Abstract
A collapsible rack assembly includes a vertical support; a first elongated shelf having a first midpoint region, a rail extending therefrom, and a first end perpendicular to the rail; and a second elongated shelf including a second midpoint region having a notch apparatus. The vertical support is structured to extend between and support the first and second elongated shelves when the collapsible rack assembly is in an ASSEMBLED position. The notch apparatus is configured to receive the first end in order to allow the first elongated shelf to nest within the second elongated shelf when the collapsible rack assembly is in a COLLAPSED position.
Claims
1. A collapsible rack assembly comprising: a plurality of elongated shelves, each elongated shelf having a first side, a second side, a first end, a second end, a top side, and a bottom side and comprising: a first side midpoint region disposed between a pair of first side corner regions, a second side midpoint region disposed between a pair of second side corner regions, a first sleeve disposed at the first side midpoint region, a second sleeve disposed at the second side midpoint region, a midline rail extending from the first sleeve to the second sleeve; and at least one vertical support structured to extend between and support the plurality of elongated shelves when the collapsible rack assembly is in an assembled position.
2. The collapsible rack assembly according to claim 1, wherein each midline rail has a top side rail and a bottom side rail, each having ends connected to the first sleeve and the second sleeve.
3. The collapsible rack assembly according to claim 2, wherein the bottom side rail of the midline rail includes a pair of first notches defined between the first sleeve and the second sleeve.
4. The collapsible rack assembly according to claim 3, wherein each first notch is formed by a first segment coupled at a first obtuse angle with a second segment, the second segment coupled at a second obtuse angle with a third segment, the third segment coupled to one of the first sleeve or the second sleeve.
5. The collapsible rack assembly according to claim 3, wherein each of the plurality of elongated shelves further comprises a plurality of end members extending from at least one of the first sleeve or the second sleeve in opposing directions and perpendicular to the midline member.
6. The collapsible rack assembly according to claim 5, wherein at least one of the first notches of a first elongated shelf of the plurality of elongated shelves is configured to allow at least one of the plurality of end members of another elongated shelf to nest within the first elongated shelf when the collapsible rack assembly is in a collapsed position.
7. The collapsible rack assembly according to claim 5, wherein each corner region has a second notch, the second notches being aligned with a corresponding first notch.
8. The collapsible rack assembly according to claim 6, wherein each second notch is formed by a third segment coupled at a third obtuse angle with a fourth segment, the fourth segment coupled at a fourth obtuse angle with a fifth segment, the fifth segment coupled at a fifth obtuse angle with a sixth segment, the sixth segment coupled to one end member at least one of the pair of first end members or the pair second end members.
9. The collapsible rack assembly according to claim 5, further comprising a third elongated shelf of the plurality of elongated shelves, the third elongated shelf comprising a plurality of adjustable feet disposed in the corner regions.
10. A collapsible rack assembly comprising: a plurality of elongated shelves, each elongated shelf having a first side, a second side, a first end, a second end, a top side configured to be a level support surface, and a bottom side and comprising: a first side midpoint region disposed between a pair of first side corner regions, a pair of first end rails coupling the first side midpoint region to the first side corner regions and extending downward from the top side, and a midline rail extending downward from the top side, extending from the first side midpoint region, and defining a pair of first notches; at least one vertical support structured to extend between and support the plurality of elongated shelves when the collapsible rack assembly is in an assembled position, wherein the pair of first notches of a first elongated shelf of the plurality of elongated shelves is configured to allow at least one of the first end rails of another elongated shelf to nest within the first elongated shelf when the collapsible rack assembly is in a collapsed position.
11. The collapsible rack assembly according to claim 10, wherein each midline rail has a top side rail and a bottom side rail, each having ends configured to detachably couple to the at least one vertical support.
12. The collapsible rack assembly according to claim 11, further comprising a pair of side rails defining the first side and the second side and defining pairs of second notches disposed between the first end and the second end.
13. The collapsible rack assembly according to claim 12, wherein each side rail has a top side rail and a bottom side rail, and each side rail is connected to the pair of first end rails.
14. The collapsible rack assembly according to claim 13, wherein the pair of first end rails extends perpendicular to the midline rail.
15. The collapsible rack assembly according to claim 11, further comprising: a second side midpoint region disposed on an opposing side of the midline rail from the first side midpoint region and coupled to a pair of second end rails, a first sleeve disposed at the first side midpoint region; and a second sleeve disposed at the second side midpoint region.
