MODULAR STORAGE SYSTEM

Abstract

A storage system is provided with a first modular closet storage assembly packaged separately. The first modular closet storage assembly includes a pair of upright side supports to be supported upon an underlying support surface. A first plurality of horizontal cross members interconnects the pair of upright side supports. A second modular closet storage assembly is packaged separately. The second modular closet storage assembly includes only one upright side support to be supported upon the underlying support surface. A second plurality of horizontal cross members interconnects the only one upright side support to at least one of the pair of upright side supports of the first modular closet storage assembly.

Claims

1. A storage system comprising: a first modular closet storage assembly packaged separately, the first modular closet storage assembly comprising: a pair of upright side supports to be supported upon an underlying support surface, and a first plurality of horizontal cross members to interconnect the pair of upright side supports; and a second modular closet storage assembly packaged separately, the second modular closet storage assembly comprising: only one upright side support to be supported upon the underlying support surface, and a second plurality of horizontal cross members to interconnect the only one upright side support to at least one of the pair of upright side supports of the first modular closet storage assembly.

2. The storage system of claim 1 further comprising; a first shelf supported by the pair of upright side supports and the first plurality of horizontal cross members; and a second shelf supported by one of the pair of upright side supports, the only one upright side support of the second modular closet storage assembly, and the second plurality of horizontal cross members.

3. The storage system of claim 1 wherein each of the upright side supports is further defined as an upright side support assembly comprising: a pair of elongate vertical rails, each with elongate grooves formed along a length, and a series of incrementally spaced apart slots formed within the grooves; and at least one horizontal rail interconnecting the pair of elongate vertical rails.

4. The storage system of claim 3 further comprising: a plurality of connectors, each at a terminal end of one of the first plurality of horizontal cross members or one of the second plurality of horizontal cross members and sized to be inserted into one of the elongate grooves in one of the pair of elongate vertical rails; and a plurality of fasteners to fasten the plurality of connectors to the pair of elongate vertical rails.

5. The storage system of claim 3 wherein each of the pair of elongate vertical rails and the at least one horizontal rail are hollow with mitered ends; and wherein the closet storage system further comprises a plurality of corner connectors, each sized to be received in an end of the at least one horizontal rail and an end of one of the pair of elongate vertical rails to interconnect the at least one horizontal rail to the pair of elongate vertical rails.

6. The storage system of claim 5 further comprising a plurality of levelers, each fastened to one of the plurality of corner connectors.

7. A method for retailing a closet storage system comprising: providing a first modular closet storage assembly with a pair of upright side supports, and a first plurality of horizontal cross members in a first package; and providing a second modular closet storage assembly with only one upright side support, and a second plurality of horizontal cross members in a second package.

8. The storage system of claim 1 further comprising: at least one shelf; and a pair of connectors mounted to the at least one shelf so that the at least one shelf can translate relative to a pair of horizontal cross members of the first plurality of horizontal cross members and the second plurality of cross members, during installation and fasten to the pair of horizontal cross members.

9. The storage assembly of claim 8 wherein a pair of channels are formed in the shelf, each sized to receive one of the pair of connectors.

10. The storage assembly of claim 9 further comprising a first pair of retainers, each oriented in one of the pair of channels to receive and retain one of the pair of connectors.

11. The storage assembly of claim 10 further comprising a second pair of retainers, each oriented in one of the pair of channels to receive and retain one of the pair of connectors.

12. The storage assembly of claim 11 wherein the second pair of retainers are each deformable for manual release of the second pair of retainers.

13. The storage system of claim 1 further comprising: a pair of brackets connected for translation upon a pair of horizontal cross members of the first plurality of horizontal cross members and the second plurality of cross members, to attach the pair of brackets to the upright support surface.

14. The storage system of claim 13 wherein the pair of brackets are connected to a rear horizontal cross member of the pair of horizontal cross members.

15. The storage system of claim 14 wherein a series of slots are formed into the rear horizontal cross member to receive the pair of brackets at various orientations along the rear horizontal cross member.

