to this frame
US 8,006,858 B2
7 8
are also generally perpendicular to one another. For example, 35 edge 74b, central portion 74c, side extensions 74d. and lower
molded plastic. 45 76c, side extensions 76d. and lower extension 76e.
Now, with reference to FIGS. 1, 3, and 3A, the details of In an alternative example, pieces of mesh 74 and 76 can be
drawer 14b will be discussed. Drawer 14b includes a runner formed of a single piece of material separate from first piece
portion that comprises upper rail 54 and basket portion 55. of mesh 72. In such event, the two pieces of mesh 74 and 76
Basket portion 55 is coupled to upper rail 54. In the present would be joined by another mesh segment (not shown) that
example, basket portion 55 is formed of expanded metal plate 50 would be shaped similar to bottom wall portion 56. As a
(i.e., sheet metal) or “mesh' and has small openings 55a result, bottom wall of basket 55 would be formed of two
therein. In the present specification and appended claims layers of mesh material that overlap.
"mesh' means flat metal that is pierced and stretched so that Referring to FIG. 5A, first, second, and third pieces of
no material is separated from the original raw material, as mesh 72, 74, and 76 have been joined together so that bottom
known by those of ordinary skill in the art. On the other hand, 55 seams 78 are formed. Seams 78 are where the material of
unlike mesh, punching portions of waste material out of sheet bottom wall 56 of first piece of mesh 72 overlaps with lower
metal material forms perforated metal. For example, open extension 74e of second and third pieces of mesh 74 and 76
ings 55a (see FIG.3A) in the mesh have an area less than 25.4 (see FIG. 4). When corners 64 are formed, side seams 80 (as
mm by 25.4 mm. In another example, openings 55a (see FIG. shown in FIG. 3) are formed adjacent each corner 64. Seams
3) in the mesh have an area less than 20 mm by 10 mm. In yet 60 80 are where the material of sidewalls 62 offirst piece of mesh
another example. In another example, openings 55a (see FIG. 72 overlaps with side extensions 74d and 76d of second and
3) in the mesh have an area less than 6 mm by 3 mm. third pieces of mesh 74 and 76, respectively. Seams 80 are
US 8,006,858 B2
10
as is known by those of ordinary skill in the art. seams 80 has an appropriately sized fixture including clamp
Second and third pieces of mesh 74 and 76 are formed and (S), elongated member(s) and cathode electrode(s) for Smaller
shaped as shown in FIG. 4. This involves cutting pieces of pieces 74 and 76. For example, the cathode electrode(s) may
mesh 74 and 76 with the desired dimensions and shape from be tapered to match trapezoidal extensions 74d, 76d so that
a roll of mesh using a conventional press machine. Then, 10 pieces 74 and 76 are suitably clamped to end walls 58 and 60
mesh piece 74 is bent using a conventional hydraulic press during welding.
Next, lower extensions 74e, 76e of each piece 74, 76 are tion 55 extends above rail 54; and spot-welding contact sur
curved side extensions 74d, 76d of pieces 74, 76 are con as basket portion 55 so that these components can be welded
nected by welding to sidewalls 62 of first piece 72 to form together. Thus, for example, rail 54 is formed of any metal
seams 80 (as shown in FIG. 3). Such as copper, Steel, stainless steel, mild sheet steel or alu
contact with pieces 72, 74 adjacent extension 74e. Pieces 72, 60 Anode electrode AE contacts outer surface of rail 54 and
74 are tightly compressed between electrodes 92a and 92b. cathode electrode CE contacts inner surface of basket portion
Electrodes 92a, b then discharge electric welding current 55 adjacent surface 54a, as shown in FIG. 9. An electric
US 8,006,858 B2
11 12
As shown in FIG. 1, drawers 14b-14d are of medium size example, formed similar to rail 54 (ee FIG. 10) with an
US 8,006,858 B2
13 14
In the present example, first section A has a length less than 654b, 654c. In the present example (as shown in FIG. 29), rail
FIGS. 22-23). Then, the now generally vertically-extending 65 section 854c, which is connected to extension 854d. Curved
US 8,006,858 B2
15 16
except rib 954c has been replaced with outwardly extending high-priced system and a lower priced system. Alternatively,
or projecting connection portion 1054c at the free end of one system can have drawers with various types of rails 54,
vertical second portion 1054b. When rail 1054 is joined to 45 54,354, 454,554, 654, 754, 854,954, 1054, 1154 and 1254.
basket portion 955, horizontal first portion 1054a covers Additionally, a system can use all closed-corner drawers or
upper edge 955b (shown in FIG. 34) and second portion combine closed-corner drawers with open-corner drawers in
1054b and connection portion 1054c contact basket portion one system. The system may be used with sliding drawers
955. After joining rail 1054 to basket portion 955, the use of and/or stationary and sliding shelves each Supported by a pair
electric welding could allow connection portion 1054c and 50 of runners. The system frame may also include a section for
basket portion 955 contacting connection portion 1054c to be holding hanging file folders and one or more of the inventive
fused into an integral structure (as shown in FIG. 39). drawers. The drawers of the present invention may be used
FIGS. 40-43 illustrate an alternative example of basket without a frame. In yet another alternative example, the con
portion 1155 with upper rail 954 and lower rail 1154. Basket tainers/drawers of the present invention may be retained
portion 1155 is formed by four sidewalls 1155a of mesh and 55 within a frame formed of wood, plastic, metal, or material
one bottom wall 1155b of mesh. Sidewalls 1155a are prefer with a wood finish, where the frame has components such as
ably joined by conventional methods such as welding. Bot runners and rollers thereon. The frame would cooperate with
tom wall 1155b can be joined to sidewalls 1155a by welding a stationary holder with runners and rollers thereon so that the
and/or by rail 1154. Upper rail 955 previously described with container does not move with respect to the holder, but when
reference to FIGS. 36-37 is joined to basket portion 1155 as 60 the holder moves between an extended and retracted position
previously discussed. by moving with respect to the stationary component, the
Lower rail 1154 includes horizontal first portion 1155a and container likewise moves. In such an example, the runner
vertical second portion 1155b. Horizontal first portion 1155a portion serves to connect the container to the holder without
includes inwardly projecting connection portion or rib 1154c. a sliding engagement therebetween. In addition, the container
Vertical second portion 1155b includes inwardly projecting 65 can be formed without upper rail 54 (see FIG. 3) by forming
connection portion or rib 1154d. When rail 1154 is joined to the runner portion in another way, Such as by folding the
basket portion 1155, first portion 1154a and rib 1155c contact upper edge of the basket portion upon itself to form a suffi
US 8,006,858 B2
17 18
ciently-rigid integral runner portion. Alternatively, the runner that said first and second sections of said rail are gener
portion need not extend around the entire basket and may ally parallel and horizontally extending outwardly away
extend only on the sides to work with the runners 26a-g (see from said upwardly extending opening, and said third
FIG. 1). In such an example, the end walls without the runner and fourth sections of said rail are generally parallel and
portions may have upper edges finished with portions of 5 extending downwardly away from said upwardly
metal, wood, plastic or some other Suitable material. Exem extending opening.
plary rails shown and described above with one basket con 4. The container of claim 3, wherein said rail has at least
struction can be used with basket constructions shown in two configurations, a first configuration being an open con
other examples or with conventional basket constructions. figuration in which said rail is unfastened to said upper sec
For example, the exemplary rails shown and described above 10 tion, and a second configuration being a compressed configu
can be used with baskets that include sidewalls formed from ration in which said rail is fastened to said upper section.
a single loop of mesh material joined to a separate piece of 5. The container of claim 4, wherein:
bottom wall mesh material. Thus, the details of the present when said rail is in the first configuration, said second
invention as set forth in the above-described examples should section extends angularly downwardly with respect to
not limit the scope of the present invention. 15 said first section, said third section extends angularly
Further, the purpose of the Abstract is to enable the U.S. downwardly from said first section, said fourth section
Patent and Trademark Office, and the public generally, and extends angularly downwardly from said second sec
especially the designers and practitioners in the art who are tion, such that an opening is located between said first
not familiar with patent or legal terms or phraseology, to and second sections; and
determine quickly from a cursory inspection the nature and when said rail is in the second configuration, said first and
essence of the technical disclosure of the application. The second sections of said rail are generally parallel and
Abstract is neither intended to define the invention of the horizontally extending outwardly away from said
application, which is measured solely by the claims, nor is upwardly extending opening, and said third and fourth
intended to be limiting as to the scope of the invention in any sections of said rail are generally parallel and extending
way. 25 downwardly away from said upwardly extending open
We claim as our invention: ing, such that said upper section of said first and second
1. Apparatus, comprising: pairs of opposed sidewalls is positioned inside said
a container including a pair of opposed sidewalls and a opening located between said first and second sections
bottom wall; and said joint section compresses said first and second
a first piece of metal mesh material bent to form said 30 sections to said upper section of said first and second
bottom wall and one of said pair of sidewalls that extend pairs of opposed sidewalls.
upwardly from said bottom wall, said bottom wall fur 6. The container of claim 5, wherein in the first configura
ther including a pair of spaced apart edges; tion, said first section, said second section and said joint
second and third pieces of metal mesh material, each section have a generally V-shaped form, and in the second
formed separate from said first piece of mesh material, 35 configuration, said first section, said second section, said third
each of said second and third pieces of mesh material section, said fourth section, and said joint section have a
joined to said bottom wall adjacent one of said pair of generally L-shaped form.
spaced apart edges to form the other of said pair of 7. The container of claim3, wherein said first, second, third
opposed sidewalls that extend upwardly from said bot and fourth sidewalls include an outer Surface and an inner
tom wall, 40 Surface, and said rail extends Substantially continuously
one of said pair of opposed sidewalls including a central around said outer Surface.
sidewall portion having side edges, a pair of mesh exten 8. A drawer system comprising:
sions extending respectively from said side edges of said a frame; and
central sidewall portion; the container of claim 3,
said sidewall mesh extensions overlapping and joining said 45 wherein said container is moveable with respect to said
other pair of opposed sidewalls so as to form sidewall frame between retracted and extended positions via said
corners and a basket portion only of metal mesh mate rail.
rial; 9. A method of forming a container comprising the follow
wherein said basket portion further includes a free edge: ing steps:
and 50 forming a basket portion into a bottom wall and upwardly
said container further including a runner portion compris extending first and second spaced apart sidewalls and
ing a rail having an opening that receives said free edge upwardly extending third and fourth spaced apart side
of said basket portion. walls, said first, second, third and fourth sidewalls each
2. The apparatus according to claim 1, further comprising including an upper edge portion, an outer Surface and an
a frame, said container being moveable with respect to said 55 inner Surface, said upper edge portions forming an
frame between retracted and extended positions via said rail. upwardly extending opening therebetween;
3. A container, comprising: bending said upper edgeportions of said first, second, third
a basket portion having a bottom wall, upwardly extending and fourth sidewalls generally horizontally outwardly
first and second pairs of opposed sidewalls, and an away from said upwardly extending opening;
upwardly extending opening; 60 forming a rail having a first section, a second section, a
an upper section of said first and second pairs of opposed third section, a fourth section and a joint section joining
sidewalls extending generally horizontally outwardly said first and second sections, such that an opening is
away from said upwardly extending opening; and located between said first and second sections;
a rail including a first section, a second section, a third inserting said upper edge portions of said first, second,
section, a fourth section, and a joint section compressing 65 third and fourth sidewalls into said opening; and
said first and second sections to said upper section of compressing said rail to engage said upper edgeportions of
said first and second pairs of opposed sidewalls, such said first, second, third and fourth sidewalls such that
US 8,006,858 B2
19 20
said first and second sections of said rail are parallel and cover said free edge, at least one of said first and second
extend generally horizontally and outwardly away from portions of said rail having a projection rib for connec
said upwardly-extending opening, and said third and tion to said upper portion of said basket portion.
fourth sections of said rail are parallel and extend gen 17. The container as set forth in claim 16, wherein said first
erally downwardly from said upwardly extending open 5 and second portions of said rail are offset relative to each
1ng. other.
10. The method of claim 9, wherein after compressing said 18. The container as set forth in claim 16, wherein said
rail, said first and second sections of said rail are in Substantial projection rib is V-shaped.
contact with said upper edge portions, and said third and 19. The container as set forth in claim 18, wherein said
fourth sections of said rail are in substantial contact with said 10 V-shaped projection rib is positioned on a vertical portion of
inner and outer Surfaces, respectively, of said first, second, said first and second portion of said rail.
third and fourth sidewalls. 20. A container comprising:
11. The method of claim 9, whereinforming said rail such a basket portion of metal mesh material that includes an
that said opening is located between said first and second inner Surface, an outer Surface, a bottom wall, upwardly
sections creates a first configuration of said rail; and said 15 extending first and second spaced apart sidewalls and
compressing step alters a shape of said rail from said first upwardly extending third and fourth spaced apart side
configuration to a second configuration that is Substantially walls, said basket portion further including a horizon
different from said first configuration. tally extending upper section of said first, second, third
12. A container comprising: and fourth sidewalls; and
a basket portion of metal mesh material having an inner a rail including a curved portion defining an opening for
Surface, an outer Surface, a bottom wall, upwardly receiving said upper section of said first, second, third
extending first and second spaced apart sidewalls, and fourth sidewalls, said opening being sized so that
upwardly extending third and fourth spaced apart side said rail contacts opposing Surfaces of said upper sec
walls, an upwardly extending opening, and an upper tion, said rail further including first and second exten
section extending generally horizontally outwardly 25 sions angularly offset from said curved portion, said first
away from said upwardly extending opening; extension being joined to an outer Surface of said first,
a rail including a first section, a second section, and a second, third and fourth sidewalls and said second
curved section joining said first and second sections so extension being joined to an inner Surface of said first,
as to forman opening within which said upper section of second, third and fourth sidewalls.
said basket portion is positioned, said rail further includ 30 21. The container of claim 20, wherein said first, second,
ing a first extension joined to said first section, and a third and fourth sidewalls of said basket portion are formed
second extension joined to said second section, said first from a single loop of material that is joined to said bottom
and second extensions being offset from said curved wall.
section and formed in Substantially the same shape and 22. The container of claim 20, wherein said uppersection is
being adjacent said inner and outer Surfaces of said 35 compressed within said opening whereupon said first and
basket portion; second extensions become generally downwardly oriented.
said upper section of said first, second, third and fourth 23. The container of claim 20, wherein said basket portion
sidewalls being compressed within said opening Such further includes an angled corner between said sidewalls and
that said first and second sections of said rail tightly said upper section, and wherein said rail further includes a
engage said upper section and are generally horizontally 40 curved edge which engages said angled corner when said
extending outwardly away from said upwardly extend upper section is compressed within said opening.
ing opening, and Such that said first and second exten 24. Apparatus comprising:
sions of said rail sandwich said basket portion therebe a container including first and second opposed sidewalls,
tWeen. third and fourth opposed sidewalls, and a bottom wall,
13. The container of claim 12, wherein said first, second, 45 said sidewalls and said bottom wall formed of metal
third and fourth sidewalls of said basket portion are formed mesh material;
from a single loop of material that is joined to said bottom an upwardly extending opening formed by said first, sec
wall. ond, third and fourth sidewalls;
14. The container of claim 12, wherein when said upper said first, second, third and fourth sidewalls having an
section is compressed within said opening said first and sec 50 upper section that extends outwardly from said
ond extensions become generally downwardly oriented. upwardly extending opening;
15. The container of claim 12, wherein said basket portion said first, second, third and fourth sidewalls being formed
further includes an angled corner between said sidewalls and from a single loop of metal mesh material;
said upper section, and wherein said rail further includes a said single loop of metal mesh material being joined to said
curved edge which upon said uppersection being compressed 55 bottom wall; and
within said opening engages said angled corner. said container further including a rail having an opening
16. A container comprising: that receives and compresses said upper section of said
a basket portion of metal mesh material that includes a first, second, third and fourth sidewalls so as to cause
bottom wall and upwardly extending first and second said upper section to remain extending outwardly from
spaced apart sidewalls and upwardly extending third and 60 said upwardly extending opening and be substantially
fourth spaced apart sidewalls, said first, second, third horizontal.
and fourth side wails including an upper portion having 25. The apparatus according to claim 24, further compris
a free edge; and ing a frame, said container being moveable with respect to
a rail having a first portion and a second portion coupled to said frame between retracted and extended positions via said
said upper portion of said basket portion, at least one of 65 Substantially horizontal upper section of said rail.
said first and second portions of said rail extending hori
Zontally outwardly from said basket portion so as to k k k k k
Exhibit D
USOO8584.889B2
(12) United States Patent (10) Patent No.: US 8,584.889 B2