16. The collapsible rack assembly according to claim 15, wherein each first notch is formed by a first segment coupled at a first obtuse angle with a second segment, the second segment coupled at a second obtuse angle with a third segment, the third segment coupled to one of the first sleeve or the second sleeve.
17. The collapsible rack assembly according to claim 14, wherein each second notch is formed by a third segment coupled at a third obtuse angle with a fourth segment, the fourth segment coupled at a fourth obtuse angle with a fifth segment, the fifth segment coupled at a fifth obtuse angle with a sixth segment, the sixth segment coupled to one end rail at least one of the pair of first end rails or the pair second end rails.
18. A collapsible rack assembly comprising: a plurality of elongated shelves, each elongated shelf having a first side, a second side, a first end, a second end, a top side, and a bottom side and comprising: a first side rail defining the first side and extending from the top side, a second side rail defining the second side and extending from the top side, a midline rail disposed between the first side rail and the second side rail and extending from the top side such that a pair of channels are defined on the bottom side between the first side rail and the second side rail, wherein each of the first side rail, the second side rail, and the third side rail have a pair of notches disposed between the first end and the second end, a first sleeve disposed at the first end of the midline rail, and a second sleeve disposed at the second end of the midline rail.
19. The collapsible rack assembly according to claim 18, wherein the pairs of notches of a first elongated shelf of the plurality of elongated shelves is configured to allow at least one of the first end or the second end of another elongated shelf to nest within the first elongated shelf when the collapsible rack assembly is in a collapsed position.
20. The collapsible rack assembly according to claim 19, wherein the first end and the second end are defined by at least one of the first sleeve or the second sleeve and a plurality of end members extending from first sleeve or the second sleeve toward at least one of the first side rail or the second side rail, the end members extending from the top side.
Description
DESCRIPTION OF THE DRAWINGS
[0008] These features and others will become more apparent when read in conjunction with the following Figures, in which:
[0009] FIG. 1 is a partially exploded front isometric view of a rack assembly, shown with features in phantom line drawing, in accordance with one non-limiting embodiment of the disclosed concept;
[0010] FIGS. 2-4 are top plan, side, and front views, respectively, of an elongated shelf for the rack assembly of FIG. 1;
[0011] FIG. 5 is an enlarged view of a portion of the front view of the elongated shelf of FIG. 4;
[0012] FIGS. 6-8 show different exploded views of portions of the rack assembly between ASSEMBLED and COLLAPSED positions;
[0013] FIGS. 9 and 10 show isometric and front views of elongated shelves for the rack assembly of FIG. 1 in a COLLAPSED position;
[0014] FIG. 11A is an isometric view of a rack assembly, shown in an ASSEMBLED position, in accordance with another non-limiting embodiment of the disclosed concept;
[0015] FIG. 11B is a front view of an elongated shelf for the rack assembly of FIG. 11A;
[0016] FIG. 12 is an isometric view of a rack assembly in an ASSEMBLED position, shown partially exploded, in accordance with another non-limiting embodiment of the disclosed concept;
[0017] FIG. 13 is an exploded isometric view of a portion of the rack assembly of FIG. 12;
[0018] FIGS. 14 and 15 are enlarged views of portions of the rack assembly of FIG. 13;
[0019] FIGS. 16 and 17 are enlarged views of portions of other rack assemblies, in accordance with other non-limiting embodiments of the disclosed concept;
[0020] FIGS. 18-21 show exploded and assembled views of different orientations of multiple rack assemblies and elongated shelves, in accordance with other non-limiting embodiments of the disclosed concept;
[0021] FIG. 22 is an isometric view of another elongated shelf for a rack assembly, in accordance with another non-limiting embodiment of the disclosed concept;
[0022] FIG. 23A shows an exploded isometric view of a portion of another rack assembly, in accordance with another non-limiting embodiment of the disclosed concept;
[0023] FIGS. 23B and 23C are different enlarged views of the portion of FIG. 23A;
[0024] FIG. 24 is an assembled isometric view of a portion of another rack assembly, in accordance with another non-limiting embodiment of the disclosed concept;
