TECHNICAL FIELD

[01] The invention relates to a pull down tray assembly, more specifically one that allows an individual to access items on the pull down tray assembly without the need for external means and allows the trays to be cleaned easily.

BACKGROUND

[02] Pull down tray assemblies are known in the art (e.g. US9055813, US6340214,

W02007055679A1). US9055813, US6340214, and W02007055679A1 all disclose a tray or plurality of trays that can be pulled out from a cabinet. While US9055813 and US6340214 describe a tray that deploys by being pulled downwards, W02007055679A1 discloses a tray that deploys to a raised position. The trays of US9055813 are attached to levers, which are attached to lateral webs, connected to the side of the cabinet. Regarding US6340214, the trays are fastened to the side and rear of the cabinet. The trays of W02007055679A1 are attached to lifting arms, which are attached to the side of the cabinet.

[03] Much of the prior art requires that the trays be pulled down separately, which makes removing and placing items on multiple trays inefficient. For instance, in a three tray assembly, if one would like to place an item on the bottom tray, the middle tray, and the top tray, one would have to pull down each tray separately. Not only is removing and placing items on the trays of the prior art inefficient, cleaning the trays is also inefficient if one has to pull down each tray separately.

[04] The pull down tray assembly disclosed allows for the descent of all the trays

simultaneously. It is not necessary to deploy each tray separately. Not only does this require less work for the user, since the trays can all descend at the same time, the user can easily clean all the trays and does not have to pull each tray separately for cleaning purposes. The disclosed pull down tray assembly also eliminates having to use a stepladder to access items on the high tray of a conventional cabinet and to clean those trays, which can be a nuisance. Climbing up a step ladder or upon the counter to get to an item or clean a tray is not only an annoyance, but also dangerous. The pull down tray assembly eliminates both issues.

[05] While the disclosed pull down tray assembly will most likely be used primarily in kitchens, other examples of its usage include libraries (e.g. for extra book storage), warehouses, garages, and any other situation in which overhead shelving is present, desired, possible, and beneficial. Short people will not have difficulty accessing the top tray, since the hinged door, when lowered, allows the top tray to become the bottom tray, providing easy access to items on the top tray.

SUMMARY OF THE INVENTION

[06] The tray assembly can exist in many embodiments: as an insert for a conventional outwardly opening cabinet, as a custom cabinet door-cabinet configuration, and as a standalone system that does not require a cabinet.

[07] One embodiment of the pull down shelf assembly comprises a tray or plurality of trays. The tray or plurality of trays are supported by tray support rods, pivot support rods that are contiguous with the tray support rods meeting at a pivot joint, and secured support rods that are anchored to struts on both sides of the tray or plurality of trays. The secured support rods connect to the pivot joint via a connector rod. A first crossbeam spans one end of the struts and a second crossbeam spans the other end of the struts. The first crossbeam attaches to the hinge, and the hinge attaches to a board. The board, mounted to a vertical surface, is deeper in depth than the trays to give the trays clearance in the closed position. The shelf assembly descends to the user while the tray or plurality of trays remain level to the ground. The hinge allows for smooth return of the shelf assembly from the open to the closed position and vice versa.

[08] Another embodiment of the pull down shelf assembly comprises a door that is hinged to the base of a cabinet such that the door opens downwards revealing a tray or plurality of trays that descend to the user while remaining level to the ground. The tray or plurality of trays are supported by tray support rods, pivot support rods that are contiguous with the tray support rods meeting at a pivot joint, and secured support rods that connect to the pivot joint via a connector rod which are anchored to the door by a strut. A tail gate opener that is connected to the cabinet and the door allows for smooth return of the door from the open to the closed position and vice versa.

[09] In another embodiment, the pull down tray assembly can be installed within a conventional outwardly opening cabinet. Instead of the cabinet door being hinged to the base of the cabinet, the cabinet has a conventional outwardly opening door with a second door inside the cabinet. The second door is hinged to the base of the cabinet so that the second door opens downwards, revealing a tray or plurality of trays that descend to the user while remaining level to the ground. The tray or plurality of trays are supported by tray support rods, pivot support rods that are contiguous with the tray support rods meeting at a pivot joint, and secured support rods that connect to the pivot joint via a connector rod which are anchored to the door by a strut.