16. The storage system of claim 15 wherein each of the pair of brackets has a widened aperture formed therethrough to receive a fastener to attach the pair of brackets to the upright support surface; and wherein a width of the widened apertures in combination with a spacing of the series of slots permits alignment of the pair of brackets and installation of the fasteners at a majority of a length of the rear horizontal cross member.

17. The storage system of claim 13 further comprising a pair of decorative fascias, each sized to be supported upon one of the pair of horizontal cross members to conceal a front portion of the pair of horizontal cross members and the pair of brackets.

18. The storage system of claim 1 further comprising: a plurality of decorative fascias, each sized to be supported upon one of the first plurality of horizontal cross members and the second plurality of horizontal cross members.

19. The storage system of claim 18 wherein the plurality of decorative fascias are extruded from a polymeric material.

20-29. (canceled)

30. A storage system comprising: a first modular closet storage assembly packaged separately, the first modular closet storage assembly comprising: a pair of upright side supports to be supported upon an underlying support surface, each comprising a plurality of upright rails, each with elongate grooves formed along a length, and a series of incrementally spaced apart slots formed within the grooves, and a first plurality of horizontal cross members to interconnect the pair of upright side supports; a second modular closet storage assembly packaged separately, the second modular closet storage assembly comprising: only one upright side support to be supported upon the underlying support surface, comprising a plurality of upright rails, each with elongate grooves formed along a length, and a series of incrementally spaced apart slots formed within the grooves, and a second plurality of horizontal cross members to interconnect the only one upright side support to at least one of the pair of upright side supports of the first modular closet storage assembly; a first shelf with a first pair of channels formed therein, supported by the pair of upright side supports and the first plurality of horizontal cross members; a second shelf with a second pair of channels formed therein, supported by one of the pair of upright side supports, the only one upright side support of the second modular closet storage assembly, and the second plurality of horizontal cross members; a first pair of connectors mounted to the first plurality of horizontal cross members to be received in the first pair of channels during installation; a second pair of connectors mounted to the second plurality of horizontal cross members to be received in the second pair of channels during installation; a first pair of retainers, each oriented in the first pair of channels to receive and retain the first pair of connectors; a second pair of retainers, each oriented in the second pair of channels to receive and retain the second pair of connectors; a pair of brackets connected for translation upon a rear horizontal cross member of the first plurality of horizontal cross members or the second plurality of horizontal cross members, to attach the pair of brackets to an upright support surface; a plurality of decorative fascias, each sized to be supported upon one of the first plurality of horizontal cross members or second plurality of horizontal cross members; a plurality of drawer rails, each with hooks sized to be received within the series of slots to attach to the plurality of upright rails at various height orientations along the plurality of upright rails; a drawer assembly connected the plurality of drawer rails to translate relative to the plurality of upright rails; a pair of clothing rod brackets with a pair of fastener patterns to be fastened to the plurality of horizontal cross members at two different locations, with a receptacle provided on a distal end of each bracket, and a post extending from within each receptacle; and a clothing rod sized to be received within the receptacles of the pair of clothing rod brackets, with a groove formed lengthwise in the rod to engage the post for alignment of the clothing rod.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 is a front perspective view of a modular storage system according to an embodiment;

[0035] FIG. 2 is an exploded front perspective view of a modular storage assembly according to an embodiment;

[0036] FIG. 3 is a partial side elevation view of a rail of the modular storage assembly of FIG. 2;

[0037] FIG. 4 is an exploded perspective view of a corner connector of the modular storage assembly of FIG. 2;

[0038] FIG. 5 is an exploded rear perspective view of a portion of the modular storage assembly of FIG. 2 illustrating an assembly step according to an embodiment;

[0039] FIG. 6 is an exploded rear perspective view of a portion of the modular storage assembly of FIG. 2 illustrating another assembly step;

[0040] FIG. 7 is a front perspective view of the modular storage assembly of FIG. 2;

[0041] FIG. 8 is a top plan view of the modular storage assembly of FIG. 2;

[0042] FIG. 9 is a front perspective view of a portion of the modular storage assembly of FIG. 2;