[0025] FIG. 25 is an isometric view of another elongated shelf, in accordance with yet a further embodiment of the disclosed concept;
[0026] FIG. 26 is an exploded view of another rack assembly, in accordance with another non-limiting embodiment of the disclosed concept;
[0027] FIGS. 27 and 28 are different views of portions of the rack assembly of FIG. 26, shown in a partially collapsed position;
[0028] FIG. 29 is an enlarged view of a portion of the rack assembly of FIG. 26;
[0029] FIGS. 30 and 31 are different top plan views of portions of the rack assembly of FIG. 26; and
[0030] FIG. 32 shows the rack assembly of FIG. 26 in a COLLAPSED position;
[0031] FIG. 33 is an isometric view of a rack assembly, shown in an ASSEMBLED position, in accordance with another non-limiting embodiment of the disclosed concept;
[0032] FIG. 34 is an exploded isometric view of a portion of the rack assembly of FIG. 33;
[0033] FIG. 35 is a side view of a portion of the rack assembly of FIG. 33;
[0034] FIG. 36 is an enlarged view of a portion of the rack assembly of FIG. 35;
[0035] FIG. 37 is an exploded view of another rack assembly, in accordance with another non-limiting embodiment of the disclosed concept;
[0036] FIG. 38 is a view of portions of the rack assembly of FIG. 37, shown in COLLAPSED position;
[0037] FIGS. 39, 40A-40B and 41 are top plan, side and cross-sectional, and front views, respectively, of an elongated shelf for the rack assembly of FIG. 38;
[0038] FIGS. 42A and 42B are enlarged views of a portion of the side and cross-sectional views of the elongated shelf of FIGS. 40A and 40B;
[0039] FIG. 43 is an isometric view of a rack assembly, shown in an ASSEMBLED position, in accordance with another non-limiting embodiment of the disclosed concept;
[0040] FIG. 44 is an exploded isometric view of a portion of the rack assembly of FIG. 43; and
[0041] FIG. 45 is a side view of the rack assembly of FIG. 43.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Reference to terms such as left, right, top, bottom, front and back are intended for use in respect to the orientation of the particular feature, structure, or element within the figures depicting embodiments of the invention. It would be evident that such directional terminology with respect to the actual use of a device has no specific meaning as the device can be employed in a multiplicity of orientations by the user or users.
[0043] The description of elements in each figure may refer to elements of proceeding figures. Like numbers refer to like elements in all figures, including alternate embodiments of like elements.
[0044] FIG. 1 shows a portion of a rack assembly 2, that beneficially is collapsible into a compact package for shipping purposes. Rack assembly 2 is useful for storing items in a home, office, garage, warehouse, or other facility. In certain examples, a wire decking rack assembly such as is depicted is frequently referred to as a baker's rack. As shown, rack assembly 2 includes a plurality of vertical supports 4,5,6,7 (shown in phantom line drawing), a plurality of press fit members (two members 10,11 are indicated), and a plurality of elongated shelves or racks 20,40,60,80 (see FIGS. 6 and 7 for shelf 80). Vertical supports 4,5,6,7, in certain examples, are elongated tubular members (or rods, columns, etc.) that may be formed with a plurality of annular notches spaced evenly along a length of each vertical support 104. Press fit members, e.g., wedge shaped plastic sleeves 10,11, are configured to engage one of the annular notches and position and secure the elongated shelves 20,40,60,80 to vertical supports 4,5,6,7. Additionally, in one example embodiment, vertical supports 4,5,6,7 and elongated shelves 20,40,60,80 are metallic.
[0045] Vertical supports 4,5,6,7 may each comprise a plurality of vertical members, or may be one unitary member made from a single piece of material (e.g., metal). They are structured to extend between and support elongated shelves 20,40,60,80 when rack assembly 2 is in an ASSEMBLED position. Moreover, for purposes that will be apparent below, each of elongated shelves 20,40,60,80 are preferably structured the same.
[0046] Referring to FIGS. 2-5, elongated shelf 20 includes a corner region 22, a sleeve member 23, and a rail 24 extending from sleeve member 23 (or similar mount) of corner region 22. Additionally, it will be appreciated that press fit members 10,11 are configured to be coupled to one another, be disposed within sleeve member 23, and receive vertical support 6 in order to secure vertical support 6 within sleeve member 23 in a press fit manner.