[10] In yet another embodiment in which the pull down tray assembly is installed within a conventional outwardly opening cabinet, the pull down tray assembly is connected to a support that is anchored to the base of a cupboard via any appropriate anchoring methods, such as nails, screws, etc. The support has holes at its base to accommodate the appropriate anchoring method. The support has a hole near its apex that accommodates an axle; one of the ends of the axle is connected to a tray support. Encircling the axle is a sprocket. The sprocket can be replaced with a cog. The sprocket hosts a chain. If a cog is used instead of a sprocket, the cog hosts a drive belt. The tray support has holes along its length that accommodate axles. As the pull down tray assembly is lowered, the single sprocket that is encircling the axle near the base of the cupboard and the single sprocket encircling the axle farther up the length of the tray support shaft will rotate clockwise due to the clockwise rotation of the chain. A double sprocket configuration positioned between the single sprockets and a double sprocket configuration positioned at the junction at which the tray support changes direction rotate counterclockwise; the chain around both double sprocket configurations will also rotate counterclockwise due to the chain’s counterclockwise rotation. Another double sprocket configuration at the other end of the tray support, the end farthest away from the base of the cupboard, is connected via chain to the double sprocket configuration at the junction at which the tray support changes direction. The chain connected to the double sprocket configuration at the other end of the tray support turns counterclockwise when the pull down tray assembly is lowered. The axles that accommodate the double sprocket configurations are connected at one end to the tray support and at the other end to the tray holder. As is the case for the single sprocket, double sprocket configurations can be replaced with a cog.

[11] In some embodiments, a tail gate opener is connected to the inside of the cabinet and the door and allows for smooth return of the door from the open to the closed position and vice versa.

[12] In one embodiment, the tray support rods are arranged in a square or rectangular configuration.

[13] In another embodiment, the tray support rods are arranged in an orthogonal configuration. In yet another embodiment the tray support rods are arranged in a circular configuration.

[14] In some embodiments, the pull down tray assembly is controlled manually.

[15] In some embodiment, the pull down tray assembly is controlled by electromechanical means.

[16] In some embodiments, the electromechanical means is a pneumatic piston.

[17] In other embodiments, the electromechanical means is an automatic opener.

[18] In still other embodiments the pull down tray assembly is controlled by a remote control.

[19] Regarding the pneumatic piston, one end of the pneumatic piston is connected to a thickened plate that is housed within the cabinet, while the other end is attached to the cabinet door. A structural frame mounted to the back of the cupboard maintains the integrity of the cupboard. The in and out motion of the pneumatic piston closes and opens the cabinet door, respectively. A remote control regulates this motion. Regarding the automatic opener, it has two arms connected by a joint. One arm is connected to the automatic opener and the other arm is connected to the cabinet door. The automatic opener is connected to a thickened plate housed within the cabinet. A structural frame mounted to the back of the cupboard maintains the integrity of the cupboard. Via remote control, the joint-connected arms can be controlled to open and close the cabinet door.

BRIEF DESCRIPTION OF THE DRAWINGS

[20] In FIG. 1, the pull down tray assembly 1 as shown is a representative view of the custom cabinet door-cabinet configuration. In this configuration, the cabinet door 9 attaches to the base of a cabinet via the piano hinge 10. The strut 11 anchors the secured support rods 3, 4 to the cabinet door 9.

[21] FIG. 2 provides an enlarged view of the pivot joint 2. The pivot joint 2, which encircles the connector rod 12, has pivot support rods 5, 6 that connect contiguously to the short tray support rod 7. As the cabinet door 9 is lowered into the open position, the tray 8, 15 stays upright by pivot joint 2 rotating around the connector rod 12.

[22] FIG. 3 shows the tray 8 being supported by the tray support. While the tray 8 can have a lip, a lip-less tray 15 can also be accommodated by the tray support. The tray support forms by the short tray support rod 7 and the long tray support rod 13 being joined at their ends to make an enclosed shape.

[23] FIG. 4 is a further enlarged view of the secured support rods 3, 4 attached to the strut 11. The strut is anchored to the cabinet door 9 to keep the tray assembly 1 in place.

[24] FIG. 5 shows the tailgate opener 14. Controlled either manually or electrically, the tailgate opener 14 connects to the cabinet door 9, which is attached via the piano hinge 10 to the base of the cabinet.

[25] FIG. 6 shows the lip-less tray 15 being supported by tray support rods 7, 13. The pivot support rods 5, 6 are contiguous with the tray support rods 7, 13.