[0043] FIG. 10 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0044] FIG. 11 is a front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0045] FIG. 12 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0046] FIG. 13 is a front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0047] FIG. 14 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0048] FIG. 15 is a front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0049] FIG. 16 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0050] FIG. 17 is a front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0051] FIG. 18 is bottom perspective view of a shelf assembly according to an embodiment;

[0052] FIG. 19 is a section view of the shelf assembly of FIG. 18 taken along section line 19-19;

[0053] FIG. 20 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0054] FIG. 21 is a front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0055] FIG. 22 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0056] FIG. 23 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0057] FIG. 24 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0058] FIG. 25 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0059] FIG. 26 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0060] FIG. 27 is a front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0061] FIG. 28 is an exploded front perspective view of a portion of the modular storage assembly of FIG. 2 according to an embodiment, illustrating another assembly step;

[0062] FIG. 29 is a front elevation view of a modular storage system according to an embodiment;

[0063] FIG. 30 is a front elevation view of a modular storage system according to another embodiment;

[0064] FIG. 31 is a front elevation view of a modular storage system according to another embodiment;

[0065] FIG. 32 is a front elevation view of a modular storage system according to another embodiment; and

[0066] FIG. 33 is a front elevation view of a modular storage system according to another embodiment.

DETAILED DESCRIPTION

[0067] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0068] Closet storage systems incur significant shipping expenses when shipped assembled. A significant cost-savings is provided to the end user by packaging a closet storage system disassembled. A disassembled closet storage system can be packaged relatively compact, which is often referred to as a flat-pack assembly, such as a flat-pack drawer assembly.

[0069] Closet storage furniture is often limited in flexibility. Conversely, modular closet storage systems are often difficult to assemble, and are limited in structural capabilities.

[0070] FIG. 1 illustrates a modular closet storage system 40 according to an embodiment. The storage system 40 is depicted as a singular unit with a frame and various accessories. The modular closet storage system 40 is repeatable, modular and adjustable to provide various sizes, arrangements and configurations to the end user.

[0071] FIG. 2 illustrates a modular storage assembly 42 of the modular storage system 40 with many of the accessories removed. The modular storage assembly 42 provides a frame for one unit of the modular storage system 40. The modular storage assembly 42 includes a pair of upright side support assemblies 44 to be supported upon an underlying support surface, such as a floor. Each of the pair of upright side support assemblies 44 includes a pair of elongate vertical rails 46. The vertical rails 46 may each be formed from a hollow aluminum extrusion. The vertical rails 46 may also each be identical for interchangeability, and simplification of the assembly process.

[0072] As illustrate in FIG. 3, the vertical rails 46 are also each formed with grooves 48 with a series of incrementally spaced apart slots 49 formed within the grooves 48 for mounting hardware at various locations.

[0073] Referring again to FIG. 2, the side support assemblies 44 also include a pair of shorter horizontal rails 50. The horizontal rails are also formed from extruded aluminum with a similar profile to the vertical rails 46. The horizontal rails 50 are each interchangeable for ease in assembly. The vertical rails 46 and the horizontal rails 50 are mitered to be assembled together.

[0074] Referring now to FIGS. 2 and 4, the side support assemblies 44 also include a plurality of corner connectors 52 that are sized to be inserted into the hollow mitered ends of the vertical rails 46 and the horizontal rails 50 to interconnect the side support assemblies 44. The corner connectors 52 may be formed from a polymeric material, such as nylon. A plurality of fasteners may also be provided to fasten the corner connectors 52 into each of the rails 46, 50.

[0075] Referring again to FIG. 2, the side support assemblies 44 each include a plurality of levelers 54 to contact the underlying support surface to be manually adjusted to level the modular storage assembly 42. The levelers 54 may fasten directly into the corner connectors 52.

[0076] The modular storage assembly 42 includes a plurality of horizontal crossbars interconnecting the side support assemblies 44, which are provided by a top front crossbar 56, a top rear crossbar 58, and a lower crossbar 60. The modular storage assembly 42 also includes a top shelf 62, which is supported by the pairs of side support assemblies 44 and the top crossbars 56, 58. The modular storage assembly 42 is a primary storage assembly 42 that is packaged separately for providing closet storage or a unit of closet storage.