Cheng et al. (45) Date of Patent: Nov. 19, 2013
(54) METHOD FOR MAKING MESH B65D I/42 (2006.01)
CONTAINERS WITH ARAL AND MESH B65D 6/34 (2006.01)
CONTAINER FORMED THEREFROM (52) U.S. Cl.
USPC ............. 220/485; 220/62: 220/494; 220/607;
(75) Inventors: Hsi-Ming Cheng, Chung-Hua Hsien 220/642; 29/509
(TW); R. Neal Post, Springfield, IL (58) Field of Classification Search
(US); Christopher Hardy, Springfield, USPC ................... 220/62, 485, 494, 607, 642, 676:
IL (US) 29/509, 512
See application file for complete search history.
(73) Assignee: Design Ideas, Ltd., Springfield, IL (US) (56) References Cited
(*) Notice: Subject to any disclaimer, the term of this U.S. PATENT DOCUMENTS
patent is extended or adjusted under 35
U.S.C. 154(b) by 0 days. 171,032 A 12/1875 Meyers
201959 A 4, 1878 Stockwell et al.
(21) Appl. No.: 13/208,024 (Continued)
(22) Filed: Aug. 11, 2011 FOREIGN PATENT DOCUMENTS
(65) Prior Publication Data DE 1083999 6, 1960
EP 53103-001 10, 2003
US 2012/O168433 A1 Jul. 5, 2012
(Continued)
OTHER PUBLICATIONS
Related U.S. Application Data Millers Office Products, p. 442, 1995.
(63) Continuation of application No. 12/237,926, filed on (Continued)
Sep. 25, 2008, now Pat. No. 8,006,858, which is a Primary Examiner — Anthony Stashick
continuation-in-part of application No. 10/972,308, Assistant Examiner — Madison L. Poos
filed on Oct. 22, 2004, now Pat. No. 7,270,245, which (74) Attorney, Agent, or Firm — Saidman DesignLaw Group
is a continuation of application No. 10/308.699, filed
on Dec. 3, 2002, now abandoned. (57) ABSTRACT
The present invention is directed to a method of forming a
(30) Foreign Application Priority Data container comprising forming a basket portion of metal mesh
material and a rail connected to the basket portion. The rail
Dec. 3, 2001 (TW) ................................. O902.20946 extends substantially outwardly from the outer surface of the
Feb. 27, 2002 (TW) ................................. O912O2306 basket portion and the rail extends continuously around the
Sep. 11, 2002 (TW) ................................. O91214244 outer Surface of the basket portion. In one example, the
Jul. 21, 2004 (TW) ................................. 0932.11507 method includes forming the rail so that it does not contain or
Jul. 28, 2004 (CN) .......................... 2004 2 OO84938 Surround a free edge of the basket portion. In another
Jul. 29, 2004 (CN) ....................... 2004 2 OO845461 example, the method includes forming the rail so that it
Jul. 21, 2007 (TW) ................................. O9321.1506 includes an opening for containing or Surrounding a free edge
of the basket portion. The method may also include forming
(51) Int. Cl. a lower rail. The present invention is also directed to a con
B65D 8/04 (2006.01) tainer formed by such method.
B65D 8/08 (2006.01) 7 Claims, 29 Drawing Sheets
US 8,584.889 B2
Page 2
(56) References Cited D383,283 S 9/1997 Hankins, III

D393,766 S 4/1998 MaZZola et al.
U.S. PATENT DOCUMENTS 5,810,179 A 9, 1998 Kleiman
5,842,789 A 12/1998 Derby et al.
463,964 A 11, 1891 Gates 5,851,393 A 12/1998 Carr et al.
900,162 A 10/1908 Goodwin D416, 165 S 11/1999 Zemel
933,517. A 9, 1909 Worcester D433,709 S 11/2000 Hardy
981,205 A 1/1911 Loetzer 6,176, 175 B1* 1/2001 Moreth ........................... 99.408
994,984 A 6, 1911 Dennis D437,984 S 2/2001 Weiss et al.
1,098,053 A 5/1914 Porter D444,039 S 6/2001 Tong
1,138,496 A 5/1915 Martin D444,927 S 7, 2001 Lin
1,305,148 A 5/1919 Montan D453,027 S 1/2002 Andujar
1,382,592 A 6, 1921 Ames D455,029 S 4/2002 Gusdorf
1,384,755 A T. 1921 Hall 6,461,501 B1 10, 2002 Porter
1,389,908 A 9, 1921 Shults et al. 6,508,376 B1 1/2003 Chaing
1408,026 A 2f1922 Ochiltree D476,155 S 6/2003 Post et al.
1445,259 A 2, 1923 Wiselogel D481.233 S 10/2003 Post et al.
1484,696 A 2, 1924 Wulftange D501, 105 S 1/2005 Post et al.
RE 16.431 E 9, 1926 Kratzer D513,874 S 1, 2006 Hardy et al.
1,660,410 A 2, 1928 Beckman 7,228,985 B2 6/2007 Yeh
1,688,846 A 10, 1928 Andrews
1,840,561 A 1, 1932 Miller FOREIGN PATENT DOCUMENTS
1,890,983 A 12, 1932 Griffith
1,950,921 A 3/1934 Gray et al. EP 53103-OOO2 10, 2003
2009,527 A 7, 1935 Shelton EP 53103-0003 10, 2003
2,050,980 A 8, 1936 Buhl EP 53103-0004 10, 2003
2,502,781 A 4, 1950 Erickson EP 53103-0005 10, 2003
2,507,152 A 5, 1950 Garofalo EP 53103-0006 10, 2003
2,574,998 A 11/1951 Bangert, Jr. EP 53103-0007 10, 2003
2,658,444 A 11, 1953 Wheeler EP 53103-0008 10, 2003
2,706,064 A 4, 1955 Vitols EP 53103-0009 10, 2003
2,721.671 A 10, 1955 Averill EP 53103-0010 10, 2003
2,768,022 A 10/1956 Pope EP 53103-0011 10, 2003
2,825,481 A 3/1958 Glenny EP 53103-0012 10/2003
2,826,329 A 3, 1958 Beckner EP 53103-0013 10, 2003
2.851,186 A 9/1958 Rupe, Jr. EP 1424287 B1 6, 2004
2,898,122 A 8, 1959 Beckner FR 826876 4, 1938
D194,513 S 2, 1963 Sparling GB 228338 2, 1925
3,120,323 A 2, 1964 Sparling GB 730785 6, 1955
3,138,281 A 6/1964 Schray JP 2001-270515 2, 2001
3,250,430 A 5, 1966 Cella TW O862O2707 2, 1998
3,272,377 A 9/1966 Schray
3,436,044. A 4, 1969 Martinson OTHER PUBLICATIONS
3,563,292 A 2f1971 Gordon
3,923, 187 A 12, 1975 Johansson et al. Design Ideas TM Product Catalogue, Design Ideas, Ltd., Copyright
26.6 A "E. Sk 1
angkeo et al.
1996, p. 47, product H. Mesh Pencil Cup
Wr
in Black and 3 photographs
D267,395 S 12/1982 Groenewold et al. of Design Ideas Mesh Pencil Cup in Silver.
4,664,684 A 5, 1987 Dunn et al. Hong Kong Enterprise, Oct. 1999, p. 98.
D298.403 S
4,795,041 A
11/1988 Magbert et al.
1, 1989 Remmers
Hong Kong Enterprise, Oct. 1999, p. 1126.
Baigelman & Co., Office Products Catalog, 2000, item A, p. 492.
4903,853 A 2, 1990 Lin The Container Store. The Ultimate Planning Guide, revised Nov.
D328,993 S 9, 1992 Rosenthal 2001.
D341,459 S 1 1/1993 Yang
D373,039 S 8, 1996 Cohen et al. * cited by examiner
U.S. Patent Nov. 19, 2013 Sheet 2 of 29 US 8,584.889 B2
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US 8,584,889 B2
1. 2
METHOD FOR MAKING MESH between the sidewalls of the liner may allow small objects to
CONTAINERS WITH A RAIL AND MESH fall out of the basket, which is undesirable.
CONTAINER FORMED THEREFROM Mesh material is typically formed by perforating or slitting
a piece of sheet metal and stretching it. A sheet of mesh
CROSS-REFERENCE TO RELATED material requires less raw sheet metal than a non-mesh piece
APPLICATIONS of sheet metal and a perforated piece of sheet metal. U.S. Pat.
No. 1,408,026 to Ochiltree discloses a desk tray or basket
This application is a continuation of our prior pending formed of “expanded metal' or mesh material. Similar to the
application Ser. No. 12/237,926, filed Sep. 25, 2008, which is previous containers, the Ochiltree container is formed by a
a continuation-in-part of Ser. No. 10/972,308, filed Oct. 22, 10 single blank of flat material that is cut out and folded.
2004, now U.S. Pat. No. 7,270,245, which is a continuation of ROC (Taiwan) Patent Application No. 086202709 to Chih
Ser. No. 10/308,699, filed Dec. 3, 2002, now abandoned, Ming, Ko (in transliteration), filed Feb. 21, 1997, discloses a
which claims priority to the prior ROC (Taiwan) Patent Appli system of containers Supported by a frame. The containers are
cation No. 090220946, filed Dec. 3, 2001; ROC (Taiwan) formed of a single piece of mesh with a rim connected thereto.
Patent Application No. 091202306, filed Feb. 27, 2002; and 15 Additionally, the containers do not move with respect to the
ROC (Taiwan) Patent Application No. 09 1214244, filed Sep. frame so that the contents of the lower container are not easily
11, 2002. This application also claims priority to the prior accessible.
ROC (Taiwan) Patent Application No. 0932.11506, filed Jul. A number of mesh containers are made by Design Ideas,
21, 2004; China Patent Application No. 200420084938.8, Ltd. One of these containers is the “Mesh Storage Nest.” This
filed Jul. 28, 2004; ROC (Taiwan) Patent Application No. container is formed using a first piece of mesh that has the
09321 1507, filed Jul. 21, 2004; and China Patent Application ends welded together to form a loop. A second piece of mesh
No. 200420084546.1, filed Jul. 29, 2004. These applications is welded to the lower edge of the loop so that the first piece
are incorporated by reference herein in their entirety. of mesh forms sidewalls and the second piece of mesh forms
a bottom wall. The seam at the bottom of the container is
BACKGROUND OF THE INVENTION 25 covered by a bottom rail. A top rail is connected to the upper
edge of the container. The sidewalls can be shaped to include
1. Field of The Invention a plurality of corners.
The present invention relates to containers, a system using A need exists for a lightweight container that can be incor
Such containers, and a method of making Such containers. porated into a system for storing objects. It is also desirable
More particularly, the present invention relates to rails for use 30 that the contents of such a container be made easily accessible
with drawers made of mesh material. and be prevented from accidentally falling through holes in
2. Description of Related Art the container. Furthermore, it is desirable that the container be
Forming containers out of sheet metal is well known. U.S. formed by an economical method in unlimited sizes.
Pat. No. 903,848 to Donnelly and U.S. Pat. No. 1,107,014 to
Avery disclose Such containers. In order to make these con 35 SUMMARY OF THE INVENTION
tainers, a single blank of flat material is cut out and folded
with overlapping sections. Sheet metal does not provide The present invention is directed to a method of forming a
desirable characteristics Such as drainage and ventilation. container comprising the following step: forming a basket
In an effort to make a well-ventilated container, U.S. Pat. portion of metal mesh material into a bottom wall and
No. 645,344 to White discloses a container formed of perfo 40 upwardly extending first and second spaced apart sidewalls
down from its folded state to its flat state and to be easily steps: forming a rail; and joining the rail to the outer Surface
constructed without tools. 45 such that a substantial portion of the rail extends substantially
U.S. Pat. No. 2,825,481 to Glenny discloses another such In one example, the step of joining further includes spacing
container offinely woven wire screening. In order to make the 50 the rail from a free edge of the basket portion so that an upper
under the brand name ElfaR) is formed of a wire grid with a tion of the basket portion.
plurality of separately formed wires welded together. The 55 In another example of the method, the rail is generally
runners. When the baskets are inserted in the frame, the flat becomes integral with the sidewalls after joining the rail to the
rail is supported by a pair of runners and is movable between 60 basket portion. Such method may further include forming a
user desires to store Small objects in these baskets, a plastic with.
liner can be used. The liner has a bottom wall and upwardly 65 In yet another example, the step of joining further includes
for such bending. The open corners of the basket and the slits Such an example, the step of forming the rail further includes
US 8,584,889 B2
3 4
forming the rail with a curved portion having an opening and and the second extension is joined to an inner Surface of the
a curved section joining first and second sections of the rail. first, second, third and fourth sidewalls.
The method further including the step of inserting the free According to one feature of the present invention, the rail is
edge of said basket portion within the opening. a Substantially continuous piece of material.
According to one aspect of the present invention, the step According to one feature of the present invention, the bas
of forming said rail further includes forming said rail with a ketportion includes open corners between the first and second
first extension coupled to and angularly offset from the first sidewalls and the third and fourth sidewalls. According to
section. another feature of the present invention, the basket portion
According to another aspect of the present invention, the includes closed corners between the first and second side
step of forming said rail further includes forming said rail 10 walls and the third and fourth sidewalls.
with a second extension coupled to and angularly offset from The present invention is also directed to a container com
the second section. prising a basket portion and first and second rails. The basket
The present invention is directed to a method of forming a portion is formed of metal mesh material and includes a
container comprising the following step: forming a basket bottom wall and upwardly extending first and second spaced
15 apart sidewalls and upwardly extending third and fourth
portion of metal mesh material into a bottom wall and spaced apart sidewalls. The first rail has a L-shape and is
upwardly extending first and second spaced apart sidewalls joined to the first, second, third and fourth sidewalls. The
and upwardly extending third and fourth spaced apart side second rail has a L-shape and is joined to the sidewalls and the
walls. The method further includes the following steps: bend bottom wall.
ing an upper section of the first, second, third and fourth In an alternative example, the first rail further includes a
sidewalls outwardly; forming a rail including an opening; first projecting connection portion that contacts the sidewalls
inserting the uppersection of the first, second, third and fourth and becomes integral therewith, when the first rail is joined to
sidewalls into the opening; and compressing the rail to engage the basket portion. In yet another alternative example, the
the upper section of the first, second, third and fourth side second rail further includes at least one second projecting
walls. 25 connection portion. The second projecting connection por
According to one example of the inventive method, the rail tion contacts the sidewalls or bottom wall and becomes inte
forming step further includes forming a curved portion hav gral therewith, when the second rail is joined to the basket
ing the opening and the rail forming step further includes an portion.
extension angularly offset from the curved portion. In addi Alternatively, the present invention is directed to a con
tion, the inserting step further includes locating the extension 30 tainer with a first rail or a second rail.
sidewalls.
US 8,584,889 B2
5 6
FIG.11 is a partial, elevational view of the upper rail joined 10 FIG.39 is a partial, elevational view of the upper rail joined
to the mesh piece of FIG. 10; to the mesh piece of FIG. 38, wherein welding has occurred;
example of a drawer using the upper rail and mesh piece drawer example
example with an upper rail of FIG. 36 and a first
of a lower rail;
shown in FIGS. 10 and 11:
FIG. 13 is an exploded, rear, perspective view of a third 15 40, whereinis the
FIG. 41 a perspective view of the drawer and rails of FIG.
rails are coupled to the basket portion;
example of a drawer for use in the system of FIG. 1, wherein FIG. 42 is a partial, elevational view of the upper and lower
an alternative example of two side pieces of mesh material are rails of FIG. 40 engaged with a mesh piece, wherein welding
used; has not occurred;
FIG. 14 is a partially-exploded, rear, perspective view of FIG. 43 is a partial, elevational view of the upper and lower
the drawer shown in FIG. 13, wherein three pieces of mesh rails joined to the mesh piece of FIG. 42, wherein welding has
material have been joined together, occurred;
FIG. 15 is an enlarged, rear, perspective view of a fourth FIG. 44 is a partial, elevational view of the upper rail of
example of a drawer useful in the system of FIG. 1; FIG.38 supported by a mesh piece and a second example of
FIG.16 is an exploded, rear, perspective view of the drawer a lower rail, wherein welding has not occurred; and
shown in FIG. 15: 25 FIG. 45 is a partial, elevational view of the upper and lower
FIG. 17 is a partially-exploded, rear, perspective view of rails joined to the mesh pieces of FIG. 44, wherein welding
the drawer shown in FIG. 15, wherein three pieces of mesh has occurred.
material have been joined together, DETAILED DESCRIPTION OF EXAMPLES OF
FIG. 18 is front, perspective view of a second example of a 30 THE PRESENT INVENTION
system of drawers of the present invention, where the drawers
are shown in a retracted position; Referring to FIG. 1, a first example of drawer system 10 is
FIG. 19 is an exploded, perspective view of an exemplary shown. This drawer system 10 may be used to store a variety
drawer with a third example of an upper rail; of housewares, such as kitchen items, clothing, accessories,
FIG. 20 is a perspective view of the drawer and rail of FIG. 35 sports equipment, shoes, bathroom Supplies, tools, appli
19, wherein the rail is coupled to the drawer; ances, and the like. Additionally, system 10 can be used to
FIG. 21 is an enlarged, partial, perspective view of the store a variety of other items, for example food, office Sup
upper rail of FIG. 19, wherein the rail is uncompressed; plies, office equipment, file folders, papers/documents, bags,
FIG. 22 is a partial, elevational view of the upper rail of boxes, cans, bottles, etc.
FIG. 19 disposed upon a mesh piece, wherein the rail is 40 Drawer system 10 includes frame 12 and a plurality of
uncompressed; containers or drawers 14a-d. Drawer 14a is smaller than
FIG.23 is a partial, elevational view of the upper rail joined drawers 14b-c so drawer 14a can hold a smaller volume than
to the mesh piece of FIG. 22, wherein the rail is compressed; other drawers 14b-d. Drawers 14a-daremovable with respect
FIG. 24 is a partial, elevational view of a fourth example of to frame 12 between a retracted position (shown in FIG. 1)
an upper rail separated from a mesh piece; 45 and an extended position. In the retracted position, the con
FIG.25 is a partial, elevational view of the upper rail joined tents of lower drawers 14b-d is difficult to access. In the
to the mesh piece of FIG. 24; extended position, the contents of the extended drawer are
FIG. 26 is a partial, elevational view of a fifth example of an easily accessible; the extended drawer may be fully with
upper rail separated from a mesh piece; drawn from frame 12 if desired.
FIG.27 is a partial, elevational view of the upper rail joined 50 With reference to FIG. 1, frame 12 includes two side frame
to the mesh piece of FIG. 26: members or ladders 16 that are spaced apart and joined by
FIG. 28 is a partial, elevational view of a sixth example of pairs of upper and lower cross members 18a, b, respectively.
an upper rail separated from a mesh piece; Side frame members 16 and pairs of upper and lower cross
FIG.29 is a partial, elevational view of the upper rail joined members 18a, b are formed to give frame 12 a rectangular
to the mesh piece of FIG. 28; 55 shape. The present invention is not limited to this frame
US 8,584,889 B2
7 8
are also generally perpendicular to one another. For example, 35 edge 74b, central portion 74c, side extensions 74d. and lower
molded plastic. 45 76c, side extensions 76d. and lower extension 76e.
Now, with reference to FIGS. 1,3,3A, the details of drawer In an alternative example, pieces of mesh 74 and 76 can be
14b will be discussed. Drawer 14b includes a runner portion formed of a single piece of material separate from first piece
that comprises upper rail 54 and basket portion 55. Basket of mesh 72. In such event, the two pieces of mesh 74 and 76
portion 55 is coupled to upper rail 54. In the present example, would be joined by another mesh segment (not shown) that
basket portion 55 is formed of expanded metal plate (i.e., 50 would be shaped similar to bottom wall portion 56. As a
sheet metal) or “mesh' and has small openings 56a therein. In result, bottom wall of basket 55 would be formed of two
the present specification and appended claims “mesh' means layers of mesh material that overlap.
flat metal that is pierced and stretched so that no material is Referring to FIG. 5A, first, second, and third pieces of
separated from the original raw material, as known by those mesh 72, 74, and 76 have been joined together so that bottom
of ordinary skill in the art. On the other hand, unlike mesh, 55 seams 78 are formed. Seams 78 are where the material of
punching portions of waste material out of sheet metal mate bottom wall 56 of first piece of mesh 72 overlaps with lower
rial forms perforated metal. For example, openings 56a (see extension 74e of second and third pieces of mesh 74 and 76
FIG. 3A) in the mesh have an area less than 25.4mm by 25.4 (see FIG. 4). When corners 64 are formed, side seams 80 (as
mm. In another example, openings 56a (see FIG. 3) in the shown in FIG. 3) are formed adjacent each corner 64. Seams
mesh have an area less than 20 mm by 10 mm. In yet another 60 80 are where the material of sidewalls 62 offirst piece of mesh
example. In another example, openings 56a (see FIG.3) in the 72 overlaps with side extensions 74d and 76d of second and
mesh have an area less than 6 mm by 3 mm. third pieces of mesh 74 and 76, respectively. Seams 80 are
US 8,584,889 B2
10
as is known by those of ordinary skill in the art. seams 80 has an appropriately sized fixture including clamp
Second and third pieces of mesh 74 and 76 are formed and (S), elongated member(s) and cathode electrode(s) for Smaller
shaped as shown in FIG. 4. This involves cutting pieces of pieces 74 and 76. For example, the cathode electrode(s) may
mesh 74 and 76 with the desired dimensions and shape from be tapered to match trapezoidal extensions 74d,76d so that
a roll of mesh using a conventional press machine. Then, 10 pieces 74 and 76 are suitably clamped to end walls 58 and 60
mesh piece 74 is bent using a conventional hydraulic press during welding.
Next, lower extensions 74e.76e of each piece 74.76 are tion 55 extends above rail 54; and spot-welding contact sur
curved side extensions 74d,76d of pieces 74.76 are connected as basket portion 55 so that these components can be welded
by welding to sidewalls 62 of first piece 72 to form seams 80 together. Thus, for example, rail 54 is formed of any metal
(as shown in FIG. 3). Such as copper, Steel, stainless steel, mild sheet steel or alu
contact with pieces 72.74 adjacent extension 74e. Pieces 60 Anode electrode AE contacts outer surface of rail 54 and
72.74 are tightly compressed between electrodes 92a and cathode electrode CE contacts inner surface of basket portion
92b. Electrodes 92a, b then discharge electric welding current 55 adjacent surface 54a, as shown in FIG. 9. An electric
US 8,584,889 B2
11 12
As shown in FIG. 1, drawers 14b-14d are of medium size example, formed similar to rail 54 (see FIG. 10) with an
US 8,584,889 B2
13 14
In the present example, first section A has a length less than 654b, 654c. In the present example (as shown in FIG. 29), rail
FIGS. 22-23). Then, the now generally vertically-extending 65 section 854c, which is connected to extension 854d. Curved
US 8,584,889 B2
15 16
except rib 954c has been replaced with outwardly extending high-priced system and a lower priced system.
or projecting connection portion 1054c at the free end of Alternatively, one system can have drawers with various
vertical second portion 1054b. When rail 1054 is joined to 45 types of rails 54,54,354,454,554, 654, 754,854,954, 1054,
basket portion 955, horizontal first portion 1054a covers 1154 and 1254. Additionally, a system can use all closed
upper edge 955b (shown in FIG. 34) and second portion corner drawers or combine closed-corner drawers with open
1054b and connection portion 1054c contact basket portion corner drawers in one system. The system may be used with
955. After joining rail 1054 to basket portion 955, the use of sliding drawers and/or stationary and sliding shelves each
electric welding could allow connection portion 1054c and 50 Supported by a pair of runners. The system frame may also
basket portion 955 contacting connection portion 1054c to be include a section for holding hanging file folders and one or
fused into an integral structure (as shown in FIG. 39). more of the inventive drawers. The drawers of the present
FIGS. 40-43 illustrate an alternative example of basket invention may be used without a frame. In yet another alter
portion 1155 with upper rail 954 and lower rail 1154. Basket native example, the containers/drawers of the present inven
portion 1155 is formed by four sidewalls 1155a of mesh and 55 tion may be retained within a frame formed of wood, plastic,
one bottom wall 1155b of mesh. Sidewalls 1155a are prefer metal, or material with a wood finish, where the frame has
ably joined by conventional methods such as welding. Bot components such as runners and rollers thereon. The frame
tom wall 1155b can be joined to sidewalls 1155a by welding would cooperate with a stationary holder with runners and
and/or by rail 1154. Upper rail 955 previously described with rollers thereon so that the container does not move with
reference to FIGS. 36-37 is joined to basket portion 1155 as 60 respect to the holder, but when the holder moves between an
previously discussed. extended and retracted position by moving with respect to the
Lower rail 1154 includes horizontal first portion 1155a and stationary component, the container likewise moves. In Such
vertical second portion 1155b. Horizontal first portion 1155a an example, the runner portion serves to connect the container
includes inwardly projecting connection portion or rib 1154c. to the holder without a sliding engagement therebetween. In
Vertical second portion 1155b includes inwardly projecting 65 addition, the container can be formed without upper rail 54
connection portion or rib 1154d. When rail 1154 is joined to (see FIG. 3) by forming the runner portion in another way,
basket portion 1155, first portion 1154a and rib 1155c contact Such as by folding the upper edge of the basket portion upon
US 8,584,889 B2
17 18
itself to form a sufficiently-rigid integral runner portion. 3. A container, comprising:
Alternatively, the runner portion need not extend around the a basket portion having a bottom wall, upwardly extending
entire basket and may extend only on the sides to work with first and second pairs of opposed sidewalls, and an
the runners 26a-g (see FIG. 1). In such an example, the end upwardly extending opening:
walls without the runner portions may have upper edges fin 5 an upper section of said first and second pairs of opposed
ished with portions of metal, wood, plastic or some other sidewalls extending generally horizontally outwardly
suitable material. Exemplary rails shown and described above away from said upwardly extending opening; and
with one basket construction can be used with basket con
structions shown in other examples or with conventional bas a rail including a first section, a second section, and a joint
ket constructions. For example, the exemplary rails shown 10
section compressing said first and second sections to
and described above can be used with baskets that include said upper section of said first and second pairs of
sidewalls formed from a single loop of mesh material joined opposed sidewalls, such that said first and second sec
to a separate piece of bottom wall mesh material. Thus, the tions of said rail are generally parallel and horizontally
details of the present invention as set forth in the above extending outwardly away from said upwardly extend
described examples should not limit the scope of the present ing opening.
15
invention. 4. The container of claim 3, wherein said rail has at least
Further, the purpose of the Abstract is to enable the U.S. two configurations, a first configuration being an open con
Patent and Trademark Office, and the public generally, and figuration in which said rail is unfastened to said upper sec
especially the designers and practitioners in the art who are tion, and a second configuration being a compressed configu
not familiar with patent or legal terms or phraseology, to ration in which said rail is fastened to said upper section.
determine quickly from a cursory inspection the nature and 5. The container of claim 4, wherein:
essence of the technical disclosure of the application. The said rail includes third and fourth sections extending from
Abstract is neither intended to define the invention of the said first and second sections;
application, which is measured solely by the claims, nor is wherein when said rail is in the first configuration, said
intended to be limiting as to the scope of the invention in any 25
first, second, third and fourth sections are configured to
way. form an opening that is located between said first and
We claim as our invention: second sections; and
1. Apparatus, comprising: when said rail is in the second configuration, said first and
a container including first and second pair of opposed second sections of said rail are generally parallel and
sidewalls with upper portions, and a bottom wall, said 30
horizontally extending outwardly away from said
first and second pair of opposed sidewalls being formed upwardly extending opening, and said third and fourth
from a single loop of material that is joined to said sections of said rail are generally parallel and extending
bottom wall, said sidewalls and bottom wall made of away from said upwardly extending opening, such that
metal mesh material and shaped to form a basket having said upper section of said first and second pairs of
an open top: 35
opposed sidewalls is positioned inside said opening
said basket having a free edge extending outwardly from located between said first and second sections and said
said upper portions of said first and second pair of joint section compresses said first and second sections to
opposed sidewalls; said upper section of said first and second pairs of
said container further including a rail having an opening opposed sidewalls.
that receives said free edge of said basket portion such 40
6. The container of claim 5, wherein in the first configura
that said free edge may be secured within said opening, tion, said first section, said second section and said joint
said rail extending outwardly about the upper portions of section have a generally V-shaped form, and in the second
said first and second pair of opposed sidewalls; and configuration, said first section, said second section, said third
a frame, said container being moveable with respect to said Section, said fourth section, and said joint section have a
frame between retracted and extended positions via said 45
generally L-shaped form.
rail. 7. The container of claim 5, wherein said first, second, third
2. The apparatus according to claim 1, wherein said frame and fourth sidewalls include an outer surface and an inner
includes a pair of opposed tracks for receiving said rail and Surface, and said rail extends substantially continuously
around said outer surface.
guiding said container between said retracted and extended
positions.
Exhibit E
USOOD847510S
(12 ) Post
United States Design Patent ( 10) Patent No.: US D847 ,510 S
et al. (45) Date of Patent: * * May 7 , 2019
(54 ) MESH BASKET (58 ) Field of Classification Search
USPC ..... ... D3/201, 304, 305, 306 , 312 , 314 – 315 ,
(71 ) Applicant: Design Ideas, Ltd ., Springfield , IL D3/318 - 319 ; D19 /75 – 77 , 90
(US) CPC ....... A45F 5 /00 ; A45F 5 /10 ; A45F 2005 /1006
See application file for complete search history .
(72 ) Inventors : R . Neal Post, Springfield , IL (US );
Christopher Hardy, Springfield , IL (56 ) References Cited
(US) U . S . PATENT DOCUMENTS
(73 ) Assignee : Design Ideas, Ltd ., Springfield, IL 297 ,382 A 4 /1884 Golding
(US ) 887 ,097 A 5/ 1908 Kimber
(* * ) Term : 15 Years (Continued )
(21) Appl. No.: 29 /584,668 FOREIGN PATENT DOCUMENTS