[0047] As shown in FIG. 4, corner region 22 further has a notch apparatus in the form of a bent rail 26. Bent rail 26 is advantageously structured to receive a rail of one of elongated shelves 40,60,80, such as by forming or creating a notch or inset (such as where a rail or other portion of another shelf is located in the inset or notch created by the bent rail 26, extending generally transverse or perpendicular thereto) in order to allow elongated shelf 20 to nest within the other elongated shelf 40,60,80 when the collapsible rack assembly 2 is in a COLLAPSED position. This aspect of rack assembly 2 advantageously allows for improved space savings, as compared to known rack assemblies. In this manner, manufacturers will be able to ship more rack assemblies in transit and store owners will be able to stack more collapsed rack assemblies on shelves, to name a few of the advantages. This improvement in the flow of commerce translates into a cost savings for the parties involved.
[0048] Referring to FIG. 5, bent rail 26 preferably includes a first segment 30, a second segment 31 parallel to the first segment 30, and a third segment 32 connecting the first and second segments 30,31. As shown, the third segment 32 extends at an angle 33 greater than ninety degrees from the first segment 30. This construction allows for the aforementioned nesting capability, as will be appreciated below.
[0049] Additionally, as shown in FIG. 4, elongated shelf 20 further has another corner region 27 located opposite corner region 22 and having a notch apparatus in the form of a bent rail 28 which is symmetric to the bent rail 26 of corner region 22. It will be appreciated that the other end of elongated shelf 20 has symmetric bent rails as well, which simplifies orienting rack assembly 2 in the COLLAPSED position.
[0050] As shown in FIGS. 6-10, elongated shelves 40,60 may be sandwiched between elongated shelves 20,80 when rack assembly 2 is in a COLLAPSED state. This is shown most clearly in FIG. 9, although since all elongated shelves 20,40,60,80 are preferably structured the same, it will be appreciated that the numbering of shelves are interchangeable. As shown in FIG. 9, rail 44 of elongated shelf 40 is nested within notch apparatus (e.g., bent rail 26) of elongated shelf 20. This translates into a significant space savings. More specifically, and referring to FIG. 10, elongated shelves 40,60 are structured to nest within elongated shelves 20,80 in the COLLAPSED position such that a combined height H1 of elongated shelves 20,40,60,80, when nested, is less than a combined height 4*H2 of elongated shelves 20,40,60,80, individually, where H2 is the height of each of elongated shelves 20,40,60,80 individually.
[0051] FIG. 11A shows another collapsible rack assembly 102, in accordance with another non-limiting embodiment of the disclosed concept, wherein like numbers represent like features. FIG. 11B shows a front view of elongated shelf 120. It will be appreciated with reference to FIG. 11B that corner region 122 has a cutout and the notch apparatus is in the form of an insert 126 coupled to the rack, such as the wire frame that forms a cutout. Insert 126 may be made of a different material than the rest of elongated shelf 120. As shown, insert 126 has a groove (or inset or notch) 130 for receiving a rail of elongated shelf 140 in a similar manner in which bent rail 26 (FIG. 9) of elongated shelf 20 (FIG. 9) received rail 44 (FIG. 9) of elongated shelf 40 (FIG. 9). Accordingly, stacking advantages discussed above with reference to rack assembly 2 also apply to rack assembly 102.
[0052] FIG. 12 shows another rack assembly 202 in accordance with another embodiment of the disclosed concept, wherein like reference numbers represent like features. FIG. 13 shows an exploded view of a portion of the rack assembly 202 of FIG. 12. As shown, elongated shelf 220 has an end 222 with opposing corner regions 224,226 that each have a corresponding opening 225,227. Additionally, rack assembly further has a pair of end caps 235,245 coupled to elongated shelf 220 (see also end caps 255,256,265,266,275,276,285,286 in FIG. 12 for elongated shelves 250,260,270,280). In one example embodiment, elongated shelves 220,250,260,270,280, vertical supports 204,205,206,207, and end caps 235,245,255,256,265,266,275,276,285,286 are all metallic.
[0053] Each of elongated shelves 220,250,260,270,280 is configured to couple with end caps 235,245,255,256,265,266,275,276,285,286 in order to reduce an overall footprint. In particular, the removable end caps allow for the vertical supports to be stacked on the elongated shelves when packaged, and reduce the overall height of the packaging, and allowing for more packaged rack assemblies 202 to be shipped in a shipping container.
