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Description  |
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FIELD OF THE INVENTION
The present invention relates generally to storage for tools and equipment
and methods therefor, and more specifically to a method of making liners
for the bottoms of tool box drawers and compartments. The liners are
formed to fit closely the specific tools to be contained within the
specific area of the tool box where the liner is installed.
BACKGROUND OF THE INVENTION
Mechanics and other craftsmen have traditionally stored their tools and
equipment in tool boxes, chests, or the like for safekeeping and to
protect such tools from damage or from the elements. The typical specially
designed tool box or tool chest is a relatively heavy, sturdy structure,
generally formed of sheet steel and painted in order to provide for rust
protection. As such, heavier tools (e. g., hammers, prybars, large
combination wrenches, etc.) can easily chip or scratch the painted surface
of the tool box or drawer, and expose the underlying sheet metal structure
of the box to rust. Moreover, the direct contact with the relatively hard
surfaces of the tool box can damage any plating or finish on many tools
which may be stored therein, and more delicate tools (e. g., micrometers,
verniers, gauges, etc.) may be damaged by inadvertent hard contact with
the surfaces of the tool box and/or other tools therein.
Accordingly, many mechanics and craftsmen line the interior bottom surfaces
of the various drawers and compartments of their tool boxes or chests with
a relatively soft, resilient material (carpet material, closed cell foam
sheet, etc.) in order to eliminate direct contact between tools and the
underlying drawer or box bottom surface. However, such a simple sheet of
material does nothing to prevent contact between different tools, which
may also lead to damage to the tools. Moreover, the tools may still be
placed at random in any drawer or compartment of the chest or box, making
it difficult for a person having a relatively large collection of tools
and the like to readily determine if any are missing or have been
misplaced.
No satisfactory solution to the above problem has been developed
heretofore, although specialized tool cases having specially shaped insets
for specific tools and gauges are well known. The problem with such cases
is that the tools contained therein and the cases are generally supplied
as a unit, and the specially formed case interiors are not adaptable to
other tools; it is not possible to store such articles as hammers and
files in a case specifically formed to store and protect other
instruments, such as measuring devices. As the interiors of such cases are
each specifically formed for certain specific tools, the cost of producing
the special molds required for use with other tool storage is prohibitive.
The need arises for a method of making or manufacturing custom fit tool box
liners which may be easily formed to provide a precise fit for specific
tools. The method preferably may be accomplished using relatively simple
hand tools and equipment, or alternatively may lend itself to volume
production by means of automated equipment such as cutting dies. The
resulting tool box liners must provide protection and storage for tools
contained therein which is equivalent to that provided by specially molded
cases.
DESCRIPTION OF THE PRIOR ART
Charles W. Beck U.S. Pat. No. 1,263,343 issued on Apr. 16, 1918 discloses a
Tool Box For Automobiles. A filler block of wood is installed in each half
of the box. The filler blocks have a series of slots or openings cut
therein to conform generally with various tools. The slots extend inwardly
from the periphery, as they are cut with a band saw or the like. The lack
of resilience of the wood filler block, with its underlying moisture
absorbent felt pad, is unlike the present liner or method of manufacture.
David J. McIntyre U.S. Pat. No. 3,777,882 issued on Dec. 11, 1973 discloses
a Multi-Tray Instrument Case. No lamination of an underlying sheet is
disclosed for the liner or pad, nor is any resilient coating provided
beneath the tool cutouts, as each layer of tools is supported by another
underlying or overlying pad. While die cutting of the pads is disclosed,
none of the other steps involved in the manufacture of the present
invention are disclosed.
Alfred Wolfseder U.S. Pat. No. 4,619,363 issued on Oct. 28, 1986 discloses
a Multiple Tray-Shaped Packing And Storage Unit. As each tray is
monolithically formed as a single unit, no lamination of an underlying
sheet or addition of a resilient coating within the tool pockets is
disclosed. The trays are each formed by injection molding, unlike the
method of cutting the liner sheets used for the present invention.
Finally, Michael A. Rivera U.S. Pat. No. 5,071,004 issued on Dec. 10, 1991
discloses a Tool Storage Apparatus monolithically formed of an undisclosed
material. No underlying backing sheet is disclosed, nor is any resilient
coating applied to the interior of the tool receptacles, as in the present
invention.
None of the above noted patents, taken either singly or in combination, are
seen to disclose the specific arrangement of concepts disclosed by the
present invention.
SUMMARY OF THE INVENTION
By the present invention, an improved method of making liners for tool
boxes is disclosed.