GB 228338 2 / 1925
( 22 ) Filed : Nov. 16 , 2016 TW 086202707 2 /1998
Related U .S. Application Data OTHER PUBLICATIONS
(60 ) Continuation of application No. 29/491, 966 , filed on
May 27, 2014 , now Pat. No. Des . 773 ,815 , which is The Container Store, The Ultimate Planning Guide, revised Nov .
a continuation of application No. 29/438 ,180 , filed on 2001.
Nov. 27 , 2012 , now abandoned , which is a
continuation of application No. 29 /417 , 074 , filed on
(Continued )
Mar. 29 , 2012, now Pat. No. Des. 673 ,369, which is Primary Examiner — Kelley A Donnelly
a continuation of application No. 29/388 , 154 , filed on (74 ) Attorney, Agent, or Firm — Saidman DesignLaw
Mar. 24 , 2011 , now Pat. No . Des . 658 , 881, which is Group, LLC
a continuation of application No . 29/ 375 , 897 , filed on
Sep . 29 , 2010 , now Pat. No. Des. 636 ,998 , which is (57) CLAIM
a continuation of application No . 29/ 308 ,601, filed on
Jun . 25 , 2008 , now Pat. No . Des . 624 ,753, which is a The ornamental design for a mesh basket, as shown and
continuation of application No. 29 / 307 ,556 , filed on described .
Apr. 25 , 2008, now Pat. No . Des . 653, 063, which is
a continuation of application No. 29 /238 ,378 , filed on
Sep . 14 , 2005, now Pat. No. Des. 567,553 , which is DESCRIPTION
a division of application No. 29/216 ,533 , filed on FIG . 1 is a front perspective view of a mesh basket showing
Nov. 4 , 2004 , now abandoned , which is a division of
application No. 29/ 190 ,480 , filed on Sep . 22 , 2003 , our new design ;
now Pat. No. Des . 501, 105 , which is a division of FIG . 2 is a front view thereof; and ,
application No . 29 /176 ,610 , filed on Feb . 27 , 2003, FIG . 3 is a right side view thereof, the left side being a mirror
(Continued )
image .
The broken lines illustrate environmental structure and form
(51) LOC ( 11) CI. .... ........ 03- 01 no part of the claimed design .
(52) U . S . CI.
USPC . ... ...... D3 /306 1 Claim , 2 Drawing Sheets
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US D847 ,510 S
Page 2
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D449,074
S 7 /2001
S * 10 / 2001
Tsong- Yow
Andujar ... D19 / 75
now Pat. No . Des. 481, 233 , which is a continuation D450 ,481
D451,675
S
S
11/2001
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Post
Hardy et al.
in -part of application No. 29 / 148 ,906 , filed on Sep . D453 ,027 S 1 /2002 Andujar
28 , 2001, now abandoned . D455 ,029 S 4 / 2002 Gusdorf
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atent May 7 , 2019 ????? I J0 7 US D847 ,510 S
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? ? ? ? ? ? { { ? ?? $? ? { { { : ` ? ??• '? v9ye ? ' ?? 9 ??vvvvvvvvvvvvvvy??d?Y???vvvy ??? ??? ??????y ? ?? v y ' ? 9 / 19 / it w?????vy ? ? ? ?? ?? ) ' y?
???? ? ” ? ' ? ? ? ' ' ' ' ' ' ???? ? ??? ? ? ? ???? ???? A ? ? ??? ? ???? ? ? ? ????????? ? ? ? % ?????NA4 ? . ? ????? ? ? ????? ? ??? * * ? ???? ????* * ** V +
? ? ? ¥ { * * * * * * * ? ? : * * * * ? ' ' ? ? ? ? ? ' ' * ¥ : ? ' ' 31 x 4 1 1 3 * * * ' ' ' 5 X 4 4 3 3 1 x 4 A ' ' X K * * * * * ? ' ' * * * * \ A ' ' * * N ' ' ' 1 4 4 1 1 1 3 ? ? ' ' 43 ; 13 3 ( } } ' ? ? ? ? ? ? ?
??? ? { ?? , 9 ?? : ?YY? ? v?? v ? ?? ? ? ? ?????????? ? ??.??YVV? y. s v ?w v?? ? 9 ? ? Y? v y ?? ? ? ? ? ? ? ???? ? y ' .9 ? ?? ?? 1? › › › › 5 * ' ' ?? ? ? ? : ? ›'
* * ›? ? ' A? { ! ? { { { ' ??? * * FAM A ? ? ????A????* * * ? f????????? A ? ? ?????AA??? ? ? ???????? ? ? ? ???? ? ? ???? ? ? ???? ? ? ???? ? ???? * * * * ???? ? ??? 4 .
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? ?? ? ? ? ???? ?? ? ?? ? ? ? ? ??? ? ? ? ? ??? ? * A ?AA ?? A??? * ? * * * ** * * * * * * * * * * * A ? ? ???A ?? ??? ? ? ??A? ? A ?AA ? ? ? ? ? ? ?? ? ? ??? ? ? ? ??? ?? ?AA ?A * * * * * * * * * * * * *
: 4 If * ¥ ?Y ? xx ?Y ? - ????? 4???Y }Y?fi - Y1Y 45??Y ? ?ff? ¥ : ? ? ??? " - ? If ?Y y { ! ?? ? ?- ??ff ? : ! ! * * N ' ' # $ / £ ! ? » ? 14 ? 9 x ? . 3 ?: : ? ? ? ? ? ? ' ? ? x ??ii ? ? ' ' ? . 3
Fig . 3
Exhibit F
USOOD856678S
(12 ) Hardy
Unitedet alStates Design Patent (10) Patent No.: US D856 ,678 S
. (45) Date of Patent: * * Aug . 20 , 2019
(54) MESH BASKET 463, 964 A
887 ,097 A
11/ 1891 Gates
5 / 1908 Kimber
(71 ) Applicant: Design Ideas, Ltd ., Springfield , IL 920 ,313 A 5 /1909 Franklin
1 ,098 ,053 A 5 /1914 Porter
(US) 1 ,282 ,094 A 10 / 1918 Lindner
1 ,382,592 A 6 / 1921 Ames
( 72 ) Inventors: Christopher Hardy , Springfield , IL 1 , 384, 755 A 7 / 1921 Hall
(US); R . Neal Post, Springfield , IL 1 ,408, 026 A
1,445 ,259 A
2 / 1922 Ochiltree
2 / 1923 Wiselogel
(US )
(Continued )
(73 ) Assignee : Design Ideas, Ltd ., Springfield, IL FOREIGN PATENT DOCUMENTS
(US )
(* * ) Term : 15 Years CN 202429440 9 /2012
DE 202010008455 1 / 2011
(21) Appl. No.: 29/692,384 (Continued )