[0077] The modular storage system 40 also includes secondary modular storage assemblies 64 that are packaged separately than the primary storage assembly 42. The secondary modular storage assembly 64 is provided as a kit that is similar to the primary storage assembly 42. The secondary modular storage assembly 64 includes only one side support assembly 44, and the crossbars 56, 58, 60 and the shelf 62. Only one side support assembly 44 is provided in the secondary storage assembly 64, because the secondary storage assembly 64 is assembled to the primary storage assembly 42. The modular storage system 40 is repeatable in that the end user purchases one prepackaged kit for the primary storage assembly 42 and then a prepackaged secondary storage assembly 64 for each successive unit with the system 40. The system 40 avoids the redundancies of having extra side support assemblies 44 between adjacent units.

[0078] FIG. 5 illustrates the assembly of the upper crossbars 56, 58 to the side support assemblies 44. Each of the crossbars 56, 58, 60 include connectors 66 at the terminal ends to be inserted into the grooves 48 of the vertical rails 46 of the side support assemblies 44. FIG. 6 illustrates that a plurality of screws 68 are fasten the connectors 66 to the side support assemblies 44. Referring again to FIG. 3, the vertical rails 46 are provided with apertures 69 predrilled in the grooves 48 to receive the screws 68. According to one embodiment, the apertures 69 are through holes, and in an alternative, the apertures 69 may be internally threaded.

[0079] Referring again to FIG. 4, the corner connectors 52 may also have preformed apertures 71 to receive the screws 68. According to the depicted embodiment, the corner connectors 52 are provided with internally threaded nuts 73 installed into the apertures 71. With reference to FIG. 6, the screws 68 are installed into threaded engagement with the nuts 73 to fasten the crossbars 56, 58, 60 to the side support assemblies 44.

[0080] FIGS. 7 and 8 illustrate the modular storage assembly 42 assembled. After the crossbars 56, 58, 60 are fastened to the side support assemblies 44, the top shelf 62 is installed to the top crossbars 56, 58 and the side support assemblies 44.

[0081] The modular storage assembly 42 is supported directly upon the floor to avoid distributing all of the applicable loading to a wall. The modular storage assembly 42 is a closet storage assembly 42 and therefore, is conveniently installable adjacent to a wall within the closet.

[0082] FIG. 9 illustrates that each upper rear crossbar 58 is provided with a pair of brackets 70 that are mounted for translation along the crossbar 58. The brackets 70 may lock into one of a series of slots 72 formed along the crossbar 58 to limit the translation of the brackets 70. The brackets 70 each have a widened fastener aperture 74 for attachment to the wall. The width of the fastener apertures 74 in combination with the spacing of the slots 72 permit the brackets 70 to align and receive a fastener to the wall at any location upon the wall. This flexibility permits the installer to align the fastener apertures 74 of the brackets 70 with studs, drywall anchors or the like, while also avoiding any obstacles on or in the wall.

[0083] Referring now to FIGS. 10 and 11, a decorative fascia 76 is provided that can be manually installed upon the upper front crossbar 56. The fascia 76 is extruded from a polymeric material and is placed upon the top of the upper front crossbar 56. The lower end of the fascia 76 is pivoted into engagement with a lower end of the upper front crossbar 56 and is fastened to the crossbar 56 with an interference fit. The fascia 76 covers the hardware associated with the crossbar 56 to provide a streamlined and unobfuscated ornamental appearance of the upper front crossbar 56 and consequently the modular storage assembly 42.

[0084] FIGS. 12 and 13 illustrate another decorative fascia 78 that is manually installed upon the upper rear crossbar 58 and the brackets 70. The fascia 78 is extruded from a polymeric material and is placed upon the top of the upper rear crossbar 58 and the brackets 70. The lower end of the fascia 78 is pivoted into engagement with a lower end of the upper rear crossbar 58 and is fastened to the crossbar 58 with an interference fit.

[0085] The modular storage assembly 42 is configured to receive and support various closet accessories at various orientations. The accessories can be prepackaged in separate kits so that the end customer can select and modify the modular storage system 40.

