SHELVING UNITS UTILIZING HYBRID CONNECTION SYSTEM

Abstract

A shelving assembly employing a hybrid connection system using both threaded and non-threaded fasteners, designed to provide shelving that is both relatively strong and durable, while also being capable of relatively rapid assembly and disassembly.

Claims

1. A shelving assembly, comprising: first and second side frame structures, each comprising a pair of adjacent vertical posts connected by three or more horizontal members, wherein the first and second side frame structures are connected to each other by three or more pairs of cross-members, including top-most and bottom-most pairs of cross-members; top-most and bottom-most horizontal members welded to the vertical posts; one or more shelving units located between the top-most and bottom-most horizontal members, the one or more shelving units connected by snap-fit attachment to the vertical posts; wherein the top-most and bottom-most cross-members are attached by threadable fasteners to the vertical posts; and wherein the shelving assembly may be relatively rapidly assembled.

2. The shelving assembly of claim 1, further comprising a tube member weldably and diagonally connected to a pair of adjacent vertical posts.

3. The shelving assembly of claim 1, wherein the cross-members include a flanged end with punched square apertures, and ends of the vertical posts include punched square apertures, each of the punched square apertures accommodating bolts with square necks.

4. The shelving assembly of claim 3, wherein the bolts mate with thumb nuts having serrated edges.

5. The shelving assembly of claim 1, wherein ends of the shelving units include stamped rivets or tabs for accommodating apertures on the vertical posts.

6. The shelving assembly of claim 1, wherein keyholes are stamped into substantially an entire length of the vertical posts.

7. The shelving assembly of claim 1, and wherein the vertical posts are C-shaped in cross-section, and wherein a first side of each of the C-shaped vertical posts includes side-by-side keyholes that run substantially an entire length of the vertical posts, and a second side of each of the C-shaped vertical posts, at opposing ends of the posts, includes stamped square apertures.

8. A shelving assembly, comprising: first and second side frame structures, each comprising a pair of adjacent vertical posts connected by pairs of three or more opposing horizontal members, including a pair of top-most opposing horizontal members and a pair of bottom-most opposing horizontal members, and wherein the first and second side frame structures are connected to each other by three or more pairs of cross-members, including top-most and bottom-most pairs of cross-members; wherein the pair of top-most opposing horizontal members and the pair of bottom-most opposing horizontal members are each connected by threadable fasteners to the vertical posts; one or more shelving units located intermediately between the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members, the one or more shelving units connected by snap-fit attachment to the vertical posts; wherein the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members are attached by threadable fasteners to the vertical posts; and wherein the shelving assembly may be relatively rapidly assembled.

9. The shelving assembly of claim 8, wherein the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members each have ends with punched square apertures, for accommodating bolts with square necks that also connect with punched square apertures located at ends of the vertical posts.

10. The shelving assembly of claim 9, wherein the bolts mate with thumb nuts having serrated edges.

11. The shelving assembly of claim 8, wherein ends of the shelving units include stamped rivets or tabs for accommodating apertures on the vertical posts.

12. The shelving assembly of claim 8, wherein keyholes are stamped into substantially an entire length of the vertical posts, and further comprising a coupler for attaching two adjacent vertical posts in a vertically-stacked manner.

13. The shelving assembly of claim 8, wherein the vertical posts are C-shaped in cross-section, and wherein a first side of each of the C-shaped vertical posts includes side-by-side keyholes that run substantially an entire length of the vertical posts, and a second side of each of the C-shaped vertical posts, at opposing vertical ends of the posts, includes stamped square apertures.

14. The shelving assembly of claim 8, wherein the keyholes are stamped into but not through interior sides of the vertical posts, such that the keyholes for posts adjacent an observer in front of the shelving assembly are concealed, or at least partially concealed, from the observer's view.

15. A shelving assembly, comprising: first and second side frame structures, each comprising a pair of adjacent vertical posts connected by pairs of three or more opposing horizontal members, including a pair of top-most opposing horizontal members and a pair of bottom-most opposing horizontal members, and wherein the first and second side frame structures are connected to each other by three or more pairs of cross-members, including top-most and bottom-most pairs of cross-members; wherein the pair of top-most opposing horizontal members and the pair of bottom-most opposing horizontal members are each connected by threaded fasteners to the vertical posts; one or more shelving units located intermediately between the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members, the one or more shelving units connected by snap-fit attachment to the vertical posts; wherein the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members are attached by threaded fasteners to the vertical posts; further comprising adjacent vertical posts vertically stacked, wherein the vertically-stacked posts are connected by a vertical pin; wherein the shelving assembly may be relatively rapidly assembled.