(22) Filed : May 24 , 2019 OTHER PUBLICATIONS
Related U .S . Application Data Design Ideas catalog 1995 , cover page and p . 24 .
(63 ) Continuation of application No. 29/627 ,840, filed on (Continued )
Nov. 30 , 2017 , which is a continuation of application Primary Examiner — Michael A . Pratt
No. 29 /566 ,795 , filed on Jun . 2 , 2016 , now Pat. No . (74 ) Attorney, Agent, or Firm — Saidman Design Law
Des. 807 ,036 , which is a continuation of application Group, LLC
No. 29 / 327 , 206 , filed on Oct. 31 , 2008, now Pat. No .
Des . 759,976 . (57) CLAIM
(51) LOC (12) Cl. .... 03-01 The ornamental design for a mesh basket, as shown and
(52 ) U .S . CI. described .
USPC . ............ D3/306
(58 ) Field of Classification Search DESCRIPTION
USPC .... ..... ....... .... D3/ 201, 304, 306 , 307
CPC ... B65D 7 /08 ; B65D 7 /14 ; B65D 7 /12 ; B65D The file of this patent contains at least one drawing /photo
25 / 22 ; B65D 7 / 16 graph executed in color. Copies of this patent with color
See application file for complete search history . drawing (s)/photograph (s) will be provided by the Office
upon request and payment of the necessary fee .
(56) References Cited FIG . 1 is a front perspective view of a first embodiment of
U .S . PATENT DOCUMENTS a mesh basket showing our new design ; and ,
FIGS. 2 -7 are perspectives which are respectively front, rear,
71, 881 A 12/ 1867 Howe et al. left side, right side , top and bottom views thereof.
171 ,032 A 12 / 1875 Meyers
201, 959 A 4 / 1878 Stockwell et al. 1 Claim , 7 Drawing Sheets
297, 382 A 4 / 1884 Golding (7 of 7 Drawing Sheet(s) Filed in Color )
OSONA
US D856 ,678 S
Page 2
(56 ) References Cited D503,059

D504 ,017
S *
S
3 / 2005 Post ... ........
4 /2005 Zimmerman
......... D3 /306
U . S . PATENT DOCUMENTS D513 , 874S 1 /2006 Hardy et al.
6 , 988,654
B2 1 /2006 Wnek
1,463,098 A 7/ 1923 Snyder D516 ,814 S 3 / 2006 Post et al.
RE16 ,431 E 9 / 1926 Kratzer D520 ,750 S 5 /2006 Post et al.
1 ,660,410 A 2 / 1928 Beckman D526 ,754 S 8 /2006 Hardy et al.
1,890, 983 A 12 / 1932 Griffith D528, 300 S 9 /2006 Hardy et al.
2 ,408,082 A 9 / 1946 Mack D530 ,517 S * 10 / 2006 Hardy D3/ 306
2 ,443,319 A 6 / 1948 Mack 7 ,228 ,985
B2 6 / 2007 Yeh
D152 , 140 S 12/ 1948 Crawford et al. 7 ,270 ,245
B2 9 /2007 Cheng et al.
D152 , 141 S 12 / 1948 Crawford et al. 7 ,428 ,976
B2 9 /2008 Cheng et al.
2 , 502,781 A 4 / 1950 Erickson D582 , 161S * 12 / 2008 Hardy D3 /306
2 , 768, 022 A 10 / 1956 Pope D584 ,055 S * 1/2009 Hardy ... . .. ... .. . . .......... D3/ 306
D182 ,349 S 3 / 1958 Alvord D624 ,753 S * 10 / 2010 Post ....... ..... ... ............ D3 /306
D189, 544 S 1/ 1961 Harris D632 ,080 S 2 / 2011 Hardy et al.
D189, 550 S 1/ 1961 Alvord D634 , 122 S 3 /2011 Goodman et al .
D194 ,513 S 2 / 1963 Sparling D636 ,998 S 5 / 2011 Post et al.
3 , 120, 323 A 2 / 1964 Sparling D639 , 561 S 6 / 2011 Hardy et al.
3 , 186 ,586 A 6 / 1965 Box D643 ,585 S 8 / 2011 Duvigneau
D204 ,314 S 4 / 1966 Bright D653 ,063 S 1/2012 Post et al.
3 ,935, 958 A 2 / 1976 Frangos 8 , 141, 737 B1 3 /2012 Tsai
D251,480 S 4 / 1979 Cherry D677 ,056 S 3 /2013 Hu
4 ,205 ,406 A 6 / 1980 Wangkeo et al. D752, 345 S 3 /2016 Szucs et al .
D264 ,040 S 4 / 1982 Kunze D759 ,976 S * 6 /2016 Hardy .... D3/ 306
4 ,339,048 A 7 / 1982 McMillen et al. D767, 278 S 9 / 2016 Szucs et al.
D267,395 S 12 / 1982 Groenewold et al. D773,815 S * 12 / 2016 Post D3/ 306
D276 ,401 S 11/ 1984 Daenen et al. D777 ,434 S 1/ 2017 Duvigneau
D298 ,403 S 11/ 1988 Hagberg et al. 9 ,586 ,718 B2 3 /2017 Tsai
D323 ,296 S 1/ 1992 Schoenthaler D792 ,099 S * 7 /2017 Hsu ....... D3/306
D326 ,552 S 5 / 1992 Goodell D807,036 S 1/ 2018 Hardy et al.
D328 ,993 S 9 / 1992 Rosenthal 9 , 963, 264 B2 5 / 2018 Tang
5 ,279 ,443 A 1 / 1994 Koda et al. D843, 172 S 3 /2019 McGinnis et al.
D360, 531 S 7 / 1995 Griffith D847,510 S 5 /2019 Post et al.
D360, 898 S 8 / 1995 Huerto et al. 2016 / 0052665 Al 2 / 2016 Tsai
D372 ,583 S 8 / 1996 Brightbill
D373, 039
D383 ,283
S
S
8 / 1996 Cohen et al.
9 / 1997 Hankins, III
D387 ,981S 12 / 1997 Mosior et al. FR 826876 4 / 1938
5 ,810 , 179
A 9 / 1998 Kleiman GB 228338 2 / 1925
D401,067 S 11/ 1998 Hampshire GB 730785 6 / 1955
D405 ,268 S . 2 / 1999 Apnes
D407 ,558 S 4 / 1999 Huguet et al.
D416 , 165 S 11/ 1999 Zemel OTHER PUBLICATIONS
D419 , 302 S 1/2000 Hardy et al.
D426 , 956 S 6 / 2000 Lacy et al. Miller's Office Products catalog 1995, p . 442 , Wire Mesh Desk
D431,907 S 10 / 2000 Andujar et al. Accessories ( item c ).
D433 , 709 S 11/2000 Hardy Miller's Office Products catalog 1997, p . 453 , Mesh Desk Acces
D433,711 S 11/ 2000 Andujar sories.
D434 ,074 S 11/ 2000 Hardy Miller 's Office Products catalog 1998 , p . 475, Wire Mesh Desk
D437 ,984 S 2 /2001 Weiss et al. Accessories .
D444, 927 S 7 / 2001 Lin Design Ideas catalog 1998 , cover page and pp . 61, 66 -67.
D449, 074 S 10 / 2001 Andujar Hong Kong Enterprise, Oct. 1999 , p . 1126 ,Mesh Basket, # SM 500
D450 ,481 S 11/2001 Post in center of page .
D451,675 S 12 / 2001 Hardy et al. Hong Kong Enterprise , Oct. 1999 , p . 98 , Mesh Basket, # NH -11
D453 ,027 S 1/ 2002 Andujar
D455 ,029 S 4 / 2002 Gusdorf bottom of page.
D458,429 S 6 /2002 Lenard Four digital photos of drawers of the elfa® closet system sold by
6 ,461, 501 B1 10 / 2002 Porter The Container Store® , offered for sale before Sep . 28 , 2000 (4
D471,713 S 3 / 2003 Speed pages ).
D474 ,603 S 5 / 2003 Berenguer The Container Store, The Ultimate Planning Guide, revised 1999,
D475 ,854 S 6 /2003 Caponey cover page and pp . 16 and 19 .
D476 , 155 S 6 / 2003 Post et al. The Container Store, The Ultimate Planning Guide , revised Nov .
D479 ,272 S * 9 / 2003 Hardy ... . .. . . . D19 / 92 2001, cover page and pp . 20 -21 and 34 .
6 ,718 ,635 B2 4 / 2004 Cheng et al.
D498, 375 S 11/2004 Post et al. * cited by examiner
atent Aug. 20 , 2019 Sheet 1 of 7 US D856 ,678 S
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Exhibit G
USO10524569B2
United States Patent ( 10 ) Patent No.: US 10,524,569 B2

Cheng et al. (45 ) Date of Patent: Jan. 7 , 2020
(54 ) METHOD FOR MAKING MESH (52) U.S. CI.
CONTAINERS WITH A RAIL AND MESH CPC A47B 88/40 (2017.01 ); A47B 55/02
CONTAINER FORMED THEREFORM (2013.01); A47B 67/04 ( 2013.01); B65D 7/14
(2013.01);
(71 ) Applicant: Design Ideas, Ltd., Springfield , IL (Continued )
(US) (58 ) Field of Classification Search
CPC B65D 7/20; B65D 7/14 ; B65D 25/30 ; A47B
(72 ) Inventors: Hsi-Ming Cheng, Chung-Hua Hsien 55/02; A47B 88/07 ; A47B 55/40 ; A47B
(TW ); R. Neal Post, Springfield , IL 67/04
(US) ; Christopher Hardy, Springfield , (Continued )
IL (US ) (56 ) References Cited
(73 ) Assignee : Design Ideas, Ltd., Springfield , IL U.S. PATENT DOCUMENTS
(US )
171,032 A 12/1875 Meyers
( * ) Notice : Subject to any disclaimer, the term of this 201,959 A 4/1878 Stockwell et al.
patent is extended or adjusted under 35 (Continued )
U.S.C. 154(b ) by 0 days .
( 21) Appl. No.: 15 /340,740 DE 1083999 6/1960
EP 53103-001 10/2003
(22) Filed : Nov. 1, 2016 (Continued )
(65 ) Prior Publication Data
OTHER PUBLICATIONS
US 2017/0071337 A1 Mar. 16 , 2017
Millers Office Products, p . 442, 1995 .
(Continued )
Primary Examiner James N Smalley
(63) Continuation of application No. 14 /029,498 , filed on Assistant Examiner - Madison L Poos
Sep. 17 , 2013, now Pat. No. 9,687,074 , which is a (74) Attorney, Agent, or Firm - Perry Saidman , LLC
(Continued )
(57 ) ABSTRACT
( 30 ) Foreign Application Priority Data The present invention is directed to a method of forming a
Feb. 27 , 2002 ( TW ) 91202306 U container comprising forming a basket portion of metal
Sep. 11, 2002 ( TW ) 91214244 U mesh material and a rail connected to the basketportion . The
rail extends substantially outwardly from the outer surface
(Continued ) of the basket portion and the rail extends continuously
around the outer surface of the basket portion . In one
(51) Int. CI. example , themethod includes forming the rail so that it does
A47B 88/40 ( 2017.01) not contain or surround a free edge of the basket portion. In
A47B 55/02 ( 2006.01) another example , the method includes forming the rail so
(Continued ) (Continued )
68 70 182 142
-20
26a -282
24
24H
146
200 -266
12
16
26d
140
260
264
1441
-269
26g
24
.22
22
180
US 10,524,569 B2
Page 2
that it includes an opening for containing or surrounding a 2,241,229 A