[26] FIG. 7 provides a view of the pneumatic piston 16 operated pull down tray assembly 1. The pneumatic piston 16 is attached to a thickened plate 17, while a structural frame 19 is mounted on the back of the cupboard. A back plate with perforations 20 allows fastening of the cupboard to the wall. The hinge joint 10 at the base of the cupboard swings down to expose the tray 8, 15 or plurality of trays.

[27] FIG. 8 shows a view of the automatic opener 25 operated pull down tray assembly 1. The automatic opener 25 is attached to a thickened plate 21, while a structural frame 19 is mounted on the back of the cupboard. A back plate with perforations 20 allows fastening of the cupboard to the wall. The hinge joint 10 at the base of the cupboard swings down to expose the tray 8, 15 or plurality of trays.

[28] FIG. 9 is a schematic that illustrates a perspective of a user and one embodiment of the pull down tray assembly 1.

[29] In FIG. 10, the pull down tray assembly 1 as shown is a representative view of the configuration not requiring a cupboard. In this configuration, the first crossbeam 29 spans one end of the struts 11 while the second crossbeam 30 spans the other end of the struts 11. The piano hinge 10 attaches to the first crossbeam 29 as well as a board 31. The board 31 is mounted to a vertical surface 32. The secured support rods 3, 4 are anchored to the struts 11.

[30] In FIG. 11 , the pull down tray assembly 1 as shown is a representative view of the configuration including the support 40 attached to the base of the cupboard 46.

[31] FIG. 12 is an x-ray view of the pull down tray assembly 1 described in Figure 1 1.

[32] FIG. 13 is a representative view of the pull down tray assembly 1 described in Figure 11, showing the rotation direction of the chains 44 in relation to both the sprockets 41 and double sprocket configurations 49.

[33] FIG. 14 shows the cog 47 and drive belt 48. The cog 47 can replace the sprocket 41 and double sprocket configuration 49 in the pull down tray assembly described in Figure 1 1. The drive belt 48 can replace the chain 44 in the pull down tray assembly described in Figure 11.

DETAILED DESCRIPTION [34] The above described drawings illustrate the pull down shelf assembly 1 in at least some of its embodiments. The illustrated embodiments have been set forth only for the purposes of example and should not be taken as limiting the invention as defined below.

[35] FIG. 1 shows the pull down tray assembly 1 in a custom cabinet door-cabinet configuration in its open position. When deployed from closed to open position, the tray or plurality of trays stay level and prevent spillage of items on the trays. The highest trays are brought down to the lowest point of accessibility when in the open position. The manner in which the tray or plurality of trays stays level is by way of a pivot joint 2 on either side of the tray 8, 15 or plurality of trays. The pivot joint 2 rotates around a connector rod 12, allowing the tray to be lowered into accessible position. The pivot joint 2 may be a round hollow section, a ball bearing, or any other mechanism that would allow the tray 8 or plurality of trays to be deployed and remain level during deployment. For example, in FIG. 2 the pivot joint 2 is shown encircling a 0.5-linch diameter connector rod 12 that protrudes from the apex that the pivot support rods 5, 6 form. The pivot joint rotates around the connector rod, allowing the tray to be lowered into accessible position. The pivot support rods 5, 6 can be rods or bars, such as rods with a diameter of ¼”-l”, 3/l6”-l5/16”, or l/8”-7/8” or bars of around l/4”-l” by l/4”-l”,

3/16”-l 5/16” by 3/16”-l 5/16”, or l/8”-7/8” by l/8”-7/8” in cross-sectional dimension and made of metal, aluminum, or any durable material. The pivot support rods 5, 6 can be made of metal, aluminum, or any durable material.

[36] The pivot support rods 5, 6 are attached to a strut 11 via secured support rods or bars 3, 4 (See FIG. 1). The strut 11 is anchored to the door 9. The secured support rods and strut exist in a triangular formation to provide structural bracing and even load distribution on the door 9. The strut 11 can measure around 2-4 inches wide by ¼-3/4 inch thick, or about 1-3 inches wide by 3/16-1 1/16 inch thick. The strut 11 can be comprised of metal, aluminum, or a durable material. FIG. 4 shows the connector rod 12 contiguous with the secured support rods 3, 4.