16. The shelving assembly of claim 15, wherein ends of the shelving units include stamped rivets or tabs for accommodating apertures stamped on the vertical posts.

17. The shelving assembly of claim 16, wherein the apertures stamped on the vertical posts comprise keyholes stamped into substantially an entire length of the vertical posts.

18. The shelving assembly of claim 15, wherein the vertical posts are L-shaped in cross-section, and wherein each of the two sides of the L-shaped vertical posts includes a series of stamped keyholes running substantially an entire length of the vertical posts.

19. A shelving assembly, comprising: a first shelving rack comprising two pairs of vertical posts, and cross-members and horizontal members connecting those two pairs of vertical posts to each other; and a second shelving rack comprising two pairs of vertical posts, and cross-members and horizontal members connecting those two pairs of vertical posts to each other; wherein the second shelving rack is located side-by-side to the first shelving rack, and further comprising a connector removably attachable to each of the first and second shelving racks, holding the racks together; and wherein the shelving assembly may be relatively rapidly assembled.

20. A shelving assembly, comprising: first and second side frame structures, each comprising a pair of adjacent vertical posts connected by pairs of three or more opposing horizontal members, including a pair of top-most opposing horizontal members and a pair of bottom-most opposing horizontal members, and wherein the first and second side frame structures are connected to each other by three or more pairs of cross-members, including top-most and bottom-most pairs of cross-members; wherein the vertical posts are C-shaped in cross-section, and one side of the C-shape includes side-by-side keyholes located serially along substantially an entire length of the vertical posts, and a second side of the C-shape, at opposing ends of the posts, includes stamped apertures; wherein the pair of top-most opposing horizontal members and the pair of bottom-most opposing horizontal members are each weldably connected to the vertical posts; one or more shelving units located intermediately between the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members, the one or more shelving units connected by either: (1) a snap-fit attachment to the vertical posts; or (2) mounted using a dropped-pin connection; wherein the pair of top-most opposing cross-members and the pair of bottom-most opposing cross-members are attached by threaded fasteners to the vertical posts; wherein horizontal members located intermediate between the top-most and bottom-most horizontal members, are connected to the vertical posts using thumbscrews mating with flange nuts; and wherein the shelving assembly may be relatively rapidly assembled.

21. The shelving assembly of claim 20, wherein the flange nuts comprise inverted flange nuts with a hexagon-shaped inversion, and wherein the intermediate horizontal members include hexagon-shaped cutouts sized to mate with the inversion of the flange nuts.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The novel features which are characteristic of the invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages thereof, can be better understood by reference to the following description taken in connection with the accompanying drawings, in which:

[0021] FIG. 1 is a front and side perspective view of one preferred embodiment of the shelving system of the present invention, referred to here as an industrial rack shelving system;

[0022] FIG. 2 is a front and side perspective view of another preferred embodiment of the shelving system of the present invention, referred to here as a concealed post rack shelving system;

[0023] FIG. 3 is a front and side perspective view of another preferred embodiment of the shelving system of the present invention, referred to here as a L-shape corner post rack shelving system;

[0024] FIG. 4 is a front and side perspective view of another preferred embodiment of the shelving system of the present invention, referred to here as a heavy duty rack shelving system;

[0025] FIG. 5 is a side and front perspective parts view of a frame for the industrial rack shelving system of FIG. 1;

[0026] FIG. 6 is a side and front perspective view of a side frame structure used with the industrial rack shelving system of FIG. 1;

[0027] FIG. 7 is a planar parts perspective view of an individual shelf which may be used with the industrial rack shelving system of FIG. 1;

[0028] FIG. 8a is a perspective view of a bolt which may be used with the shelving systems of the present invention;

[0029] FIGS. 8b and 8c are front and rear perspective views of a thumb nut with serrated edges which may be used to mate with the bolt of FIG. 8a for use in attachment of the shelving systems of the present invention;

[0030] FIG. 9A is a side and front perspective parts view of a frame for the concealed post rack shelving system of FIG. 2;

[0031] FIG. 9B shows rear and front perspective views, respectively, of the L-shaped corner posts which may be used with the concealed post rack shelving system of FIG. 2;

[0032] FIG. 9C is an enlarged planar perspective view of a coupler located above the end of a vertical post;

[0033] FIG. 10A is a front and side perspective view of the attached frame which may be used with the concealed post rack shelving system of FIG. 2:

[0034] FIG. 10B is an enlarged partial perspective view of the lower portion of a vertical corner post attached to a side member and a cross-member, concerning the concealed post rack shelving system of FIG. 2:

[0035] FIG. 10C is a pan-type shelf which may be used with the FIG. 2-type shelving system;

[0036] FIG. 11A is an enlarge partial perspective view of a vertical corner post, prior to attachment to a side member and a cross-member, concerning the concealed post rack shelving system of FIG. 2;

[0037] FIG. 113 is a perspective view of a bolt which may be used for fastening the side members and cross-members to the vertical corner posts, concerning the FIG. 2-type shelving system;

[0038] FIG. 12A is a side and front perspective parts view of a frame for the L-shape corner post rack shelving system of FIG. 3;

[0039] FIG. 12B is an enlarge partial perspective view of a lower or upper portion of a vertical corner post which may be used for the L-shape corner post rack shelving system of FIG. 3;

[0040] FIGS. 13A and 13B are enlarged partial perspective views showing side members and cross-members attached (FIG. 13A) and unattached (FIG. 13B) to an L-shaped vertical corner post, in connection with the L-shape corner post rack shelving system of FIG. 3;

[0041] FIG. 13C is an enlarged partial perspective view showing how rivets located at ends of intermediate side members and cross-members may be attached to adjacent keyholes located at intermediate locations on an L-shaped vertical corner post;

[0042] FIG. 13D is a planar perspective view of an individual shelf which may be used in connection with the L-shape corner post rack shelving system of FIG. 3;

[0043] FIG. 13E is a perspective view of a bolt which may be used in connection with the FIG. 3-type shelving system;

[0044] FIG. 13F shows rear and front perspective views of a thumb nut with serrated edges which may be used in connection with the FIG. 3-type shelving system;

[0045] FIG. 14 is an enlarged partial perspective view of an intermediate inner portion of two vertically-stacked generally L-shaped vertical corner posts attached by a vertical pin, which may be used in connection with the FIG. 3-type shelving system;

[0046] FIG. 15 is a side and front parts perspective view showing an unattached frame of the heavy duty rack shelving system of FIG. 4;

[0047] FIGS. 16A and 16B are enlarged partial perspective views of top and bottom portions of a vertical corner post, respectively, each showing an attached side member, and the top view showing a diagonal member as well, in connection with the FIG. 4-type shelving system;

[0048] FIGS. 17 and 18 are enlarged partial perspective views, showing a side member unattached (FIG. 17) and attached (FIG. 18, using a thumb screw and inverted flange nut) to two vertically-stacked C-shaped vertical corner posts, in connection with the FIG. 4-type shelving system;

[0049] FIG. 19A is an enlarged partial perspective view showing upper edge portions of two FIG. 4-type shelving systems, located side-by-side each other, with adjacent apertures/cutouts located at the top of adjacent C-shaped vertical corner posts;

[0050] FIG. 19B is a view similar to FIG. 19A, showing a U-shaped connector which may be used to attached the FIG. 4-type shelving systems in side-by-side location to each other;

[0051] FIG. 20 is an enlarged partial perspective view showing a dropped pin connection useful for attaching side members to cross-members in the shelving assembly examples of FIGS. 1 and 4; and

[0052] FIGS. 21-22 are enlarged partial planar perspective views of an upper portion of adjacent vertical posts (FIG. 21) or a vertical post (FIG. 22) illustrating different keyhole cutouts that may be used.

[0053] The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. In the drawings, like reference numerals designate corresponding parts throughout the several views.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] Set forth below is a description of what are believed to be the preferred embodiments and/or best examples of the invention claimed. Future and present alternatives and modifications to this preferred embodiment are contemplated. Any alternatives or modifications which make insubstantial changes in function, in purpose, in structure, or in result are intended to be covered by the claims of this patent.

[0055] Various preferred embodiments of shelving units of the present invention are shown here in order to illustrate different aspects of the present invention, including: industrial shelving rack 10 (FIGS. 1 and 5-7); concealed post shelving rack 20 (FIGS. 2, 9A-9B, 10A-10C and 11A-11B); L shaped corner post shelving rack 30 (FIGS. 3, 12A-12B, 13A-13F and 14; and heavy-duty shelving rack 40 (FIGS. 4, 15, 16A-16B, 17-18 and 19A-19B),

[0056] Referring first to industrial shelving assembly 10 of FIGS. 1 and 5-7, industrial shelving rack 10 includes, for example: four C-shaped vertical posts 11 with punched keyholes 11a located on the middle edge (FIG. 6) and running the full length of each post 11, and square punched holes 11b located at the top and bottom ends of each post 11, on each side of opposing sides of the C-shaped channel; four top and bottom cross members 12, with end flanges 12a mounting apertures 12a; four horizontal tubes 13, each of which may be welded to two adjacent vertical posts 1 as shown, and two diagonal members 15 are attached by welding to two adjacent vertical posts 11.