[0054] As shown in FIG. 12, end cap 235 has first and second thru holes 236,237 that are each aligned with a corresponding opening 225,227 of elongated shelf 220 and configured to receive vertical supports 206,207. It will be appreciated that end cap 245 likewise receives vertical supports 204,205 in a similar manner. Also shown in FIG. 12, end cap 235 has a thru hole 238 (and another thru hole disposed proximate thru hole 236) located proximate thru hole 237. Rack assembly 202 further has a pair of fasteners (e.g., without limitation, one set screw 244 is indicated) configured to extend through a corresponding one of the thru holes 238 (and the other opposing thru hole, not shown) of end cap 235 and be located proximate the vertical supports 206,207 in order to more securely maintain rack assembly 202 in an ASSEMBLED position.
[0055] Referring to FIGS. 14 and 15, rack assembly 202 further includes a number of inserts 240,246 each coupled to the vertical supports 206,207. In one example embodiment, the inserts 240,246 are each coupled to an interior of the vertical supports 206,207. Insert 240 may be a cap that is located at a top of the rack assembly 202 when rack assembly 202 is in an ASSEMBLED position and disposed on a horizontal ground. See, for example, FIG. 12. Three other inserts are also shown in this FIG., but only insert 240 is indicated. Insert 240, and the other three inserts, may function to provide surfaces for a table to advantageously be formed on rack assembly 202. Additionally, as shown in FIG. 14, insert 240 has a number of ridges 241-1,241-2,241-3 that may be configured to be located in corresponding grooves of vertical support 206 in order to maintain insert 240 in a fixed position within vertical support 206. As insert 240 functions to provide a top of rack assembly 202, insert 246 shown in FIG. 15 functions to provide a foot for rack assembly 202, so that it can more stably be positioned in an upright manner when in an ASSEMBLED position and located on a horizontal ground. As shown in FIG. 12A, three other feet (not labeled) are also provided with rack assembly 202. Continuing to refer to FIG. 15, an externally threaded sleeve 247 may be provided in order to more securely couple insert 246 to vertical support 207.
[0056] An insert 342,442 may also be threadably coupled to an interior of a vertical support 306,406-1,406-2, as shown in FIGS. 16 and 17. In the case of the embodiment of FIG. 16, insert 342, which functions as a top, is relatively securely coupled by virtue of the threads. Regarding the embodiment of the rack assembly of FIG. 17, insert 442 advantageously allows for segment 406-1 of the vertical support to be more stably connected to segment 406-2, where before they might only have been maintained at such a joint via a press fit connection.
[0057] FIGS. 18 and 19 show assembled and exploded views, respectively, of rack assemblies 502 and an elongated shelf 520 configured to be coupled in order for more versatile applications to be provided, such as further storage capabilities. FIGS. 20 and 21 show assembled and exploded views, respectively, of rack assemblies 502 and an elongated shelf 520 configured to be coupled in order for more versatile applications to be provided, such as further storage capabilities. In some configurations, connectors, such as fasteners, may be used to join the shelves 520 and/or racks 502. For example, one or more apertures may be provided in the end caps 245 (see FIG. 13), whereby aligned end caps (such as placed side by side or end to end) may be joined, such as with one or more fasteners (such as a nut/bolt, etc.)
[0058] FIG. 22 shows an isometric view of another elongated shelf 620. As shown, the elongated shelf 620 includes a first half portion 621, a second half portion 623, and an elongated sleeve 625 for connecting the first and second half portions 621,623. Accordingly, it will be appreciated that yet an even greater space savings can be afforded for rack assemblies including elongated shelves structured the same as elongated shelf 620, in that different portions 621,623 can be overlaid on top of one another in order to further reduce the footprint of a corresponding rack assembly.
[0059] FIG. 23A shows a portion of another rack assembly 702, wherein like reference numbers represent like features. As shown, end cap 735 has an aperture 738 disposed proximate thru hole 737, and a further aperture disposed on an opposing side (not shown). Referring to FIGS. 23B and 23C, elongated shelf 720 has a number of plates 740,741,742 coupled to corner region 726. Plate 742 has a push pin 743 extending outwardly therefrom and being biased away from elongated shelf 720. Push pin 743 is configured to extend through thru holes of plates 740,741, which are securely maintained on corner region 726 by engaging and being disposed between opposing wires of corner region 726. Furthermore, it will be appreciated that push pin 743 is configured to extend through aperture 738 of end cap 735 in order to securely maintain and connect end cap 735 with elongated shelf 720. Opposing corner region 724 (FIG. 23A) and end cap 745 (FIG. 23A) are similarly structured and coupled in this pin to aperture manner, and so are other end caps and elongated shelves of rack assembly 702 (not shown). Accordingly, if end cap 735 is caused to slide with respect to elongated shelf 720, the engagement between push pin 743 and plates 740,741 advantageously prevents decoupling.