Accordingly, one of the objects of the present invention is to provide an
improved method which provides custom formed liners to fit a specific
arrangement of specific tools in a tool box drawer, chest, or other
container, as selected.
Another of the objects of the present invention is to provide an improved
method which incorporates a relatively thin and firm and/or dense backing
sheet laminated to a relatively thicker and more resilient tool receptacle
sheet.
Yet another of the objects of the present invention is to provide an
improved method by which the receptacle sheet may be hand cut or die cut
as desired for a specific application and tool arrangement.
Still another of the objects of the present invention is to provide an
improved method which may include the addition of a liquid material into
each receptacle to form a resilient bottom surface for each receptacle
when the liquid material is cured.
A further object of the present invention is to provide an improved method
which may provide for different colors for the bottom surfaces of
different tool receptacles, in order to assist in the proper placement of
tools therein and in the determination of missing tools.
An additional object of the present invention is to provide an improved
method which may incorporate a variety of materials in the formation of
the present tool box liner.
A final object of the present invention is to provide an improved method
for the purposes described which is inexpensive, dependable and fully
effective in accomplishing its intended purpose.
With these and other objects in view which will more readily appear as the
nature of the invention is better understood, the invention consists in
the novel combination and arrangement of parts hereinafter more fully
described, illustrated and claimed with reference being made to the
attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tool box having liners of the method of
manufacture of the present invention installed therein.
FIG. 2 is an exploded perspective view of the liner or tool receptacle
sheet and backing sheet therefor.
FIG. 3 is a perspective view of the step of tracing the tool outlines on
the liner or tool receptacle sheet.
FIG. 4 is a perspective view of the step of cutting out the tool outlines
from the liner or tool receptacle sheet.
FIG. 5 is a perspective view of the step of adding a liquid plastic
material to each of the tool receptacles, to form a plastic coating for
the floor of each of the receptacles after the liquid material has cured.
FIG. 6 is a block diagram showing the steps involved in the present method
of manufacture of liners for tool boxes.
Similar reference characters denote corresponding features consistently
throughout the several figures of the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the present invention will be seen to relate
to a method of making or manufacturing liners for tool boxes and the like.
The liners may be custom made to fit specific tool boxes, drawers, etc.,
and specific tools to be placed therein, rather than being required to use
mass produced liners made for only a single type of tool box and tool
assortment. Moreover, the present liners lend themselves to modification
to add further tools after they are completed, still using most of the
steps of the present method.
FIG. 1 provides a view of two completed liners 10a and 10b as they would be
installed within a tool box T and drawer D. The liners made according to
the present method are preferably constructed using a relatively thick and
resilient closed cell foam plastic sheet material for the upper or tool
receptacle sheet, and a relatively thinner backing sheet preferably of a
firmer material, such as a more dense rubber or plastic sheet material,
plywood or other wood sheet, aluminum or other metal sheet, etc. Each of
the tool receptacles R is preferably partially filled (sufficiently to
cover the bottoms of the receptacles) with a liquid plastic or vinyl
material 26, which is formulated to cure or harden by exposure to air. A
similar plastic material is used to provide a coating for tool handles, by
dipping the tool handles in the liquid and exposing the handles to the air
until the liquid is cured.
FIG. 2 shows the second step in the construction of the present tool box
liners, after cutting the tool receptacle sheet 12 and backing sheet 14 to
the desired size, as disclosed in the first step 16 of FIG. 6. The area
(drawer, cabinet bottom, compartment, etc.) desired to be lined is
measured, and the measurements transposed to the receptacle and backing
sheets 12 and 14. The two sheets 12 and 14 are then laminated or bonded
together with a suitable adhesive (depending upon the material used for
the sheets 12 and 14 and their flexibility, etc.) to provide a completed
blank, in accordance with the second step 18 of FIG. 6. Alternatively, two
relatively large sheets 12 and 14 may be laminated together before
cutting, and then cut to the desired size after bonding.
FIG. 3 discloses the third step in the present tool box liner construction
method, also described in block 20 of FIG. 6. The present method lends
itself well to the construction of tool box liners for virtually any
arrangement of tools, as the specific tools and arrangement thereof
desired may be laid out on the upper surface of the upper tool receptacle
sheet 12, and the outline O of the tool T traced around its periphery. A
felt tip marking pen P or the like, providing a suitable contrasting color
to that of the tool receptacle sheet 12, may be used. The advantage to the
present method is that the tools may be arranged according to the
preference of the user of the present liners, rather than according to
some arrangement determined by a manufacturer, which may or may not be
suitable for a user of the liner or toolbox so equipped. Also, liners
completed according to the present method may be removed from the tool box
T or drawers D, and additional tool outlines O traced thereon and tool
receptacles R cut out, as additional tools are added to the collection.