[0057] Each adjacent pair of vertical posts 11, together with welded horizontal tubes 13 and diagonal member 15, forms a separate side frame structure 14. Each side frame structure 14 may be attached to the four top-most and bottom-most cross-members using threaded fasteners.

[0058] Preferably, the threaded fasteners employed are bolts and thumb nuts with serrated edges. Bolts 50 with square necks 52 (FIG. 8A) are preferred, as they will fit into square apertures 12a on cross members 12, to prevent the bolts from rotating during assembly or use. Serrated edges 56 of thumb nuts 54 (FIGS. 8B-8C) offer enhanced manual purchase to facilitate tightening.

[0059] Shelves 16 (FIG. 7) may be located at intermediate locations between the top-most and bottom-most cross-members 12. Shelves 16 may include, e.g., wire racks 17, cross members 18, and end flanges 16a mounting rivets 16a. Shelves 16 may be rapidly attached by moving rivets 16a into keyholes 11a on vertical posts 11, and pushing down on the shelving, causing the rivets 16a to move down in the keyhole from the wider portion of the keyhole to the narrower portion, wherein the shelving is fixed into position. Consumers have the choice of adding additional, adjustable-height shelves using the rivet/keyhole attachment based on individual needs and usage preferences, as keyholes are preferably located along substantially the entire length of the posts, other than the top-most and bottom-most locations of the posts (to more easily accommodate the square cutouts on cross-members 12 for connection to the posts using the threaded fasteners),

[0060] It will now be understood that threaded fasteners are integral to the assembly here, as without their use as indicated, the shelving units disclosed here will collapse. However, because each side frame structure may already be integrally formed (due to the welded horizontal tubes 13 and the welded diagonal members 15), once the top-most and bottom-most cross-members 12 are attached to the posts using threaded fasteners, the shelves may be rapidly manually assembled without the use of special tools, by simply pushing shelve rivets 16a into the corresponding keyholes on vertical posts 11 (tabs and slots may alternatively be used). This hybrid connection system provides more rapid assembly than if only threaded fasteners were used, while also providing enhanced strength and durability as compared to shelving systems using only non-threaded fasteners.

[0061] Referring now to FIGS. 2, 9A-9B, 10A-10C and 11A-11B, an alternative embodiment of the present invention, concealed post shelving assembly 20, is shown, and includes: four L-shaped vertical posts 22 with punched keyholes 22a located on one of the two sides of the L-shape and running the full length of each post 22, and square punched holes 22b located at the top and bottom of each post 22, and on each of the two sides of the L-shape; four top and bottom cross members 24 with square apertures 24a located at opposing ends of each cross member 24, for connection using threaded fasteners to post holes 22h; and four horizontal tubes 23, with apertures 23a, each of which connect using threaded fasteners to post holes 22b of two adjacent vertical posts 22.

[0062] As shown in FIG. 2, keyholes 22 are concealed from exterior view due to the fact that the keyholes are located on the inside edges of vertical posts 22, and they are stamped only through an interior surface of the post, and not through the entire side of the post, as shown.

[0063] Two adjacent vertical posts 22, and two bottom-most and top-most corresponding horizontal tubes 23, threadably fastened to the posts, form a side frame structure 25.

[0064] Again, where threaded fasteners are called for above, bolts 50 with square necks 52 may be used, and may mate with thumb nuts 54 with serrated edges 56.

[0065] Shelves 26 (FIG. 10C) may be located intermediate of the top-most and bottom-most cross-members 24. Shelves 26 may be pan-shaped, as shown, or alternatively employ wire racks as with shelves 16. Shelves 26 again may be rapidly attached to the posts, as shelves 26 may include rivets 26a for coupling to keyholes 22a on vertical posts 22, as shown in FIG. 10C. Shelf 26 may include floor 27 and downwardly extending sides 28, with corner cutouts 28a for accommodating post 22.

[0066] Referring now to FIGS. 3, 12A-12B, 13A-13F and 14, yet another embodiment of the present invention, L-shaped corner post shelving assembly 30, is shown, and includes: four L-shaped vertical posts 32 with punched keyholes 32a running the full length of each of two L-shaped sides of each post 32, and square punched holes 32b located at the top and bottom of each of the two L-shaped sides of post 32; four top and bottom cross members 34 with square apertures 34a located at opposing ends of each cross member 34; and four horizontal tubes 33 with end apertures 33a for connection using threaded fasteners to apertures 32a on one side of L-shaped post 32.