[0060] FIG. 24 shows yet a further embodiment of the disclosed concept, wherein a portion of a rack assembly 802 is shown. As shown, rack assembly 802 has an elongated shelf 820 which is devoid of notches proximate end portions that couple to end capssuch as by not including an end rail at all, but wherein the end cap forms the end portion of the rack.
[0061] In one configuration, as illustrated in FIG. 25, the elongated shelf 920 may define having cutout portions proximate corner regions 922,924,926,928, which regions accept the end caps, including the associated sleeves. The resulting reduced thickness, as discussed above, advantageously allows elongated shelf 920 to be shipped with a reduced footprint, and may allow end caps to either be fixedly attached thereto, or otherwise be connected thereto during shipping and shelving.
[0062] One aspect of this version of the invention is that elongated shelf 820 and other elongated shelves of rack assembly 802 can be stacked with a minimal footprint. Additionally, because of the reduced thickness proximate end portions of elongated shelf 820, end caps may be able to be fixedly attached to end portions, or otherwise connected while elongated shelf 820 is being shipped, thereby saving assembly time downstream. For example, in one packing configuration, the end caps are removed from a first rack, allowing it to be placed between second and third racks having the end caps attached thereto (wherein the reduced thickness of the first rack allows it to be placed between the second and third racks without an increase in stack dimension due to the space between the second and third racks created because of the increased dimension of the end cap/sleeves of the second and third racks).
[0063] In particular, FIG. 26 shows an exploded view of another rack assembly 1002, which includes vertical supports 1004-1,1005-1,1006-1,1007-1,1004-2,1005-2,1006-2,1007-2, elongated shelves 1020,1040,1060,1080,1090, and end caps 1025,1026,1085, 1086,1095, 1096. FIGS. 27 and 28 show different partially exploded views of the rack assembly 1002. As will be appreciated below, rack assembly 1002 is configured to collapse in a relatively ergonomic manner. FIGS. 29-31 show different views of portions of the rack assembly of FIG. 26, and FIG. 32 shows an isometric view of rack assembly 1002 in a COLLAPSED position. As shown, the vertical supports (shown but not labeled) are enclosed by the elongated shelves 1020, 1080,1090 without any being sacrificed, as can be appreciated by viewing the end caps. As shown, with two end caps 1085,1095 removed and coupled externally, all of the elongated shelves (e.g., including shelves 1040,1060 from FIG. 26, which fit between shelves 1020,1080) can fit in the collapsed assembly. Additionally, as shown in FIGS. 29-31, the collars of end caps 1086 have notches in order to allow the shelves that have the removed end caps (e.g., end caps 1085,1095, see FIG. 32) to be slid into the notch a predetermined distance, so that the side rails fit into the slot in the collar of the end cap of the shelf above it. It will be appreciated that the two collars of end cap 1086 and the two collars of end cap 1096 have such notches, as shown in FIG. 32. In one embodiment, utilizing this notched collar configuration, the shelves that have the removed end caps need to only be slid over or offset by 0.25 to align the side rails into the notches, thus facilitating nearly aligned stacking of the shelves, but at the same time allowing the shelves without the end caps to be located in between the pairs of shelves with the end caps (this 0.25 inch offset is much smaller than other stacking configurations, such as the configuration where a notch is located in the wire of the decking or in an insert adjacent to the collar, in versions described above, and is much less in stacking height as compared to existing prior art where the shelves are directly placed on top of one another).
[0064] As illustrated in FIG. 1, in one configuration the sleeves 23 may extend upwardly above and downwardly below a top and/or bottom of the shelf. However, in other embodiments, the top and/or bottom of the sleeve (such as integrated into the end cap) might be generally flush with the top (and/or bottom) thereof, such as illustrated in FIGS. 24-25, and also in FIG. 13 (and whereby the cap or insert 240 (see FIG. 14) may merely be used to close the opening in the end cap or sleeve, with the top of the cap being generally flush with the top of the end cap.