2,275,268 A
5/1941 Williams
3/1942 Prinzler
free edge of the basket tion . Themethod may also include 2,446,499 A 8/1948 Van Denberg
forming a lower rail. The present invention is also directed 2,464,921 A 3/1949 Chandler
to a container formed by such method . 2,502,781 A 4/1950 Erickson
2,507,152 A 5/1950 Garofalo
21 Claims, 29 Drawing Sheets 2,574,998 A 11/1951 Bangert, Jr.
2,658,444 A 11/1953 Wheeler
2,706,064 A 4/1955 Vitols
2,721,671 A 10/1955 Averill
2,768,022 A 10/1956 Pope
Related U.S. Application Data 2,825,481 A 3/1958 Glenny
2,826,329 A 3/1958 Beckner
continuation of application No. 13 /208,024 , filed on 2,851,186 A 9/1958 Rupe , Jr.
2,898,122 A 8/1959 Beckner
Aug. 11, 2011, now Pat. No. 8,584,889 , which is a 2,999,559 A 9/1961 Boyer
continuation of application No. 12 /237,926 , filed on D194,513 S 2/1963 Sparling
Sep. 25 , 2008, now Pat. No. 8,006,858 , which is a 3,120,323 A 2/1964 Sparling
continuation of application No. 11/000,295, filed on 3,138,281 A 6/1964 Schray
Nov. 30 , 2004 , now Pat. No. 7,428,976 , which is a 3,250,430 A 5/1966 Cella
continuation -in -part of application No. 10 /972,308, 3,272,377 A 9/1966 Schray
3,436,044 A 4/1969 Martinson
filed on Oct. 22 , 2004 , now Pat. No. 7,270,245 , which 3,563,292 A 2/1971 Gordon
is a continuation of application No. 10 /308,699 , filed 3,807,596 A 4/1974 Baker
12/1975 Johansson et al.
on Dec. 3 , 2002 , now abandoned . 3,923,187 A
4,173,289 A 11/1979 Nesti
( 30 ) Foreign Application Priority Data 4,205,406 A 6/1980 Wangkeo et al.
D267,395 S 12/1982 Groenewold et al .
4,664,684 A 5/1987 Dunn et al.
Jul. 21 , 2004 ( TW ) 93211506 U D298,403 S 11/1988 Magbert et al.
Jul. 21, 2004 ( TW ) 93211507 U 4,795,041 A 1/1989 Remmers
Jul. 28 , 2004 (CN ) 2004 2 0084938 U 4,903,853 A 2/1990 Lin
Jul. 29 , 2004 (CN ) 2004 2 0084546 U D328,993 S 9/1992 Rosenthal
5,226,586 A 7/1993 Grone
D341,459 S 11/1993 Yang
(51) Int. Ci. 5,330,063 A 7/1994 Remmers
A47B 67/04 ( 2006.01) D373,039 S 8/1996 Cohen et al.
B65D 6/08 (2006.01) D383,283 S 9/1997 Hankins, III
B650 25/30 ( 2006.01) D393,766 S 4/1998 Mazzola et al .
5,810,179 A 9/1998 Kleiman
(52) U.S. Cl. 5,842,789 A 12/1998 Derby et al.
CPC B65D 7/20 (2013.01 ); B650 25/30 5,851,393 A 12/1998 Carr et al .
( 2013.01); Y10T 29/49915 ( 2015.01) D411,045 S 6/1999 Morandi
D416,165 S 11/1999 Zemel
(58 ) Field of Classification Search D419,302 S 1/2000 Hardy et al.
USPC 220/642, 62, 607 , 676 , 485 , 494 ; 29/509, D433,709 S 11/2000 Hardy
29/512 6,176,175 B1 1/2001 Moreth
See application file for complete search history . D437,984 S 2/2001 Weiss et al .
D444,039 S 6/2001 Tong
(56 ) References Cited D444,927 S 7/2001 Lin
D451,675 S 12/2001 Hardy et al.
U.S. PATENT DOCUMENTS D453,027 S 1/2002 Andujar
D455,029 S 4/2002 Gusdorf
463,964 A 11/1891 Gates 6,419,103B1 7/2002 Wang
900,162 A 10/1908 Goodwin 6,461,501B1 10/2002 Porter
920,313 A 5/1909 Franklin 6,508,376B1 1/2003 Chiang
933,517 A 9/1909 Worcester D476,155 S 6/2003 Post et al.
981,205 A 1/1911 Loetzer D481,233 S 10/2003 Post et al.
994,984 A 6/1911 Dennis 6,718,635B2 4/2004 Cheng et al.
1,098,053 A 5/1914 Porter D501,105 S 1/2005 Post et al.
1,138,496 A 5/1915 Martin D513,874 S 1/2006 Hardy et al.
1,224,234 A 5/1917 Taber 7,228,985 B2 6/2007 Yeh
1,305,148 A 5/1919 Montan 9,687,074 B2 6/2017 Cheng et al.
1,382,592 A 6/1921 Ames
1,384,755 A 7/1921 Hall FOREIGN PATENT DOCUMENTS
1,389,908 A 9/1921 Shults et al.
1,408,026 A 2/1922 Ochiltree EP 53103-0002 10/2003
1,445,259 A 2/1923 Wiselogel EP 53103-0003 10/2003
1,463,098 A 7/1923 Snyder EP 53103-0004 10/2003
1,484,696 A 2/1924 Wulftange EP 53103-0005 10/2003
RE 16,431 E 9/1926 Kratzer EP 53103-0006 10/2003
1,660,410 A 2/1928 Beckman EP 53103-0007 10/2003
1,688,846 A 10/1928 Andrews EP 53103-0008 10/2003
1,840,561 A 1/1932 Miller EP 53103-0009 10/2003
1,890,983 A 12/1932 Griffith EP 53103-0010 10/2003
1,950,921 A 3/1934 Gray et al. EP 53103-0011 10/2003
2,009,527 A 7/1935 Shelton EP 53103-0012 10/2003
2,050,980 A 8/1936 Buhl EP 53103-0013 10/2003
2,174,577 A 10/1939 Friedman EP 1424287 B1 6/2004
US 10,524,569 B2
Page 3
( 56 ) References Cited
FR 826876 4/1938
GB 228338 2/1925
GB 730785 6/1955
JP 2001-270515 2/2001
TW 086202707 2/1998
OTHER PUBLICATIONS
Design Ideas TM Product Catalogue , Design Ideas, Ltd., Copyright
1996 , p . 47 , product H.Mesh Pencil Cup in Black and 3 photo
graphs of Design Ideas ' Mesh Pencil Cup in Silver.
Hong Kong Enterprise , Oct. 1999 , p . 98 .
Hong Kong Enterprise , Oct. 1999 , p . 1126 .
Baigelman & Co., Office Products Catalog , 2000 , item A , p . 492 .
The Container Store, The Ultimate Planning Guide, revised Nov.
2001.
Pending Ex Parte Reexamination No. 90 /014,233, filed Nov. 7 , 2018
for reexamination of claims 1 and 2 of U.S. Pat. No. 9,687,074 .
U.S. Patent Jan. 7 , 2020 Sheet 1 of 29 US 10,524,569 B2
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US 10,524,569 B2
1 2
METHOD FOR MAKING MESH rail is supported by a pair of runners and is movable between
CONTAINERS WITH A RAIL AND MESH retracted and extended positions . The wire grid used for the
CONTAINER FORMED THEREFORM Elfa® basket has large holes measuring about 1 inch by 1
inch . The Elfa® basket also has openings at its corners . If a
CROSS -REFERENCE TO RELATED 5 user desires to store small objects in these baskets , a plastic
APPLICATIONS liner can be used . The liner has a bottom wall and upwardly
bendable sidewalls ,with slits between the sidewalls to allow
This application is a continuation of our prior application for such bending. The open corners of the basket and the slits
Ser. No. 14 /029,498 , filed Sep. 17 , 2013, which is a con between the sidewalls of the liner may allow small objects
tinuation of our prior application Ser. No. 13/208,024 , filed 10 to fall out of the basket, which is undesirable .
Aug. 11 , 2011, now U.S. Pat . No. 8,584,889, which is a Mesh material is typically formed by perforating or
continuation of Ser . No. 12 /237,926 , filed Sep. 25 , 2008 , slitting a piece of sheet metal and stretching it. A sheet of
now U.S. Pat. No. 8,006,858 , which is a continuation of Ser. mesh material requires less raw sheetmetal than a non -mesh
No. 11 /000,295 , filed Nov. 30 , 2004 , now U.S. Pat. No. piece of sheet metal and a perforated piece of sheet metal .
7,428,976 , which is a continuation -in -part of Ser. No. 15 U.S. Pat. No. 1,408,026 to Ochiltree discloses a desk tray or
10 / 972,308, filed Oct. 22 , 2004, now U.S. Pat. No. 7,270 , basket formed or “ expanded metal” or mesh material. Simi
245 , which is a continuation of Ser. No. 10 / 308,699, filed lar to the previous containers, the Ochiltree container is
Dec. 3 , 2002, now abandoned , which claims priority to the formed by a single blank of flatmaterial that is cut out and
prior ROC ( Taiwan ) Patent Application No. 090220946 , folded .
filed Dec. 3 , 2001; ROC ( Taiwan ) Patent Application No. 20 ROC ( Taiwan ) Patent Application No. 086202709 to
091202306 , filed Feb. 27 , 2002; and ROC ( Taiwan ) Patent Chih -Ming, Ko (in transliteration ), filed Feb. 21, 1997 ,
Application No. 091214244 , filed Sep. 11, 2002. This appli discloses a system of containers supported by a frame. The
cation also claims priority to the prior ROC ( Taiwan ) Patent containers are formed of a single piece ofmesh with a rim
Application No. 093211506 , filed Jul. 21, 2004 ; China connected thereto . Additionally, the containers do not move
Patent Application No. 200420084938.8 , filed Jul . 28 , 2004 ; 25 with respect to the frame so that the contents of the lower
ROC ( Taiwan ) Patent Application No. 093211507, filed Jul. container are not easily accessible .
21, 2004 ; and China Patent Application No. A number of mesh containers are made by Design Ideas ,
200420084546.1 , filed Jul. 29, 2004. These applications are Ltd. One of these containers is the “Mesh Storage Nest.”
incorporated by reference herein in their entirety . This container is formed using a first piece ofmesh that has
30 the ends welded together to form a loop . A second piece of
BACKGROUND OF THE INVENTION mesh is welded to the lower edge of the loop so that the first
piece of mesh forms sidewalls and the second piece ofmesh
Field of the Invention formsa bottom wall. The seam at the bottom of the container
The present invention relates to containers, a system using is covered by a bottom rail. A top rail is connected to the
such containers, and a method of making such containers . 35 upper edge of the container. The sidewalls can be shaped to
More particularly, the present invention relates to rails for include a plurality of corners.
use with drawers made of mesh material. A need exists for a lightweight container that can be
Description of Related Art incorporated into a system for storing objects . It is also
Forming containers out ofsheet metal is well known. U.S. desirable that the contents of such a container be made easily
Pat.No. 903,848 to Donnelly and U.S. Pat.No. 1,107,014 to 40 accessible and be prevented from accidentally through holes
Avery disclose such containers. In order to make these in the container. Furthermore, it is desirable that the con
containers, a single blank of flat material is cut out and tainer be formed by an economical method in unlimited
folded with overlapping sections. Sheet metal does not sizes .
provide desirable characteristics such as drainage and ven
tilation . 45 SUMMARY OF THE INVENTION
In an effort to make a well-ventilated container, U.S. Pat.
No. 645,344 to White discloses a container formed of The present invention is directed to a method of forming
perforated sheet metal, wire -netting or another open -work a container comprising the following step : forming a basket
material. The White container is intended to have a folded portion of metal mesh material into a bottom wall and
state and a flat state . This container is designed to be readily 50 upwardly extending first and second spaced apart sidewalls
knocked down from its folded state to its flat state and to be and upwardly extending third and fourth spaced apart side
easily constructed without tools . walls, the first , second , third and fourth sidewalls including
Other patents attempt to make lightweight, drainable an outer surface . The method further includes the following
and /or ventilated containers. U.S. Pat. No. 1,994,553 to steps: forming a rail; and joining the rail to the outer surface
Wolcott discloses one such container of finely woven wire 55 such that a substantial portion of the rail extends substan
screening. U.S. Pat. No. 2,825,481 to Glenny discloses tially outwardly from the outer surface of the first, second ,
another such container of finely woven wire screening. In third and fourth sidewalls , and the rail extending substan
order to make the White, Wolcott and Glenny containers, a tially continuously around the outer surface of the basket
single blank of flat woven wire is cut out and folded with portion .
overlapping sections. 60 In one example, the step of joining further includes
Another wire container that is commercially available spacing the rail from a free edge of the basket portion so that
under the brand name Elfa® is formed of a wire grid with an upper section of the basket portion extends above the rail .
a plurality of separately formed wires welded together . The In such a method , the method further includes the step of
Elfa® container includes a basket portion and a flat rail cutting the upper section of the basket portion from the
around the top edge of the basket portion . The Elfa® baskets 65 remaining portion of the basket portion .
are designed for use in a frame having a plurality of pairs of In another example of the method , the rail is generally
runners . When the baskets are inserted in the frame, the flat L -shaped and has a first portion joined to the basket portion
US 10,524,569 B2
3 4
and a second outwardly -extending portion . In such a upper section of the first, second , third and fourth sidewalls .
method , the rail further includes a projecting connection The opening is sized so that the rail contacts opposing
portion that becomes integral with the side ails after joining surfaces of said upper section .
the rail to the basket portion . Such method may further According to one aspect of the present invention , the rail
include forming a second rail having a L -shape and two 5 further includes a curved portion and an extension angularly
connection portions. The second rail being joined to the offset from the curved portion . The curved portion defines
sidewalls and the bottom wall such that the connection the opening and the extension is joined to the first , second ,
portions become integral therewith . third and fourth sidewalls .
In yet another example , the step of joining further According to another aspect of the present invention , the
includes containing a free edge of the basket portion with the 10 rail further includes first and second extensions angularly
rail. In such an example, the step of forming the rail further offset from a curved portion . The first extension is joined to
includes forming the rail with a curved portion having an an outer surface of the first , second , third and fourth side
opening and a curved section joining first and second walls and the second extension is joined to an inner surface
sections of the rail. The method further including the step of of the first, second , third and fourth sidewalls.
inserting the free edge of said basket portion within the 15 According to one feature of the present invention , the rail
opening is a substantially continuous piece of material.
According to one aspect of the present invention , the step According to one feature of the present invention , the
of forming said rail further includes forming said rail with a basket portion includes open corners between the first and
first extension coupled to and angularly offset from the first second sidewalls and the third and fourth sidewalls . Accord
section . 20 ing to another feature of the present invention , the basket
According to another aspect of the present invention , the portion includes closed corners between the first and second
step of forming said rail further includes forming said rail sidewalls and the third and fourth sidewalls .
with a second extension coupled to and angularly offset from The present invention is also directed to a container
the second section . comprising a basket portion and first and second rails. The
The present invention is directed to a method of forming 25 basket portion is formed of metal mesh material and
a container comprising the following step : forming a basket includes a bottom wall and upwardly extending first and
portion of metal mesh material into a bottom wall and second spaced apart sidewalls and upwardly extending third
upwardly extending first and second spaced apart sidewalls and fourth spaced apart sidewalls. The first rail has a L -shape
and upwardly extending third and fourth spaced apart side and is joined to the first, second , third and fourth sidewalls.
walls . The method further includes the following steps: 30 The second rail has a L - shape and is joined to the sidewalls
bending an upper section of the first, second , third and fourth and the bottom wall.
sidewalls outwardly ; forming a rail including an opening; In an alternative example, the first rail further includes a
inserting the upper section of the first, second, third and first projecting connection portion that contacts the sidewalls
fourth sidewalls into the opening ; and compressing the rail and becomes integral therewith , when the first rail is joined
tofourth
engage the upper section of the first, second , third and 35 to the basket portion . In yet another alternative example , the
sidewalls . second rail further includes at least one second projecting
According to one example of the inventive method, the connection portion . The second projecting connection por
rail forming step further includes forming a curved portion tion contacts the sidewalls or bottom wall and becomes
having the opening and the rail forming step further includes integral therewith , when the second rail is joined to the
an extension angularly offset from the curved portion . In 40 basket portion .
addition , the inserting step further includes locating the Alternatively , the present invention is directed to a con
extension adjacent the basket portion ; and the method fur tainer with a first rail or a second rail .
ther includes welding the extension to the first, second, third
and fourth sidewalls . BRIEF DESCRIPTION OF THE DRAWINGS
According to another aspect of the present invention , the 45
rail forming step further includes forming the rail with a The present invention will be more fully appreciated as
curved portion and a curved section joining first and second the same becomes understood from the following detailed
sections of the rail and the curved portion forms the opening , description of the best mode presently contemplated for
and the method further includes forming the rail with first carrying out the present invention when viewed in conjunc
and second extensions angularly offset from the curved 50 tion with the accompanying drawings, in which :
portion . Additionally, the compression step further includes FIG . 1 is front, perspective view of a first example of a
locating the first extension adjacent an outer surface of the system of drawers of the present invention , where the
first, second , third and fourth sidewalls and locating the drawers are in a retracted position ;
second extension adjacent an inner surface of the first, FIG . 2A is an enlarged , perspective view of an L - connec
second, third and fourth sidewalls . The method further 55 tor for use with the system of FIG . 1 ;
includes welding the first extension to the outer surface of FIG . 2B is an enlarged , end view of the L -connector
the first, second , third and fourth sidewalls and welding the shown in FIG . 2A ;
second extension to the inner surface of the first, second , FIG . 2C is an enlarged , perspective view of a T- connector
third and fourth sidewalls . for use with the system of FIG . 1;
The present invention is also directed to a container 60 FIG . 2D is an enlarged , end view of the T -connector
comprising a basket portion and a rail. The basket portion is shown in FIG . 2C ;
formed of metalmesh material that includes a bottom wall FIG . 3 is an enlarged , rear, perspective view of the first
and upwardly extending first and second spaced apart side example of a drawer shown in FIG . 1 ;
walls and upwardly extending third and fourth spaced apart FIG . 3A is an enlarged , perspective view of a portion of
sidewalls. The basket portion further includes an outwardly 65 the drawer shown in FIG . 3 ;
extending upper section of the first, second , third and fourth FIG . 4 is an exploded , rear, perspective view of the drawer
sidewalls. The rail includes an opening for receiving the shown in FIG . 3 ;
US 10,524,569 B2
5 6
FIG . 5 is an exploded , rear, perspective view of a portion FIG . 30 is a partial, elevational view of a seventh example
of the drawer shown in FIG . 3 , wherein all of the mesh of an upper rail separated from a mesh piece ;
pieces have been bent ; FIG . 31 is a partial, elevational view of the upper rail
FIG . 5A is a partially -exploded, rear , perspective view of joined to the mesh piece of FIG . 30 ;
the drawer shown in FIG . 4 , wherein three pieces of mesh 5 FIG . 32 is a partial, elevational view of an eighth example
material have been joined together; of an upper rail separated from a mesh piece ;
FIG . 6 is a schematic representation of some of themesh FIG . 33 is a partial, elevational view of the upper rail
pieces of FIG . 5 and a portion of a welding machine for joined to the mesh piece of FIG . 32 ;
joining such pieces; FIG . 34 is an exploded , perspective view of a drawer with
FIG . 7 is a schematic representation of some of the mesh 10 a ninth example of an upper rail ;
pieces of FIG . 5 and a portion of the welding machine of FIG . 35 is a perspective view of the drawer and rail of
FIG . 6 ; FIG . 34 , wherein the rail is coupled to the drawer;
FIG . 8 is a partial, elevational view of a first example of FIG . 36 is a partial, elevational view of the upper rail of
an upper rail joined to one of themesh pieces shown in FIG . 15 FIG . 34 supported by a mesh piece , wherein welding has not
5 , wherein an upper portion of the mesh piece is uncropped ; occurred ;
FIG . 37 is a partial, elevational view of the upper rail
FIG . 9 is a partial, elevational view of the upper rail joined joined to the mesh piece of FIG . 36 , wherein welding has
to the mesh piece of FIG . 8 , wherein the upper portion of the occurred ;
mesh piece is cropped ; FIG . 38 is a partial, elevational view of a tenth example
FIG . 10 is a partial, elevational view of a second example 20 of an upper rail supported by a mesh piece,wherein welding
of an upper rail separated from a mesh piece ; has not occurred ;
FIG . is a partial , elevational view of the upper rail FIG . 39 is a partial, elevational view of the upper rail
joined to the mesh piece of FIG . 10 ; joined to the mesh piece of FIG . 38 , wherein welding has
FIG . 12 is an exploded , rear , perspective view of a second occurred ;
example of a drawer using the upper rail and mesh piece 25 FIG . 40 is an exploded , perspective view ofan alternative
shown in FIGS. 10 and 11 ; drawer example with an upper rail of FIG . 36 and a first
FIG . 13 is an exploded , rear, perspective view of a third example of a lower rail;
example of a drawer for use in the system of FIG . 1 , wherein FIG . 41 is a perspective view of the drawer and rails of
an alternative example of two side pieces ofmesh material FIG . 40, wherein the rails are coupled to the basket portion ;
are used; 30 FIG . 42 is a partial, elevational view of the upper and
FIG . 14 is a partially -exploded , rear, perspective view of lower rails of FIG . 40 engaged with a mesh piece , wherein
the drawer shown in FIG . 13, wherein three pieces ofmesh welding has not occurred ;
material have been joined together ; FIG . 43 is a partial, elevational view of the upper and
FIG . 15 is an enlarged , rear, perspective view of a fourth lower rails joined to the mesh piece of FIG . 42 , wherein
example of a drawer useful in the system of FIG . 1 ; 35 welding has occurred ;
FIG . 16 is an exploded , rear, perspective view of the FIG . 44 is a partial, elevational view of the upper rail of
drawer shown in FIG . 15 ; FIG . 38 supported by a mesh piece and a second example of
FIG . 17 is a partially -exploded , rear, perspective view of a lower rail, wherein welding has not occurred ; and
the drawer shown in FIG . 15 , wherein three pieces ofmesh FIG . 45 is a partial, elevational view of the upper and
material have been joined together ; 40 lower rails joined to the mesh pieces of FIG . 44 , wherein
FIG . 18 is front, perspective view of a second example of welding has occurred .
a system of drawers of the present invention , where the
drawers are shown in a retracted position ; DETAILED DESCRIPTION OF EXAMPLES OF
FIG . 19 is an exploded , perspective view of an exemplary THE PRESENT INVENTION
drawer with a third example of an upper rail ; 45
FIG . 20 is a perspective view of the drawer and rail of Referring to FIG . 1, a first example of drawer system 10
FIG . 19 , wherein the rail is coupled to the drawer ; is shown. This drawer system 10 may be used to store a
FIG . 21 is an enlarged , partial, perspective view of the variety of housewares , such as kitchen items, clothing ,
upper rail of FIG . 19 , wherein the rail is uncompressed ; accessories, sports equipment, shoes , bathroom supplies,
FIG . 22 is a partial, elevational view of the upper rail of 50 tools , appliances, and the like. Additionally , system 10 can
FIG . 19 disposed upon a mesh piece , wherein the rail is be used to store a variety of other items, for example food ,
uncompressed ; office supplies , office equipment, file folders , papers /docu
FIG . 23 is a partial, elevational view of the upper rail ments , bags, boxes, cans, bottles , etc.
joined to the mesh piece of FIG . 22 , wherein the rail is Drawer system 10 includes frame or rack 12 and a
compressed ; 55 plurality of containers or drawers 14a -d . Drawer 14a is
FIG . 24 is a partial, elevational view of a fourth example smaller than drawers 14b - c so drawer 14a can hold a smaller
of an upper rail separated from a mesh piece ; volume than other drawers 14b - d . Drawers 14a - d are mov
FIG . 25 is a partial, elevational view of the upper rail able with respect to frame 12 between a retracted position
joined to the mesh piece of FIG . 24 ; ( shown in FIG . 1 ) and an extended position . In the retracted
FIG . 26 is a partial, elevational view of a fifth example of 60 position , the contents of lower drawers 14b - d is difficult to
an upper rail separated from a mesh piece ; access. In the extended position , the contents of the extended
FIG . 27 is a partial, elevational view of the upper rail drawer are easily accessible; the extended drawer may be
joined to the mesh piece of FIG . 26 ; fully withdrawn from frame 12 if desired .
FIG . 28 is a partial, elevational view of a sixth example With reference to FIG . 1 , frame 12 includes two side
of an upper rail separated from a mesh piece ; 65 vertical support frame members or ladders 16 that are spaced
FIG . 29 is a partial, elevational view of the upper rail apart and joined by pairs of upper and lower cross members
joined to the mesh piece of FIG . 28 ; 18a ,b, respectively. Side frame members 16 and pairs of
US 10,524,569 B2
7 8
upper and lower cross members 18a ,b are formed to give so that no material is separated from the original raw
frame 12 a rectangular shape. The present invention is not material, as known by those of ordinary skill in the art . On
limited to this frame shape . the other hand , unlike mesh , punching portions of waste
Frame 12 further includes L -connectors 20 (as best seen material out of sheet metal material forms perforated metal.
in FIG . 2A ) and T -connectors 22 (as best seen in FIG . 2C ) 5 For example, openings 56a (see FIG . 3A ) in themesh have
for joining side frame members 16 to cross frame members an area less than 25.4 mm by 25.4 mm . In another example ,
18a,b . For example , L - connectors 20 connect upper cross openings 56a (see FIG . 3 ) in the mesh have an area less than
member 18a to side frame members 16 , if no additional 20 mm by to mm . In another example , openings 56a (see
frames are to be added above the one illustrated in FIG . 1 . FIG . 3 ) in the mesh have an area less than 6 mm by 3 mm .
If an additional frame is to be added above frame 12 shown 10 Basket portion 55 , for example, is formed of any metal
in FIG . 1 , T -connectors 22 are used to join upper cross such as copper, steel, stainless steel or aluminum , and the
members 18a to frame members 16. For example, T- con like . Basket portion 55 includes bottom wall 56 , a pair of
nectors 22 also connect lower cross members 18b to side spaced apart sidewalls 58 and 60 , and another pair of
framemembers 16. Alternatively , T-connectors 22 joined to sidewalls 62. Bottom wall 56 and sidewalls 58 , 60 and 62 are
lower cross members 18b can be replaced with plugs with 15 each substantially flat.For example, sidewalls 58 , 60 and 62
casters ( not shown ) thereon to make system to movable, as are joined together to form closed curved corners 64. Side
is apparent to those of ordinary skill in the art. walls 58 , 60 and 62 extend upwardly from bottom wall 56
Referring again to FIG . 1 , each side frame member 16 to form upwardly -facing opening 66 .
includes a pair of spaced apart vertical rods or support As shown in FIG . 3, corners 64 are curved so that they
members 24 coupled by vertically spaced apart horizontally- 20 deviate from straightness in a smooth , continuous fashion .
extending runners 26a - g . Each side frame member 16 is The present invention, however, is not limited to drawers
formed so that runners 26a-g of each side framemember 16 with curved corners and drawers with more angular corners
are aligned with runners 26a- g of other side framemember are also considered inventive. The present invention is also
16 to form a plurality ofpairs ofrunners . Each runner 26a - g not limited to drawers with a radius of curvature greater at
is a generally U -shaped member with inwardly extending 25 the top of the drawer (adjacent the rail 54 ) than at the
gap 28 defined therein . Runners 26a-g may include a bore bottom . Thus, drawers with , for example , a constant radius
(not shown ) in the rear end for receiving a pin (not shown ) of curvature are also considered inventive . Each of the
for preventing rearward movement of drawers 14a -d out of corners 64 extend upwardly and outwardly from bottom wall
frame 12. To make frame 12 independent of direction the 56 .
bore (not shown ) may be formed at both ends of each runner 30 In this example, sidewall 58 forms a front end wall that
and the pin (not shown ) disposed in the desired end for use . includes curved cutout68 bordered by handle rail 70. Cutout
Frame 12 is , for example , formed of any metal with 68 forms a place where a user can easily grasp drawer 14b
sufficient rigidity and formability, for example mild sheet to move it between the retracted and extended positions. In
steel , stainless steel, aluminum , copper or the like can be an alternative example , cutout 68 can be replaced with other
used . Vertical rods 24 and runners 26a - g are , for example, 35 methods to aid the user in moving drawer 14b , such as a
welded together using conventional welding techniques . protruding handle connected to wall 58. Handle rail 70 may
Frame 12 may be subjected to a powder painting treatment, have a circular cross -sectional shape and be cut and formed
similar to that discussed below for drawers 14a - d . to extend along the edge of cutout 68. In the present
Referring to FIGS. 1 , 2A and 2B , L -connector 20 includes example , rail 70 is of the samematerial as upper rail 54 and
centralbody 30 and first and second generally perpendicular 40 is spot-welded to basket portion 55. In this example , side
legs 32 and 34 extending therefrom . For example , 3 pairs of wall 60 forms a rear end wall.
cross members 18a,b and vertical rods 24 are hollow so that Referring to FIG . 4 , drawer 14b is shown in a disas
legs 32 and 34 are received therein to join these components sembled state . Basket portion 55 is formed by first piece of
together. Referring to FIGS. 1, 2C and 2D , T -connector 22 mesh 72 , second piece of mesh 74 and third piece of mesh
includes central body 36 and first, second , and third legs 38 , 45 76. First, second , and third pieces of mesh 72 , 74 , 76 are
40, and 42 , respectively , extending therefrom . First and formed separately from one another. First piece of mesh 72
second legs 38 and 40 are generally perpendicular to one is bent along lines 72a ,b to form edges as shown in FIG . 5
another similar to L -connector 20. Third and secondSecond to define bottom wall 56 and sidewalls 62. The angle
and third legs 40 and 42 are also generally perpendicular to between bottom wall 56 and sidewalls 62 is greater than
one another. For example , first leg 38 and third leg 42 may 50 about 90 ° , but the present invention is not limited to this
be inserted into hollow vertical rods 24 , and second leg 40 configuration .
is inserted in hollow associated cross members 18a,b . Second piece of mesh 74 includes outer edge 74a , inner
L -connectors 20 and T -connectors 22 are, for example , edge 74b , central portion 74c , side extensions 74d , and
formed of any metal with sufficient rigidity and formability . lower extension 74e . Central portion 74c is between outer
For example, connectors 20 and 22 can be cast of die -cast 55 edge 74a and lower extension 74e and between side exten
aluminum or any alloy, using conventional techniques sions 74d . Side extensions 74d have a trapezoidal shape so
known to those of ordinary skill in the art. Connectors 20 that they taper downward from outer edge 74a to lower edge
and 22 , however, can also be formed of another material like 74b. Second piece ofmesh 74 is bent to form front end wall
injection molded plastic . 58 , curved corners 64, and lower extension 74e that is
Now , with reference to FIGS. 1, 3, and 3A , the details of 60 and
drawer 14b will be discussed . Drawer 14b includes a runner
generally perpendicular to front end wall 58 (see FIGS. 3
5 ). Third piece of mesh 76 is formed similarly to second
portion that comprises upper rail 54 and basket portion 55 . piece of mesh 74 to include upper edge 76a , lower edge 76b ,
Basket portion 55 is coupled to upper rail 54. In the present central portion 76c, side extensions 76d, and lower exten
example , basket portion 55 is formed of expanded metal sion 76e .
plate ( i.e., sheet metal) or “mesh ” and has small openings 65 In an alternative example, pieces of mesh 74 and 76 can
56a therein . In the present specification and appended be formed of a single piece of material separate from first
claims “ mesh ” means flatmetal that is pierced and stretched piece of mesh 72. In such event, the two pieces ofmesh 74
US 10,524,569 B2
9 10
and 76 would be joined by another mesh segment (not In order to join lower extension 74e of second piece 74 to
shown ) that would be shaped similar to bottom wall portion bottom wall 56 of first piece 72 , already -bent first piece 72
56. As a result, bottom wall of basket 55 would be formed is disposed on cathode electrodes 92b so that sidewalls 62
of two layers of mesh material that overlap . extend downward (as shown in FIG . 6 ) toward the floor.
Referring to FIG . 5A , first , second , and third pieces of 5 Bent second piece 74 is disposed between member 90 and
mesh 72 , 74 , and 76 have been joined together so that cathode electrode 92b , as shown in FIG . 7. Next, clamp 88
bottom seams 78 are formed. Seams 78 are where the is actuated so that clamping force F moves member 90 from
material of bottom wall 56 of first piece ofmesh 72 overlaps a retracted position (shown in FIG . 6 ) into a clamping
with lower extension 74e of second and third pieces ofmesh 10 position (shown in FIG . 7). In the clamping position , mesh
74 and 76 (see FIG . 4 ). When corners 64 are formed , side piece 74 is compressed between member 90 and cathode
seams 80 (as shown in FIG . 3 ) are formed adjacent each electrode 92b . Clamping force F must be sufficient to hold
corner 64. Seams 80 are where the material of sidewalls 62 mesh piece 74 into contact with mesh piece 72 for the
of first piece ofmesh 72 overlaps with side extensions 74d welding operation .
and 76d of second and third pieces of mesh 74 and 76 , 15 Then , anode electrode 92a moves in direction Di into
respectively . Seams 80 are generally vertically extending contact with pieces 72,74 adjacent extension 74e. Pieces
side seams. 72,74 are tightly compressed between electrodes 92a and
Themethod ofmaking drawer 14b will now be discussed . 92b . Electrodes 92a,b then discharge electric welding cur
Referring to FIGS. 4 and 5, first piece of mesh s formed and rent through the place to be welded and seam 78 (see FIG .
shaped as shown. This involves cutting piece of mesh 72 20 5A ) is formed . Third piece 76 , as shown in FIG . 5 , is
with the desired dimensions from a roll of mesh using a similarly joined to first piece 72. In the present example,
conventional press machine . Then , first piece of mesh 72 is weldingmachine 84 is properly configured so that the fixture
bent into a U -shape that includes bottom wall 56 and end includes two clamps, two elongated members 90 and two
walls 62 (as shown in FIG . 5 ). A conventional hydraulic pairs of electrodes 92a ,b . As a result, second and third pieces
press machine is used to bend mesh piece 72. The hydraulic 25 74 and 76 can , for example , be simultaneously welded to
press machine includes a mold for achieving the desired bent first piece 72 .
shape , as is known by those of ordinary skill in the art. Another spot -welding machine similar to machine 84 is
Second and third pieces ofmesh 74 and 76 are formed and used to weld pieces 74 and 76 to piece 72 adjacent the
shaped as shown in FIG . 4. This involves cutting pieces of corners 64 to form seams 80. This spot-welding machine for
mesh 74 and 76 with the desired dimensions and shape from 30 forming seams 80 has an appropriately sized fixture includ
a roll of mesh using a conventional press machine . Then , ing clamp( s), elongated member(s ) and cathode electrode(s )
mesh piece 74 is bent using a conventional hydraulic press for smaller pieces 74 and 76. For example , the cathode
machine so that side extensions 74d are curved and lower electrode ( s) may be tapered match trapezoidal extensions
extension 74e is angularly offset from center section 74c . 74d ,76d so that pieces 74 and 76 are suitably clamped to end
The hydraulic press machine includes a mold , as is known 35 walls 58 and 60 during welding.
by those of ordinary skill in the art. Third piece of mesh 76 With reference to FIG . 3, upper rail 54 is subsequently
is bent similarly to second piece 74 (as shown in FIG . 5 ) . connected to upper section of end walls 58 and 60 and
Handle rail 70 may be welded to mesh piece 74 at this point sidewalls 62 by spot-welding. Referring to FIGS. 3 and 8-9 ,
or later, when upper rail 54 is joined to basket portion 55 . the step of connecting upper rail 54 to basket portion 55
Next, lower extensions 74,76e of each piece 74,76 are 40 further, for example , includes the steps of forming generally
connected by welding to the side edge of bottom wall 56 of flat upper rail 54 ; contacting rail 54 to basket portion 55 on
first piece 72 (as shown in FIG .5A ) to form seams 78. Then , contact surface 54a so that upper section 55a of basket
curved side extensions 74d ,76d of pieces 74,76 are con portion 55 extends above rail 54 ; and spot-welding contact
nected by welding to sidewalls 62 of first piece 72 to form surface 54a to outer surface of basket portion 55 .
seams 80 ( as shown in FIG . 3 ). 45 Upper rail 54 is, for example , formed of the samematerial
After drawer 14b is completely formed ( including attach as basket portion 55 so that these components can be welded
ing rail 54), a process of powder painting may be used to together. Thus, for example , rail 54 is formed of any metal
coat drawer 14b , as is known by those ofordinary skill in the such as copper , steel, stainless steel, mild sheet steel or
art . One exemplary paint is an epoxy coat. The paintingmay aluminum , and the like . In an example using sheet steel, a
provide a decorative (colored and /or metallic ) finish to 50 roll of sheet steel strip material with a circular cross -section
drawer 14b, if desired , and will also provide some protection is used . This material is passed through a conventional roll
for the drawer 14b from water and other corrosive elements . forming machine with a number of pairs of rollers using a
Referring to FIGS. 5 , 6 , and 7 , the equipment used to predetermined compression pressure to continuously and
connect first, second and third pieces ofmesh 72 , 74 , and 76 gradually change the circular cross - section into a generally
together will now be discussed . The equipment, for example , 55 flat rectangular cross -section , as is known by those of
comprises spot-welding machine 84 including base 86 , ordinary skill in the art.
clamp 88 supported on base 86 ,movable elongated member The material with the flat rectangular cross- section is then
90 movable by clamp 88 to provide clamping force F , and a fed into a bending machine that includes spaced apart pairs
pair of anode electrodes 92a and a pair of cathode electrodes of guide rollers for guiding the material through themachine
926. Base 86 , clamp 88 ,member 90, and cathode electrodes 60 and bending the material into four spaced apart right angles
92b form a fixture for supporting mesh pieces 72 , 74 , and 76 to form a rectangular ring . Hydraulic power can be used to
during welding . As shown, for example, cathode electrodes provide the bending force to the associated pairs of guide
92b are, for example , bar - like and parallel to one another to rollers . Where the bending pairs of guide rollers are located ,
properly support and clamp mesh pieces 72 , 74 , and 76. In the machine further includes rollers for preventing vertical
an alternative example , the spot-welder can be used without 65 expansion of the material. Once the rectangular ring is
clamp 88 and elongated member 90 , where the pieces may formed , the free ends of the ring are joined by welding to
be manually held during welding . form upper rail 54 .
US 10,524,569 B2
11 12
Rail 54 is not limited to the above configuration , shape and/or thickened to provide more rigidity thereto . Width W
and materials . For example , it can be hollow with various of the mesh (FIG . 4 ) can be set by the machine forming the
shapes , such as a circular cross -section . Rail 54 can also beraw material so that the edges of piece 72 that will be
solid with various shapes, such as a circular cross-section . connected to pieces 74 and 76 are smooth and require no
Rail 54 can also be formed of a plastic that is connected to 5 cutting or grinding.
basket portion 55 by glue or adhesive , for example . FIGS. 10-12 illustrate an alternative example of upper rail
Referring to FIGS. 8 and 9, the step of contacting rail 54 54 ' for use with alternative example of basket portion 55 '. To
to basket portion 55 on contact surface 54a may, for form upper rail 54' raw material is bent to include portion
example , further include the step of using spot-welding 54a ' with opening 54b ' and extension 54c' angularly offset
machine with fixture F for supporting rail 54 at a sufficient 10 from portion 54a ' using a roll formingmachine . Portion 54a'
elevation above a table (not shown) so thatupper section 55a further includes first section A , second section B , and curved
of basket portion 55 extends above rail 54. Fixture F may section C joining first and second sections A , B so that
also provide a clamping force for assuring surface 54a is in opening 546 ' is located therein . Sections A and B are
solid contact with basket portion 55 or this force may be generally flat and have parallel horizontal sections. Exten
provided by movable anode and cathode electrodes AE and 15 sion 54c' is joined to first section A via curved section 54d".
CE , respectively . For example , electrodes AE and CE are The material for rail 54' is bent into a closed rectangular loop
circular welding wheels. Anode electrode AE contacts outer and welded together, similar to rail 54 so that rail 54' is
surface of rail 54 and cathode electrode CE contacts inner continuous.
surface of basket portion 55 adjacent surface 54a , as shown Basket portion 55 ' is formed similarly to basket portion 55
in FIG . 9. An electric current is discharged through elec- 20 except end walls 58 , 60 and sidewalls 62' all have an
trodes AE and CE , rail 54 and basket portion 55 to spot-weld outwardly bent upper section 55a ' terminating in an end or
rail 54 to basket portion 55. For example, sufficient elec free edge 55c'. Upper section 55a' is formed by a conven
trodes AE and CE are provided to make the welding of rail tional hydraulic press machine with a mold at the same time
54 to basket portion 55 efficient. Since electrodes AE and CE other bends are formed in pieces 72 , 74 , 76 (see FIG . 5 ).
are movable vertically in directions V and horizontally in 25 That is when piece 72 is bent to form edges 72a and 72b ,
directions H?, the spot-welder can be used to weld variously piece 72 is also bent to form upper section 55a'. Similarly,
size rails and baskets together. upper section 55a' is formed on pieces 74 and 76 , when
The step of connecting upper rail 54 may further include edges 74d and 74e and edges 76e and 76d , respectively, are
cutting and grinding steps. In the cutting step , upper section formed . Then , pieces 72, 74 , 76 are welded together.
55a (as shown in FIG . 8 ) of basket portion 55 is severed 30 Bent upper section 55a ' is inserted into opening 546 ' of
using a conventional severing apparatus , such as one includ upper rail 54 ' (as shown in FIG . 11 ). Portion 54a ' is then
ing a reciprocating saw blade . In the grinding step , exposed compressed by a conventional press machine so that opening
upper edge 55b (FIG . 9 ) ofbasket portion 55 is worked using 546 ' is minimized and curved portion 54a' tightly engages
a conventional grinding machine so that upper edge 55b basket portion 55a ' so that inner surfaces of portion 54a'
becomes smooth .Rail 54 aids in providing structural rigidity 35 contact basket portion 55a'. This step also results in front
to basket portion 55 and is the only rail circumscribing each curved tip or portion 54d' of rail 54' engaging angled corner
drawer's perimeter. or junction 556 of basket portion 55 '. Then , vertically
Once rail 54 is joined to the outer surface of the basket extending extension 54c' is welded to the basket using a
portion , a substantial portion of rail 54 extends substantially spot-welding machine and fixture similar to the method used
outwardly from the outer surface of first, second, third and 40 for rail 54 (shown in FIGS. 8 and 9 ).
fourth sidewalls of basket portion 55 and rail 54 extends Once upper rail 54' is joined to basket portion 55 ' in this
continuously around the outer surface of basket portion (as manner, it provides additional structural rigidity to basket
shown in FIG . 3 ). portion 55. Using rail 54' eliminates the need to cut upper
Referring to FIGS . 1 and 3 , in use drawer 14b is inserted section 55a of basket portion 55 , as when using rail 54, as
into system to by disposing upper rail 54 within gap 28 of 45 shown in FIGS. 8 and 9. Consequently , rail 54' eliminates
opposed , aligned pair of runners 26b .Rail 54 and gap 28 are the need to deburr or grind basket portion 55 '.
sized to allow free sliding movement of drawer 14b with In an alternative exemplary method , pieces 72, 74 , 76 (see
respect to frame 12 between the retracted and extended FIG . 5 ) are bent to form edges 72a and 72b in piece 72 ,
positions . edges 74d and 74e in piece 74, and edges 76e and 76d in
Since drawer 14b is formed of mesh with very small 50 piece 76. Then , pieces 72 , 74 , 76 are welded together. Next,
openings 56a (see FIG . 3), small objects, such as pens, paper joined pieces 72 , 74 , and 76 are placed in a conventional
clips, and the like, can be stored in drawer 14b without a hydraulic press machine with a mold and bent to create
liner and will not fall through openings 56a . In addition , outwardly bent upper section 55a ' on each piece 72 , 74 , 76 .
since drawer 14b has closed corners 64 , small objects also Subsequently, rail 54' is coupled to basket 55' as previously
cannot fall out of this area of drawer 14b . 55 discussed .
As shown in FIG . 1 , drawers 146-14d are ofmedium size Referring back to FIG . 1 , basket 14a includes a rectan
and vertically extend across two sets of vertically spaced gular cutout 68 ' on front of wall 58'. Metal handle rail 70'
runners. Drawer 14a is a small size and consequently covers the free end of the mesh within cutout 68 '. Handle rail
extends across only one set of vertically spaced runners. The 70 ' is, for example , formed similar to rail 54 ' (see FIG . 10 )
drawers may be sized differently, see FIG . 4 , particularly by 60 with an opening that is compressed about themesh , once the
changing the length L of first piece of mesh 72 and the height mesh is inserted therein . For example, handle rail 70' also
H of second and third pieces ofmesh 74 and 76. This allows includes an extension , similar to extension 54c' of rail 54 ',
containers of a variety of sizes to be formed without excess that can be spot-welded to securely attach rail 70' to the
machinery costs, particularly large containers having depth mesh . In such an example, opening in rail 70 ' extends
D from bottom wall 56 to top surface of top rail 54 (see FIG . 65 vertically along with its extension similar to extension 54c '.
3 ) equal to or greater than about 11 inches. If larger baskets In an example of handle rail 70 ' without such an extension ,
are desired , the basket material may need to be changed rail 70 'may still be spot-welded to the mesh .
US 10,524,569 B2
13 14
Referring to FIGS. 13-14, third drawer example 114b is extensions 354c and 354e angularly offset from curved
shown. Drawer 114b comprises runner portion or upper rail portion 354a . Curved portion 354a further includes first
154 and basket portion 155.Upper rail 154 may be formed section A , second section B , and curved section C joining
like rail 54 or rail 54 ' previously discussed . Basket portion first and second sections A , B so that opening 354 is located
155 includes bottom wall 156 , end walls 158 and 160 , and 5
sidewalls 162. Bottom and end walls 156 and 158 and 160
therein . In the present example, first section A has a length
less than second section B. First extension 354c is joined to
are also sidewalls. First piece of mesh 172 is bent to form first section A. Second extension 354e is joined to second
bottom wall 156 and end walls 158 and 160. Sidewalls 162 section B. Rail 354 is bent so that curved portion 354a has
are formed of separate second and third pieces of mesh 174 a generally V -shape form , as shown in FIG . 21 .
and 176 , respectively . End wall 158 includes first piece of 10 Referring to FIGS. 22 and 23 , bent upper section 355a of
mesh 172 with cutout 168 similar to end wall 58 .
For drawer 114b , different from drawer 14b , second piece basket portion 355 , which is similar to basket portion 55', is
ofmesh 174 includes central portion 174c , rectangular side inserted into opening 354b of upper rail 354'. As a result,
extensions 174d and lower extension 174e. Third piece of first and second extensions 354c and 354e are adjacent to
mesh 176 has a similar configuration. When pieces 172 , 174 15 outer and inner surfaces, respectively, of basket portion 355 .
Curved portion 354a is then compressed, as indicated by
and 176 are connected using a method similar to that used arrows F in FIG . 22 , by a conventional press machine . As a
in forming drawer 14b, drawer 114b has closed smoothly
curved corners similar to corners 64 (as shown in FIG . 3 ), result , opening 354b is minimized (as shown in FIG . 23 ) and
but corners of drawer 114b will have a substantially constant curved portion 354a tightly engages basket portion 355a .
radius. Drawer 114b also includes four side seams 80 at each 20 This compression also results in extensions 354c and 354e
corner and two bottom seams 178 . sandwiching basket portion 355 therebetween . Additionally
Referring to FIGS. 15-17 , fourth drawer example 214b is after compression , extensions 354c, 354e are generally
shown . Drawer 214b comprises runner portion or upper rail vertically oriented and first and second sections A ,B are
254 and basket portion 255. Upper rail 254 may be formed generally horizontally oriented (as best shown in FIG . 23 ).
like rails 54 , 54', 154 ' or 254 ' discussed above . Basket 25 In addition , compression results in curved edge 354d of rail
portion 255 includes bottom wall 256 , end walls 258 and 354 engaging angled corner or junction 355b of basket
260, and sidewalls 262. portion 355 (see FIGS. 22-23). Then , the now generally
End walls 258 and 260 are also sidewalls. First piece of vertically -extending extensions 354c and 354e are welded to
mesh 272 is bent to form bottom wall 256 and end walls 258 outer and inner surfaces, respectively , of basket portion 355
and
third 260. Sidewalls
pieces of mesh262274areandformed of separate
276. End wall 258second and 30 using a spot-welding machine and fixture similar to the
includes
cutout 268 similar to end wall 58 . method used for rail 54 (shown in FIGS. 8 and 9 ).
In drawer 214b , different from drawers 14b and 114b , Rail 354 adds structural rigidity to basket portion 355 and
second and third pieces ofmesh 274 and 276 do not include eliminates the need to cut and deburr basket portion 355 .
FIGS . 24-25
extensions . When pieces 272 , 274 and 276 are connected 35 upper rail 454 for illustrate an alternative fourth example of
using themethod of forming drawer 14b , pieces 274 and 276 FIGS. 8 and 24 ). Railuse454 with basket portion 55 (shown in
is similar to rail 54 ' as shown in
only overlap piece 272 on the bottom not on the sides. As a
result , drawer 214b has open corners 264 (as shown in FIG . FIG . 10 except as discussed below . Upper rail 454 is bent to
15 ) and two bottom seams 278. Drawers configured like include first portion 454a and angularly offset second por
drawer 214b can be used in systems like system 10 (shown 40 tion 454b . Second portion 454b includes contact surface
in FIG . 1 ) and move between extended and retracted posi 454c.
tions. Drawers similar to drawer 214b can come in a number Second portion 454b of rail 454 is connected to basket
of sizes. Drawer 214b is formed similarly to drawer 14b by portion 55 by spot-welding, similar to rail 54 shown in
bending and spot-welding the mesh pieces. FIGS. 8 and 9. The step of connecting upper rail 454 to
Referring to FIG . 18 , a second example of drawer system 45 basket portion 55 further includes, for example , the steps of
310 is shown. Drawer system 310 includes frame 312 and forming generally L -shaped rail 454 , contacting contact
plurality of drawers 314a and 314b . Frame 312 includes four surface 454c of rail 454 to basket portion 55 so that upper
pairs of runners 326a -d . This example illustrates that any section 55a of basket portion 55 extends above rail 454 and
number of pairs of runners can be used depending on how first portion 454a is spaced from upper edge 55b , spot
large a system is desired . Frame 312 is otherwise configured 50 welding contact surface 454c to outer surface of basket
and formed similarly to frame 12 (shown in FIG . 1). System portion 55 (as shown in FIG . 25 ), and cutting upper section
310 further may include solid table top or shelf 327 that is 55a of basket portion 55. A finishing or grinding step may
securely connected to the top of frame 312 by a press fit so be used to assure that upper edge 55b of basket portion 55
that objects can be stored or displayed thereon. Alterna is not sharp . Alternatively , rail 454 can be joined to basket
tively , shelf 327 may be sized differently (larger or smaller 55 portion 55 so that free end of portion 454b is aligned with
than ) frame 312 and connected to frame 312 with conven edge 55b . As a result, no additional cutting of basket portion
tional fasteners such as screws and L -brackets . Drawer 314a is necessary. First portion 454a of the rail is operatively
is small and extends across one pair of runners 326a. Drawer associated with runners 26a - g of frame 12 (see FIG . 1)
314b is large and extends vertically across three pairs of during use .
runners 326b - d . Drawers 314a and 314b are configured and 60 FIGS. 26-27 illustrate an alternative fifth example of
manufactured similar to drawer 14b ( see FIG . 1 ), but draw upper rail 554 for use with basket portion 55 ( shown in
ers configured like drawers 114b and 214b can also be used FIGS . 3 and 26 ). Upper rail 554 is similar to upper rail 454
with system 310 . except rail 554 is oriented differently when joined to basket
FIGS. 19-23 illustrate an alternative third example of portion 55. As shown in FIG . 27 , when rail 554 is joined to
upper rail 354 for use with basket portion 355. As shown in 65 basket portion 55 , first portion 554a is aligned with upper
FIG . 21, upper rail 354 is formed similar to rail 54 ' to include edge 55b and second portion 554b is coupled to basket
curved portion 354a with opening 354b and first and second portion 55. Rail 554 is joined to basket portion 55 as
US 10,524,569 B2
15 16
previously discussed with respect to rail 454. Rail portion can be varied . As shown in FIG . 37, when rail 954 is joined
554a is operatively associated with runners 26a-g of frame to basket portion 955 , horizontal first portion 954a covers
12 (see FIG . 1 ) during use . upper edge 955b (shown in FIG . 34 ) and second portion
FIGS. 28-29 illustrate an alternative sixth example of 954b and rib 954c contact basket portion 955. After joining
upper rail 654 for use with basket portion 55 (shown in 5 rail 954 to basket portion 955 , the use of electric welding
FIGS. 3 and 28 ). Upper rail 654 is similar to upper rail 454 could allow rib 954c and basket portion 955 contacting rib
except as noted below . Rail 654 includes first portion 654a 954c to be fused into an integral structure (as shown in FIG .
angularly offset from second portion 654b which is offset 37 ). This is due to the heat collection and pressure of
from third portion 654c to form recess 654d between second resistors used during welding .
and third portions 654b , 654c. In the present example (as 10 Rail 954 adds structural rigidity to basket portion 955 and
shown in FIG . 29 ), rail thickness tr of second portion 654b eliminates need to cut and deburr basket portion 955. Rail
is less than mesh thickness ty of basket portion 55 so that portion 954a is operatively associated with runners 26a -g of
upper edge 55b of basket portion 55 is not fully received frame 12 (see FIG . 1 ) during use .
within recess 64d and must therefore be ground to ensure FIGS. 38-39 illustrate an alternative tenth example of
edge 55b is smooth . Alternatively, the offset between second 15
and third portions 654b , 654c can be increased so that edge upper rail 1054 for use with basket portion 955. Upper rail
55b is fully received within recess 654d. In yet another 1054 is similar to upper rail 954 (shown in FIGS. 36-37 ),
alternative , rail 754 (see FIGS. 30-31 ) can be configured except rib 954c has been replaced with outwardly extending
similar to rail 654 , except rail thickness tr of second portion or projecting connection portion 1054c at the free end of
754b is greater than mesh thickness ty of basket portion 55 20 vertical second portion 1054b . When rail 1054 is joined to
so that upper edge 55b ofbasket portion 55 is fully received basket portion 955 , horizontal first portion 1054a covers
within recess 754b and thus does not require grinding . upper edge 955b ( shown in FIG . 34 ) and second portion
Rails 654, 754 are joined to basket portions 55 as previ 1054b and connection portion 1054c contact basket portion
ously discussed with respect to rail 454. Rail portions 654a , 955.After joining rail 1054 to basket portion 955, the use of
754a are operatively associated with runners 26a -g of frame 25 electric welding could allow connection portion 1054c and
12 (see FIG . 1 ) during use . basket portion 955 contacting connection portion 1054c to
FIGS. 32-33 illustrate an alternative eighth example of be fused into an integral structure (as shown in FIG . 39 ).
upper rail 854 for use with basket portion 55 (shown also in FIGS. 40-43 illustrate an alternative example of basket
FIG . 3 ). Rail 854 is similar to rail 454 shown in FIG . 24 , portion 1155 with upper rail 954 and lower rail 1154. Basket
except second portion 854b of rail 854 is connected to 30 portion 1155 is formed by four sidewalls 1155a of mesh and
curved section 854c , which is connected to extension 854d . one bottom wall 1155b of mesh . Sidewalls 1155a are pref
Curved portion 854e of rail 854 is formed by second portion erably joined by conventional methods such as welding .
854b , curved section 854c and extension 854d and also Bottom wall 1155b can be joined to sidewalls 1155a by
defines opening 854f. Rail 854 is bent so that curved portion welding and /or by rail 1154. Upper rail 955 previously
854e has a generally open V - shape (as shown in FIG . 32 ). 35 described with reference to FIGS. 36-37 is joined to basket
Upper edge 55b of basket portion 55 is inserted into portion 1155 as previously discussed .
opening 854f so that when rail 854 is compressed by a Lower rail 1154 includes horizontal first portion 114a and
conventional press machine, as shown in FIG . 33, second vertical second portion 54b. Horizontal first portion 54a
portion 854b and extension 854d are adjacent to outer and includes inwardly projecting connection portion or rib 154c .
inner surfaces , respectively , of basket portion 55. Compres- 40 Vertical second portion 54b includes inwardly projecting
sion also minimizes opening 854f (as shown in FIG . 33 ) and connection portion or rib 1154d. When rail 1154 is joined to
causes curved section 854c to tightly engage basket portion basket portion 1155 , first portion 1154a and rib 11550
55. Additionally, after compression extension 854d is gen contactbottom wall 1155b and second portion 1154b and rib
erally vertically -extending and second portion 854b and 1155d contact sidewalls 1155a . After joining rail 1154 to
extension 854d are welded to the outer and inner surfaces, 45 basket portion 1155 , the use of electric welding (using heat
respectively, of basket portion 55 using a spot-welding collection and pressure ) could allow the ribs 1154c,d and
machine and fixture similar to the method used for rail 54 basket portion 1155 contacting ribs 1154c,d to be fused into
(shown in FIGS. 8 and 9 ). an integral structure (as shown in FIG . 43 ).
Once upper rail 854 is joined to basket portion 55 in this FIGS. 44-45 illustrate basket portion 1155 with upper rail
manner, it provides additional structural rigidity to the 50 1054 and alternative lower rail 1254. Basket portion 1155 is
basket portion 55.Using rail 854 eliminates the need to cut previously described with reference to FIGS. 40-41 . Upper
upper section 55a of basketportion 55 as when using rail 54 , rail 1054 previously described with reference to FIGS.
as shown in FIGS. 8 and 9. Consequently, rail 854 eliminates 38-39 is joined to basket portion 1155 as previously dis
the need to deburr basket portion 55 . cussed .
FIGS. 34-37 illustrate an alternative ninth example of 55 Lower rail 1254 is similar to lower rail 1154 (shown in
upper rail 954 for use with basket portion 955. Basket FIGS. 42-43 ), except ribs 1154c,d have been replaced with
portion 955 terminates in an upper free edge or end 955b . inwardly extending or projecting connection portions
Upper rail 954 is similar to upper rail 454 (shown in FIGS . 1254c,d at the free end of first and second portions 1254a ,b ,
24-25 ), except vertical second portion 954b of rail 954 respectively . When rail 1254 is joined to basket portion
includes an outwardly extending or projecting connection 60 1155 , first portion 1254a and rib 1254c contactbottom wall
portion or rib 954c .Rail 954 terminates at one end in a lower 1155b and second portion 1254b and rib 1254d contact
free edge or end 954d and at the other end a free edge or end sidewalls 1155a . After joining rail 1254 to basket portion
954e that is also the terminus of horizontal portion 954a . 1155 , the use of electric welding (using heat collection and
Vertical portion 954b and horizontal portion 954a intersect pressure) could allow connection portions 1254c,d and
at junction 954f. This intersection of vertical portion 954b 65 basket portion 1155 contacting the connection portions
and horizontal portion 954a forms an approximate right 1254c,d to be fused into an integral structure (as shown in
angle . The location of rib 954c along vertical portion 954b FIG . 45) .
US 10,524,569 B2
17 18
Rails 354 , 454 , 554 , 654 , 754 , 854 , 954 , 1054 , 1154 and Abstract is neither intended to define the invention of the
1254 are generally rectangular rings that are continuous application , which is measured solely by the claims, nor is
about their respective basket portions . These ails are formed intended to be limiting as to the scope of the invention in any
of materials similar to those discussed with respect to rails way .
54 and 54 '. 5 We claim as our invention :
Those skilled in the art will appreciate that the conception , 1. An apparatus comprising :
upon which this disclosure is based ,may readily be utilized a basket portion of expanded metal mesh material includ
as a basis for designing other products for carrying out the ing an inner surface , an outer surface, a substantially
several purposes of the present invention . It is important, flat bottom wall, substantially flat and upwardly and
therefore, that the claims be regarded as including such 10 outwardly extending from said bottom wall first and
equivalent constructions insofar as they do not depart from second spaced apart sidewalls, and substantially flat
the spirit and scope of the present invention as defined in the and upwardly and outwardly extending from said bot
appended claims. Therefore , this invention is not to be tom wall third and fourth spaced apart sidewalls , said
limited to the specific examples depicted therein . For first, second, third and fourth sidewalls connected to
example, the features of one example disclosed above can be 15 each other to form four corners, each of said corners
used with the features of another example . Furthermore, the extending upwardly and outwardly from said bottom
various rail examples 54 , 54', 354 , 454 , 554, 654 , 754 , 854 , wall;
954 , 1054 , 1154 and 1254 can be used exclusively in a rail including a substantially flat horizontal portion and
different systems of drawers to provide systems that cost a substantially flat vertical portion connected to each
different amounts, e.g., a high -priced system and a lower 20 other at a junction ;
priced system . Alternatively, one system can have drawers said basket portion further including an upper section of
with various types of rails 54, 54', 354 , 454 , 554, 654, 754, said first, second , third and fourth sidewalls , said upper
854 , 954 , 1054, 1154 and 1254. Additionally , a system can section extending only vertically and having a first end
use all closed -corner drawers or combine closed - corner that terminates said upper section at said junction ;
drawers with open -corner drawers in one system . The sys- 25 wherein said vertical portion of said rail is attached to said
tem may be used with sliding drawers and /or stationary and upper section of said inner surface of said basket and
sliding shelves each supported by a pair of runners. The has a lower second end that terminates said vertical
system framemay also include a section for holding hanging portion , said horizontal portion of said rail having a
file folders and one or more of the inventive drawers . The third end that terminates said horizontal portion , said
drawers of the present invention may be used without a 30 vertical portion and said horizontal portion extending
frame. In yet another alternative example , the containers / substantially continuously around said basket portion .
drawers of the present invention may be retained within a 2. The apparatus of claim 1, wherein said upper section of
frame formed of wood , plastic , metal, or material with a said basket is supported only by said vertical portion of said
wood finish , where the frame has components such as rail.
runners and rollers thereon . The framewould cooperate with 35 3. The apparatus according to claim 1 , wherein said
a stationary holder with runners and rollers thereon so that vertical portion is attached to said upper portion only on said
the container does not move with respect to the holder, but inner surface of said basket portion .
when the holder moves between an extended and retracted 4. The apparatus according to claim 1, wherein said rail
position by moving with respect to the stationary compo consists only of said horizontal portion and said vertical
nent, the container likewise moves. In such an example, the 40 portion , said horizontal portion and said vertical portion
runner portion serves to connect the container to the holder forming an approximate right angle with respect to each
without a sliding engagement therebetween . In addition , the other .
container can be formed without upper rail 54 (see FIG . 3 ) 5. The apparatus according to claim 1 , wherein said first,
by forming the runner portion in another way, such as by second , third and fourth sidewalls are connected to each
folding the upper edge of the basket portion upon itself to 45 other to form four corners.
form a sufficiently - rigid integral runner portion . Alterna 6. The apparatus according to claim 5 , wherein each of
tively, the runner portion need not extend around the entire said four corners extend upwardly and outwardly from said
basket and may extend only on the sides to work with the bottom wall.
runners 26a - g (see FIG . 1). In such an example , the end 7. The apparatus according to claim 1, further comprising
walls without the runner portions may have upper edges 50 a rack having vertical support members arranged to form a
finished with portions of metal, wood , plastic or some other substantially rectangular frame, said rack having opposed
suitable material. Exemplary rails shown and described pairs of runners connected horizontally between said support
above with one basket construction can be used with basket members .
constructions shown in other examples or with conventional 8. The apparatus according to claim 7, wherein each of
basket constructions. For example , the exemplary rails 55 said runners comprises a U - shaped portion adapted to
shown and described above can be used with baskets that receive the horizontal portion of said rail slidingly therein ,
include sidewalls formed from a single loop ofmesh mate such that said basket portion may be freely moved to be
rial joined to a separate piece of bottom wall mesh material. within or outside of said rack .
Thus, the details of the present invention as set forth in the 9. An apparatus comprising:
above- described examples should not limit the scope of the 60 a basket portion of expanded metal mesh material includ
present invention . ing an inner surface , an outer surface , a substantially
Further, the purpose of the Abstract is to enable the U.S. flat bottom wall, substantially flat and upwardly and
Patent and Trademark Office , and the public generally , and outwardly extending from said bottom wall first and
especially the designers and practitioners in the art who are second spaced apart sidewalls, and substantially flat
not familiar with patent or legal terms or phraseology , to 65 and upwardly and outwardly extending from said bot
determine quickly from a cursory inspection the nature and tom wall third and fourth spaced apart sidewalls , said
essence of the technical disclosure of the application. The first, second, third and fourth sidewalls connected to
US 10,524,569 B2
19 20
each other to form four corners , each of said corners 13. The container according to claim 11, wherein said
extending upwardly and outwardly from said bottom first, second, third and fourth sidewalls are connected to
wall ; each other to form four corners .
a rail including a substantially flat horizontal portion and 14. The container according to claim 13, wherein each of
a substantially flat vertical portion connected at a right 5 said four corners extend upwardly and outwardly from said
angle to each other at a junction ; bottom wall .
said basket portion further including an upper section of 15. The container according to claim 11, further compris
said first, second , third and fourth sidewalls , said upper ing a rack having vertical supportmembers arranged to form
section extending only vertically and having a first end a substantially rectangular frame, said rack having opposed
that terminates said upper section at said junction ; 10
pairs of runners connected horizontally between said support
wherein said verticalportion ofsaid rail is attached to said members.
upper section of said inner surface of said basket and 16. The container according to claim 15 , wherein each of
has a lower second end that terminates said vertical said runners comprises a U - shaped portion adapted to
portion , said horizontal portion of said rail having a
third end that terminates said horizontal portion, said 15 such
receivethatthesaidhorizontal portion may
basket portion of saidberailfreelyslidingly
movedtherein
to be,
vertical portion and said horizontal portion extending within or outside of said rack .
substantially continuously around said basket portion ; 17. A container, comprising :
and
a rack having vertical support members arranged to form a basket portion of expanded metalmesh material having
a substantially rectangular frame, said rack having 20 a bottom wall from which upwardly and angularly
opposed pairs of runners connected horizontally outwardly extends substantially flat first and second
between said support members, each of said runners spaced apart sidewalls and substantially flat third and
comprising a U - shaped portion adapted to receive the fourth spaced apart sidewalls, said sidewalls forming
horizontal portion of said rail slidingly therein , such an upwardly and outwardly extending opening, said
that said basket portion may be freely moved to be 25 sidewalls joined to a horizontally extending upper
within or outside of said rack . section , said upper section and said sidewalls meeting
10. The apparatus according to claim 9, wherein said at a substantially right-angled junction ;
vertical portion is attached to said upper portion only on said a rail extending horizontally and including a first section ,
inner surface of said basket portion . a second section, and a connecting section joining said
11. A container, comprising: 30 first and second sections to define an opening therein ,
a basket portion of expanded metalmesh material having said connecting section having a curved, U -shaped
a bottom wall from which upwardly and angularly portion of substantially the same thickness as said first
outwardly extends substantially flat first and second and second sections, said upper section of said basket
spaced apart sidewalls and substantially flat third and having a terminal portion positioned in said opening ;
fourth spaced apart sidewalls, said sidewalls forming 35 said first section and said second section of said rail
an upwardly and outwardly extending opening , said extending from said opening to at least said right
sidewalls joined to a horizontally extending upper angled junction of said upper section and said side
section , the intersection of said sidewalls and said walls ; and
upper section forming a substantially right-angled junc said upper section being secured in said opening by
tion ; 40 compression of said first and second sections of said
a rail extending substantially horizontally from said open rail so as not to be removable from said opening , said
ing and including a first section , a second section , and upper section of said basket portion and said rail
a curved, U -shaped connecting section joining said first horizontally extending outwardly away from said
and second sections to define an opening, said first, upwardly -extending opening substantially continu
second and connecting sections being of substantially 45 ously around said first, second , third and fourth side
the same thickness; walls of said basket portion .
said upper section of said basket having a terminal portion 18. The container of claim 17 , wherein said first and
positioned in said opening , said first and second sec second ends terminate at approximately at the same position
tions having first and second ends, respectively, each of opposite to each other.
which extends over said junction ; 50 19. The container of claim 18 , wherein said first and
said upper section of said basket being secured in said second sections of said rail have first and second ends,
opening by compression of said first and second sec respectively, each of which extends at least to said substan
tions of said rail so as not to be removable from said tially right-angled junction .
opening, said upper section of said basket portion and said20.container
The container of claim 17 , further comprising a frame,
being movable with respect to said frame
said rail horizontally extending outwardly away from 55
said upwardly -extending opening substantially con between retracted and extended positions via said rail.
tinuously around said first, second , third and fourth frame 21. The container according to claim 20 , wherein said
sidewalls of said basket portion . includes a pair of opposed tracks for receiving said
12. The container of claim 11, wherein said first and rail and guiding said container between said retracted and
second ends terminate at approximately at the same position 60 extended positions.
opposite to each other.
Exhibit H
USOOD8952915
( 12) United States Design Patent ((4510)) Date