[0086] FIGS. 14 and 15 illustrate a pair of shelf brackets 80 during installation to the modular storage assembly 42. Each shelf bracket 80 includes hooks 82 that are inserted through the grooves 48 and into the slots 49 of the side support assemblies 44 to support the shelf bracket 80. Once the hooks 82 are inserted in the slots 49, the shelf bracket 80 is pivoted downward as illustrated in FIG. 15. The shelf brackets 80 include a connector 84 for connecting to a shelf assembly 86. The connectors 84 are each formed as a bent metal portion extending away from the bracket 80, upward, and then further away from the bracket 80.

[0087] FIGS. 16 and 17 illustrate a method for assembling the shelf assembly 86 to the shelf brackets 80. In FIG. 16, the shelf assembly 86 is placed upon the shelf brackets 80 to receive a pair of the shelf connectors 84. Then, the shelf assembly 86 is slid forward, thereby fastening the shelf assembly 86 to the shelf brackets 80.

[0088] FIGS. 18 and 19 illustrate the shelf assembly 86 in greater detail. The shelf assembly 86 includes a shelf body 88 formed from wood, a wood composite, a polymer, or the like. A pair of channels 90 are formed in the shelf body 88 spaced apart to align with the shelf connectors 84 of the shelf brackets 80. A first shelf retainer 92 is provided in each channel 90. A second shelf retainer 94 is provided at another end of each channel 90. During installation of the shelf assembly 86, the connectors 84 are received in the channels 90 between the retainers 92, 94. As the shelf assembly 86 is translated into the modular storage assembly 42, the first pair of shelf retainers 92 connect to the rear pair of shelf connectors 84. Likewise, the second pair of shelf retainers 94 engage a forward pair of the shelf connectors 84, thereby fastening the shelf assembly 86 to the shelf brackets 80 with requiring additional tools. The second pair of shelf retainers 94 are deformable and can be manually released to disassemble or modify the modular storage system 40.

[0089] FIGS. 20 and 21 illustrate drawer brackets 96 installed into the side support assemblies 44. The drawer brackets 96 include hooks 98 that are inserted into the slots 49 in the grooves 48 of the side support assemblies 44. Referring now to FIG. 1, a drawer 100 is assembled to the drawer brackets 96 for translation relative to the modular storage assembly 42.

[0090] FIG. 22 illustrates one of a pair of clothing rod brackets 102 installed to apertures 104 in the horizontal rails 50 of the side support assemblies 44 with screws 106. FIGS. 23 and 24 illustrate the installation of a clothing rod 108 upon the clothing rod brackets 102. The clothing rod brackets 102 each include a receptacle 110 to receive a terminal end of the clothing rod 108. A post 112 extends up from each receptacle 110. A groove 114 is formed along the length of the clothing rod 108 to engage the post 112. During assembly, the clothing rod 108 is placed into the receptacles 110 of the clothing rod brackets 102 with the groove 114 in alignment with the posts 112. The cooperation of the post 112 in the groove 114 limits rotation of the clothing rod 108, and provide an interference fit to fasten the clothing rod 108 to the clothing rod brackets 102.

[0091] FIG. 25 illustrates that the clothing rod brackets 102 can also be assembled to the shelf brackets 80. The shelf brackets 80 are modular and can be utilized to also support the clothing rod brackets 102. Apertures 116 are provided in the shelf brackets 80 so that the clothing rod brackets 102 can be fastened to the shelf brackets 80 with screws 118. FIGS. 26 and 27 illustrate assembling the shelf brackets 80 with the clothing rod brackets 102 to the side support members 44. The shelf support brackets 80 can be installed at any user-selected height for the clothing rod 108. FIG. 28 illustrates the installation of the clothing rod 108 to the clothing rod brackets 102.

[0092] FIGS. 29-33 illustrate some examples of the modular closet storage system 40, each with one primary modular storage assembly 42 and one or more secondary modular storage assemblies 64 to build the modular closet storage system 40 to the preferences of the user. Each of the examples 40 in FIGS. 29-33 also illustrate examples of the modularity in combination with many of the accessories depicted in the various embodiments.

[0093] While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.