[0065] FIG. 24 also illustrates how the rail portions of the shelf, such as the side rails (but also the end rails, as in the configuration illustrated in FIG. 1) may be solid rails, rather than formed from wires (such as parallel wires with an intermedia Z-wire).
[0066] As indicated above, the end caps may be generally permanently mounted to one or more of the shelves, but in other embodiments, they may be removably attached, such as to for shipping and storage. In such a configuration the end caps might be connected to the shelf by one or more fasteners (nuts/bolts, push-pins, etc.)
[0067] FIGS. 33 and 34 show another collapsible rack assembly 1102, in accordance with another non-limiting embodiment of the disclosed concept, wherein like numbers represent like features. Collapsible rack assembly 1102 may comprise similar features as previously disclosed rack assemblies, such as end caps, inserts, sleeves, elongated sleeves, solid rails, cutouts, etc. It should be appreciated that, for brevity, such features may not be repeated or may not be repeated below in as much detail, but these features are also compatible with the rack assembly 1102. Collapsible rack assembly 1102 comprises a plurality of vertical supports 1104,1106, a plurality of press fit members 1110,1111, and a plurality of elongated shelves or racks 1120,1140,1160,1180. Vertical supports 1104,1106, in certain examples, are like vertical supports 4,5,6,7. Press fit members 1110,1111, in certain examples, are like press fit members 10,11. Elongated shelves 1120,1140,1160,1180 are like elongated shelves 20,40,60,80.
[0068] With reference to FIGS. 39-42B, elongated shelf 1120 may have rail and notch features similar to those of elongated shelf 20. However, elongated shelf 1120 comprises sleeve members 1123 located at a midpoint region 1121 of rack 120 rather than a corner region 1122. Elongated shelf 1120 may comprise a midpoint region 1121, a sleeve member 1123 disposed at the midpoint region 1121, and a midline rail 1124 extending from sleeve member 1123. Midline rail 1124 may extend from a top side of elongated shelf 1120. Additionally, it will be appreciated that press fit members 1110,1111 are configured to be coupled to one another, be disposed within sleeve member 1123, and receive vertical support 1106 in order to secure vertical support 1106 within sleeve member 1123 in a press fit manner. Elongated shelf 1120 may comprise corner regions 1122 formed by perpendicular rails 1125,1135. Rails 1125,1135 may be coupled to each other to form corner regions 1122.
[0069] While generally referred to as side rails 1125 (or rails 1125), rails 1125 may comprise side rails 1125a, 1125b (see FIG. 39). Rail 1125a may extend along a first side of elongated shelf 1125. Rail 1125b may extend along a second side of elongated shelf 1120.
[0070] While generally referred to as end rails 1135 (or rails 1135, end members 1135), rails 1135 may comprise end rails 1135a,1135b. End rail 1135a may extend from sleeve 1123 toward a first side of elongated shelf 1120. End rail 1135b may extend from sleeve 1123 toward a second side of elongated shelf 1125. Rails 1135 and sleeves 1123 may define a first end or a second end of elongated shelf 1120.
[0071] Each of rails 1124,1125,1135 may extend from a top side of elongated shelf 1120. The top side of elongated shelf 1120 may comprise a wire decking forming a level support surface. For example, and with brief reference to FIG. 43, elongated shelves 1120,1220 may form level support surfaces for tools, bins, etc. In this manner, rails 1124, 1125,1135 may form the perimeter of gaps, or channels, defining a bottom side of elongated shelf 1120.
[0072] A cross-section of elongated shelf 1120 is shown in FIG. 40B. More specifically, a side view of midline rail 1121 is illustrated. Midline rail 1121 may have a top side rail 1161 and a bottom side rail 1162. Midline rail 1121 may have a notch apparatus in bottom side rail 1162 in the form of a bent rail 1126. Bent rail 1126 is advantageously structured to receive a rail of one of elongated shelves 1140,1160,1180, such as by forming or creating a notch or inset (such as where a rail or other portion of another shelf is located in the inset or notch created by the bent rail 1126, extending generally transverse or perpendicular thereto) in order to allow elongated shelf 1120 to nest within the other elongated shelf 1140,1160,1180 when the collapsible rack assembly 1102 is in a COLLAPSED position.