After tracing or marking the outlines O of the tools as desired on the
upper, tool receptacle sheet 12, the outlines or patterns O are cut out as
shown in FIG. 4 and described in the fourth step 22 of the block diagram
of FIG. 6. A manually operated knife K (e. g., pen knife, etc.) may be
used, or alternatively, a die or dies may be constructed to provide for
the automation of this step. While such die(s) would be impractical for
the construction of a relatively few identical liners, in the vent it is
desired to form a relatively large number of liners having the same
pattern, a die or dies might be more practical, particularly if the
individual tool punches or cutouts are removable in a die so they may be
rearranged as desired. At the same time, finger holes or hand holds might
be cut in order to provide for ease of removal of the liners from a tool
box or drawer, if desired. The depth of the cuts should be completely
through the upper or receptacle sheet 12, down to (but not penetrating
into) the bottom sheet 14. If the upper, tool receptacle sheet 12 is of
sufficient thickness, the resulting tool receptacles R will be of
sufficient depth to hold securely the tools intended to be placed therein,
even with additional material in the bottoms of the receptacles R, as
provided for below.
The above described steps will be seen to be sufficient to provide a
completed tool box liner(s). However, the bottom(s) of the tool
receptacle(s) thus formed may be relatively rough and uneven, due to any
residue from the removed receptacle sheet tool cutout and/or remaining
adhesive therein, from the attachment of the backing sheet 14. An
additional step, providing a better base for each of the tool receptacles
R, is desirable and is shown in FIG. 5 and described in the fifth block 24
of FIG. 6.
In FIG. 5, a liquid vinyl or plastic material L is shown being poured into
the tool receptacles R. A relatively thin layer of the liquid L is used
(e. g., 1/16th to 1/8th inch), sufficient to provide a smooth, even layer
in the bottoms of the tool receptacles R, without filling the receptacles
R to any great degree and thereby reducing the space therein for the
retaining of tools therein. The liquid plastic material L is of an air
curing type, so that the material will harden to provide a resilient vinyl
or plastic bottom surface 26 for the tool receptacle R, as shown in FIG.
1. This is particularly desirable for liners which may use a metal backing
sheet 14, to preclude damage to relatively delicate instruments or gauges
stored in the liner(s). The resilient bottom surface 26 also helps to
protect softer backing sheet 14 material, if such is used.
Such air curing, liquid plastic material is readily available in a variety
of colors, and a person using the present method to construct tool box
liners may wish to use different colors for liners to be used for
retaining different tools, or for liners to be installed in different
areas of the tool box. The use of such different colors provides further
assistance in the placement of the proper tool in the proper compartment
or receptacle, and thus serves to reduce the loss or misplacing of tools.
Other air curing resilient materials are known (e.g., insulation foam,
etc.) which might be used to form a bottom surface for each of the tool
receptacles, but such material is relatively soft and would not be
desirable for use in receptacles at least for relatively heavy tools
(wrenches, hammers, etc.). Some persons using the present tool box liner
construction method may wish to use such foam material for measuring
instrument and gauge receptacles, however.
When the completed liner(s) is/are placed within a tool box B or drawer D,
as shown in FIG. 1 and described in the final step 28 of FIG. 6, the
result is an aesthetically pleasing and useful article providing for the
safe and efficient storage and protection of tools therein. A tool which
is missing or has been borrowed or misplaced will be immediately noticed
due to the empty tool receptacle, thus enabling the owner thereof to keep
track of his/her tools better and to reduce or eliminate the expense of
replacement. The protection provided by surrounding the tools on all
sides, as well as the bottom, with a resilient protective material custom
formed to fit each specific tool, provides superior protection for each
tool contained therein in comparison to a mere resilient sheet across the
bottom of a tool box drawer or compartment, which sheet does nothing to
prevent tools from contacting one another. The present method enables
anyone owning or responsible for tools and equipment and their associated
tool boxes or containers, to provide excellent protection for those tools
and equipment, and thus reduce the expense of maintenance and replacement
thereof.
It is to be understood that the present invention is not limited to the
sole embodiment described above, but encompasses any and all embodiments
within the scope of the following claims.
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