[37] A hinge 10 connects the door 9 to the base of a cabinet to allow for the opening and closing of the cabinet door 9. In some cases, a tailgate 14 attaches to the inside side surface of a cabinet at one end and to the cabinet door 9 at the other end (see FIG. 5). [38] The tray 8, 15 or plurality of trays rests on top of a tray supports 7, 13 arranged in an enclosed fashion with the short tray support rods 7 contiguous with the pivot support rods 5, 6. (see FIG. 3). Tray supports can be rods or flat sheets of a suitable length, such as rods measuring around 3/8”-l” by 3/8”-l”, 5/16”-l5/16” by 5/16”- 15/16”, or ¼”-7/8” by ¼”-7/8” in cross- sectional dimension or sheets with a thickness of ¼”-l”, 5/16”-15/16”, or 3/16”-7/8”. Suitable materials include metal, aluminum, or any durable material.

[39] Each tray 8, 15 has a bottom surface, a top surface, and at least one side surface that is contiguous with the tray’s bottom and top surfaces. The tray 8, 15 or plurality of trays is between 0.02 - 2 inches thick, 0.03-1.5 inches thick, 0.06-1 inch thick, 0.1-0.75 inches thick or 0.19-0.5 inches thick. The material of the trays must be durable, lightweight, and easily cleanable.

Suitable materials include metals like titanium, aluminum, and stainless steel, hard plastic, and acrylic. The material of the trays can also be opaque, translucent, or transparent. In some cases, the trays have a lip 8, in other cases they do not have a lip, existing as a flat tray 15 (see FIG. 6).

[40] The pull down tray assembly 1 can be controlled manually or by remote control, fully automated with push-button or touchless/motion controls that will allow for self-opening and closing.

[41] FIG 7 shows the embodiment that discloses a pneumatic piston 16. The pneumatic piston 16 is attached to a thickened plate 17 that is housed within the cabinet containing the pull down tray assembly 1. The thickened plate measures at most 1 inch thick. A structural frame 19 is mounted at the back of the cabinet. Both the structural frame and the thickened plate can be made of metal, aluminum, or a durable material. All materials are corrosion-resistant. A perforated back plate 20 fastens the cabinet to the wall. The hinge 10 allows the trays 8, 15 to be lowered to an accessible position.

[42] The automatic opener 25 embodiment, as seen in FIG. 8, discloses an automatic opener 25 that has two arms 26, 27 connected by a joint 28. The automatic opener 21 is mounted to the side of the cabinet on a thickened plate 21. A structural frame 19 is mounted at the back of the cabinet similarly to the pneumatic piston 16 embodiment. A perforated back plate 20 allows the cabinet to be fastened to the wall. A hinge 10 allows downward and upward movement of the cabinet door 9, exposing the trays 8, 15.

[43] FIG. 10 shows the pull down tray assembly 1 in a cupboard-less configuration in its open position. The cupboard-less embodiment, as seen in FIG. 10, discloses a first crossbeam 29 that attaches to one end of the struts 11, and a second crossbeam 30 that attaches to the other end of .. the struts 11. The secured rods 3, 4 attach to the struts 11, while the pivot rods 5, 6 connect to the secured rods 3, 4 via the joint 2. The first crossbeam 29 attaches to the hinge 10. The hinge 10 connects to a board 31, which is deeper in depth than the tray 8, 15. The board 31 is mounted to a vertical surface 32. The manner in which the tray or plurality of trays stays level is by way of a pivot joint 2 on either side of the tray 8, 15 or plurality of trays. The pivot joint 2 rotates around a connector rod 12, allowing the tray to be lowered into accessible position. The pivot joint 2 may be a round hollow section, a ball bearing, or any other mechanism that would allow the tray 8, 15 or plurality of trays to be deployed and remain level during deployment. The first crossbeam 29 and second crossbeam 30 can be rods or bars, with rods of a diameter ¼”-l”, 3/l6”-l5/l6”, or l/8”-7/8” or bars of around l/4”-l” by l/4”-l”, 3/16”-l5/l6” by 3/l6”-l5/l6”, or l/8”-7/8” by l/8”-7/8” in cross-sectional dimension and made of metal, aluminum, plastic or any durable material. The board 31 can be made of metal, aluminum, wood, plastic or any durable material.