Hardy et al .
PatentofNoPatent
.: : US D895,291 S
* Sep. 8, 2020
( 54 ) MESH BASKET ( 56 ) References Cited
( 71 ) Applicant: Design Ideas , Ltd. , Springfield , IL U.S. PATENT DOCUMENTS
( US ) 71,881 A 12/1867 Howe et al.
171,032 A 12/1875 Meyers
( 72 ) Inventors: Christopher Hardy , Springfield , IL (Continued )
( US ) ; R. Neal Post, Springfield , IL
( US ) FOREIGN PATENT DOCUMENTS
( 73 ) Assignee : Design Ideas , Ltd. , Springfield , IL CN 202429440 9/2012
( US ) DE 202010008455 1/2011
( Continued )
( * ) Notice: This patent is subject to a terminal dis
claimer . OTHER PUBLICATIONS
( ** ) Term : 15 Years Design Ideas catalog 1995 , cover page and p . 24 .
(Continued )
( 21 ) Appl. No .: 29 /727,771
Primary Examiner Kelley A Donnelly
(22) Filed : Mar. 13 , 2020 (74 ) Attorney, Agent, or Firm - Perry Saidman , LLC
( 57 ) CLAIM
Related U.S. Application Data The ornamental design for a mesh basket , as shown and
described .
( 63 ) Continuation of application No. 29/ 718,845 , filed on DESCRIPTION
Dec. 30 , 2019 , which is a continuation of application
No. 29/ 702,026 , filed on Aug. 16 , 2019 , now Pat. No.
Des . 873,567 , which is a continuation of application The file of this patent contains at least one drawing/photo
No. 29/ 627,840 , filed on Nov. 30 , 2017 , now Pat. No. graph executed in color. Copies of this patent with color
Des . 865,365 , which is a continuation of application drawing (s )/photograph (s ) will be provided by the Office
No. 29 / 566,795 , filed on Jun . 2 , 2016 , now Pat . No. upon request and payment of the necessary fee .
Des . 807,036 , which is a continuation of application FIG . 1 is a front perspective view of a first embodiment of
( Continued ) a mesh basket showing our new design ;
FIG . 2 is a front view thereof;
( 51 ) LOC ( 12) CI . 03-01 FIG . 3 is a rear view thereof;
( 52) U.S. CI. FIG . 4 is a right side view thereof;
USPC D3 /306 FIG . 5 is a left side view thereof;
( 58) Field of Classification Search FIG . 6 is a top view thereof; and ,
USPC D3 / 201 , 304 , 306 , 307 ; D19 / 102 , 75 , 78 , FIG . 7 is a bottom view thereof.
D19 / 86 , 95 The broken lines represent environmental subject matter that
CPC . B65D 7/08 ; B65D 7/14 ; B65D 25/22 ; B65D forms no part of the claimed design .
7/16 ; B65D 21/00 ; B65D 1/22 ; B65D
1/38 1 Claim , 7 Drawing Sheets
See application file for complete search history . (7 of 7 Drawing Sheet( s) Filed in Color)
US D895,291 S
Page 2
Related U.S. Application Data D479,272 S