[0067] Again, where threaded fasteners are called for above, and referring to FIGS. 11A and 11B, bolts 50 with square necks 52 may be used, and mated with thumb nuts 54 with serrated edges 56.

[0068] Shelves 36 may again be located intermediate of the top-most and bottom-most cross-members 34. Shelves 36 may be rapidly attached to posts 32 using the rivet/keyhole connection, or a slot/tab connection. Shelf 36 may include floor 37 and downwardly extending sides 38, with corner spaces 38a for accommodating post 32.

[0069] With this example, and for the shelving rack examples that utilize an L-shaped vertical post (FIGS. 2 and 3), a pin 39 may be slid into correspondingly-sized brackets 32c which may be located on the inside corner of L-shaped post 32, to hold two adjacent vertical posts in vertical position; this allows the shelving height to be increased, as desirable, Pin 39 may be of sufficient length, thickness and material selection to provide the vertical posts that it supports with sufficient strength and durability, as will be understood by those of skill in the art.

[0070] Alternatively, with the FIG. 2-type shelving assembly example, a separate coupler 67 may employed, as shown in FIG. 9B, having stamped protrusions 67a on the inside surface of the coupler that frictionally engage with the inside surfaces of the adjacent vertical post ends to provide a snug fit with the post and hold the coupler in place. Near the end of each vertical post is a stop 69 engaging the end of the coupler, to hold the coupler in position.

[0071] Finally, referring to FIGS. 4, 15, 16A-163, 17-18 and 19A-19B, still another embodiment of the present invention, heavy duty shelving assembly 40, is shown, and includes: four generally C-shaped vertical posts 42 with punched keyholes 42a running the full length of each post 42, with two side-by-side keyholes located on the main side 42, and square punched holes 42b located at the top and bottom of each of posts 32, on the main side 42; four top and bottom cross members 44 with square apertures 34a threadably fastened to posts 42 at opposing ends of each cross member 44; four horizontal tubes 43, each tube 43 welded at an end to a vertical post 42 as shown; and four diagonal members 45, each welded to an inside edge of post 42 as shown.

[0072] An adjacent pair of vertical posts 42, together with top-most and bottom-most welded horizontal tubes 43, and a pair of welded diagonal tubes 45, form a sturdy side frame structure 46. Each side frame structure may be connected via threaded fasteners to a pair of top-most, and a pair of bottom-most, cross members 44.

[0073] Again, where threaded fasteners are employed, bolts 50 with square necks 52, mating with thumb nuts 54 with serrated edges 56, may be used.

[0074] Referring now to FIGS. 17-18, with the heavy-duty shelving rack 40, for example, intermediate horizontal tubes 43 (i.e., tubes 43 other than the top-most and bottom-most tubes 43) may be connected to vertical posts 42 using thumbscrew 70 with serrated edges 71, which mates with inverted flange nut 72 having hexagon-shaped neck 73. For this purpose, the bottom of posts 42 may include internal extending flange 42c with aperture 42c, for accepting thumbscrew 70, Referring now to FIGS. 19A-19B, heavy duty shelving racks 40 may be located side-by-side, as shown. For this purpose, large U-shaped connector 80 may be inserted into adjacent apertures/cutouts 42d located at the upper ends of posts 42, to retain racks 40 together when placed side-by-side.

[0075] Referring now to FIG. 20 and to U.S. Pat. No. 10,806,257, the dropped pin connection shown there (see joint pin 23 shown in FIG. 4 of the '257 patent, and described at 4:30-41) may also be preferably employed in the two shelving rack examples shown in FIGS. 1 and 4. Thus, referring to FIG. 20, dropped pin 68 may be used to connect cross members 12/44 to horizontal tubes 13/43, respectively. Wire shelving 17 may be attached as shown. Flange F on cross-member 12/441 may be attached to post P as shown.

[0076] Referring to FIGS. 21-22, to further differentiate the shelving assemblies, vertical posts P carry keyholes with different shapes which may be used, such as keyholes KHa with a curved top portion and keyholes KHb with a flat top portion. With either keyhole, similar-shaped rivets may be used for engagement.

[0077] The above description is not intended to limit the meaning of the words used in the following claims that define the invention. Persons of ordinary skill in the art will understand that a variety of other designs still falling within the scope of the following claims may be envisioned and used. It is contemplated that these additional examples, as well as future modifications in structure, function, or result to that disclosed here, will exist that are not substantial changes to what is claimed here, and that all such insubstantial changes in what is claimed are intended to be covered by the claims.