[44] The components of the pull down tray assembly 1 can have the following dimensions, but are not restricted to these dimensions. The functionality of the pull down tray assembly 1 will not be affected if the dimensions fall below or above the ranges ascribed herein. The connector rod 12 ranges from approximately 1/4-2 inches, 3/16-15/16 inches, or 1/8-7/8 inches diameter. The secured support rods 3, 4 range between approximately ¼”-l” by ¼”-l”, 3/16”- 15/16” by 3/16”- 15/16”, or l/8”-7/8”by l/8”-7/8 inches in cross-sectional dimension.

[45] To use the pull down tray assembly 1 manually, the user grasps a tether or other protrusion attached to the face of the door 9 to which the pull down tray assembly 1 is not attached. Gentle tension on the tether or other protrusion causes the door 9 to open downwardly by engaging the hinge 10 and revealing the tray 8, 15 or plurality of trays at a level easily reachable by the user. To place the pull down tray assembly 1 in its resting state, the user exerts gentle upward pressure on the door 9 to close it upwardly. [46] For embodiments equipped with pneumatic piston or automatic opener, the user selects the appropriate mechanism on the remote control to lower or raise the pull down tray assembly 1.

[47] In FIG. 11, the pull down tray assembly 1 as shown is a representative view of the configuration including the support 40 attached to the base of the cupboard 46. The support 40 has a hole that can accommodate an axle 42. Encircling the axle 42 is a sprocket 41, which presses against the tray support 43. A chain 44 turns the sprocket 41 when the pull down tray assembly 1 is lowered. Further up the tray support 43 is another sprocket 41 that encircles an axle 42. The same chain 44 that turns the sprocket 41 near the support 40 turns the sprocket 41 further up the tray support 43. This chain 44 turns in a clockwise manner when the pull down tray assembly 1 is lowered. A double sprocket configuration 49 is positioned between the sprockets 41. The double sprocket configuration 49 encircles an axle 42; the axle 42 connects the tray support 43 and the tray holder 45. At the junction where the tray support 43 changes direction, there is another double sprocket configuration 49 that encircles an axle 42. This axle 42 also connects the tray support 43 with the tray holder 45. Both double sprocket configurations 49 have a chain 44 encircling them that rotates the double sprocket configurations

counterclockwise when the pull down tray assembly 1 is lowered. The double sprocket configuration 49 at the junction where the tray support 43 changes direction is connected via a chain 44 to another double sprocket configuration 49. This double sprocket configuration 49 encircles an axle 42; the axle 42 connects the tray support 43 and the tray holder 45. The chain 44 turns counterclockwise when the tray pull down assembly 1 is lowered. The tray holder 45 supports the tray 50 at the tray holder’s 45 base. At its peak, the tray holder 45 has a hole that can accommodate an axle 42. At base of the tray holder 45, it can accommodate a tray 50. The tray holder 45 can accommodate the tray 50 by the tray 50 sliding into the base of the tray holder 45, by resting on the base of the tray holder 45, or any other means that would keep the tray 50 upright when being lowered. The tray holder 45 and tray support 43 can be constructed of rods or bars, with rods ofa diameter ¼”-l”, 3/16”-15/l6”, or l/8”-7/8” or bars of around l/4”-l” by 1/4”- 1”, 3/16”-l5/l6” by 3/16”-l5/16”, or l/8”-7/8” by l/8”-7/8” in cross-sectional dimension and made of metal, aluminum, plastic or any durable material. [48] FIG. 12, a transparent view of the pull down tray assembly 1 described in FIG. 11, shows the positioning of the sprockets 41, double sprocket configurations 49, and chains 44 in relation to the tray holder 45. FIG. 13 provides a clearer depiction of the rotation direction of the chains 44. The chain 44 connects the single sprockets 41 and rotates clockwise. The chain 44

connecting the double sprocket configuration 49 between the single sprockets 41 and the double sprocket configuration 49 at the junction where the tray support 43 changes direction rotates counterclockwise. The chain 44 connecting the double sprocket configuration 49 at the junction where the tray support 43 changes direction and the double sprocket configuration at the top of the tray support 43 rotates counterclockwise. FIG. 14 shows the cog 47 and drive belt 48. The cog 47 is an alternative for the sprocket 41 and double sprocket configuration 49. Instead of the sprocket 41 or double sprocket configuration 49 encircling the axle 42, the cog 47 would encircle the axle 42 instead. The drive belt 48 is an alternative for the chain 44. The drive belt 48 rotates the cog 47 when the pull down tray assembly 1 is lowered.