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D471,713 S 3/2003 Speed Miller's Office Products catalog 1997 , p . 453 , Mesh Desk Acces
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US D895,291 S
Page 3
( 56 ) References Cited
OTHER PUBLICATIONS
Design Ideas catalog 1998 , cover page and pp . 61 , 66-67 .
Hong Kong Enterprise, Oct. 1999 , p . 1126 , Mesh Basket, #SM 500
in center of page .
Hong Kong Enterprise, Oct. 1999 , p . 98 , Mesh Basket , #NH - 11
bottom of page .
Four digital photos of drawers of the elfa® closet system sold by
The Container Store® , offered for sale before Sep. 28 , 2000 (4
pages ).
The Container Store , The Ultimate Planning Guide, revised 1999 ,
cover page and pp . 16 and 19 .
The Container Store , The Ultimate Planning Guide, revised Nov.
2001 , cover page and pp . 20-21 and 34 .
* cited by examiner
U.S. Patent Sep. 8, 2020 Sheet 1 of 7 US D895,291 S
FIG
1
.
U.S. Patent Sep. 8 , 2020 Sheet 2 of 7 US D895,291 S
0 2
.
FIG
U.S. Patent Sep. 8 , 2020 Sheet 3 of 7 US D895,291 S
3
.
FIG
4
.
FIG
5
.
FIG
FIG
6
.
7
.
FIG
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UNITED STATES DISTRICT COURT FOR THE WESTERN DISTRICT OF MICHIGAN
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Knape &amp; Vogt Mfg. v. Design Ideas - Complaint

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Case 1:20-cv-01216 ECF No. 1, PageID.

1 Filed 12/17/20 Page 1 of 26

DE19842666; GB672538; JPH08322662; JPH09234131; and JP3070896U anticipate the claims

DE19842666; GB672538; JPH08322662; JPH09234131; and JP3070896U anticipate the claims

DE19842666; GB672538; JPH08322662; JPH09234131; and JP3070896U anticipate the claims

No. 6,467,860; DE19842666; GB672538; JPH08322662; JPH09234131; and JP3070896U

(12) United States Patent (10) Patent No.: US 7428,976 B2

U.S. PATENT DOCUMENTS 3,563,292 A 2f1971 Gordon

U.S. Patent Sep. 30, 2008 Sheet 2 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 3 of 27 US 7.428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 4 of 27 US 7.428,976 B2

U.S. Patent US 7.428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 6 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 7 of 27 US 7.428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 8 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 9 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 10 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 11 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 12 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 13 Of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 14 of 27 US 7.428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 15 of 27 US 7428.976 B2

U.S. Patent Sep. 30, 2008 Sheet 16 of 27 US 7.428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 17 Of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 18 of 27 US 7428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 19 of 27 US 7.428,976 B2

U.S. Patent Sep. 30, 2008 Sheet 20 of 27 US 7428,976 B2

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(12) United States Design Patent (10) Patent No.: USD624,753 S

U.S. PATENT DOCUMENTS D411,045 S 6/1999 Morandi

(12) United States Patent (10) Patent No.: US 8,006,858 B2

U.S. PATENT DOCUMENTS D298.403 S 1 1/1988 Magbert et al.

U.S. Patent Aug. 30, 2011 Sheet 2 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 3 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 6 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 7 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 8 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 9 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 10 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 11 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 12 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 13 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 14 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 15 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 16 of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 19 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 20 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 21 of 29 US 8,006,858 B2

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U.S. Patent Aug. 30, 2011 Sheet 22 of 29 US 8,006,858 B2

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U.S. Patent Aug. 30, 2011 Sheet 23 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 24 of 29 US 8,006,858 B2

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U.S. Patent Aug. 30, 2011 Sheet 25 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 27 Of 29 US 8,006,858 B2

U.S. Patent Aug. 30, 2011 Sheet 29 of 29 US 8,006,858 B2

(12) United States Patent (10) Patent No.: US 8,584.889 B2

Knape & Vogt Mfg. v. Design Ideas - Complaint

Knape & Vogt Mfg. v. Design Ideas - Complaint