[0073] Referring to FIG. 42B, bent rail 1126 preferably includes a first segment 1130, a second segment 1131 parallel to the first segment 1130, and a third segment 1132 connecting the first and second segments 1130,1131. As shown, the third segment 1132 extends at an angle 1133 greater than ninety degrees from the first segment 1130. This construction allows for the aforementioned nesting capability, as will be appreciated below.
[0074] Additionally, as shown in FIG. 40B, elongated shelf 1120 further has another midpoint region 1141 located opposite midpoint region 1121 and having a notch apparatus in the form of a bent rail 1146 which is symmetric to the bent rail 1126 of midpoint region 1121. It will be appreciated that the other end of elongated shelf 1120 has symmetric bent rails as well, which simplifies orienting rack assembly 1102 in the COLLAPSED position.
[0075] A side view of the length of elongated shelf 1120 is shown in FIG. 40A. More specifically, a side view of side rail 1125 is illustrated. Side rail 1125 may have a top side rail 1163 and a bottom side rail 1164. Side rail 1125 may have a second notch apparatus in bottom side rails 1164 in the form of a bent rail 1136. Bent rail 1136 is advantageously structured to receive a rail of one of elongated shelves 1140,1160,1180, such as by forming or creating a notch or inset (such as where a rail or other portion of another shelf is located in the inset or notch created by the bent rail 1136, extending generally transverse or perpendicular thereto) in order to allow elongated shelf 1120 to nest within the other elongated shelf 1140,1160,1180 when the collapsible rack assembly 1102 is in a COLLAPSED position.
[0076] Referring to FIG. 43A, bent rail 1136 preferably includes a first segment 1150, a second segment 1151 parallel to the first segment 1150, and a third segment 1152 connecting the first and second segments 1150,1151. As shown, the third segment 1152 extends at an angle 1153 greater than ninety degrees from the first segment 1150. Bent rail 1136 preferably includes a fourth segment 1156 and a fifth segment 1154 connecting the second and fourth segments 1151,1156. As shown, the fifth segment 1154 extends at an angle 1155 greater than ninety degrees from the fourth segment 1156. This construction allows for the aforementioned nesting capability, as will be appreciated below.
[0077] Additionally, as shown in FIGS. 39 and 40A, elongated shelf 1120 further has another corner region 1142 located opposite corner region 1122 and having a notch apparatus in the form of a bent rail 1148 which is symmetric to the bent rail 1136 of corner region 1122. It will be appreciated that the other end of elongated shelf 1120 has symmetric bent rails as well, which simplifies orienting rack assembly 1102 in the COLLAPSED position.
[0078] In the embodiment described, the bent rails 1136,1126 and 1136 at one end of the rack 1102 are aligned transversely (from the front to the back of the shelf) and the bent rails 1148, 1146,1148 at the other end of the rack 1102 are also aligned transversely, allowing those sets of aligned bent rails to accept an elongate (and linear) element in the notches formed thereby, and particularly, rail portions of another shelf.
[0079] FIG. 34 shows an exploded isometric view of a portion of the collapsible rack assembly 1102, wherein like reference numbers represent like features. As shown, elongated shelf 1180 has an end 1222 with opposing corner regions 1224, 1226 and a midpoint region 1221. Midpoint region 1221 has an opening 1225. Collapsible rack assembly 1102 may have end caps (not shown) similar to end caps 235,245,255,256,265,266,275,276,285,286.
[0080] While in some embodiments the bottom end of the vertical supports 1104,1106 might simply press-fit into the sleeves 1123 of the bottom shelf 1180, in other embodiments, they may be fastened thereto, such as to prevent them from disconnecting from the sleeves 1123 due offset loading or the like. In one embodiment, collapsible rack assembly 1102 may have a number of inserts 1240,1246 each coupled to the vertical supports 1104,1106. In one example embodiment, the inserts 1240,1246 are each coupled to an interior of the vertical supports 1104,1106, such as where the inserts 1240,1246 each have a threaded stud which extends upwardly to engage a threaded aperture in an insert or other portion of the vertical support 1104,1106. In one embodiment, the user might rotate the inserts 1240,1246 to couple them with the vertical supports 1104,1106, and in others, might turn an exposed head of the fastener (such as located at the bottom of the insert) to so connect them. In other embodiments, the inserts 1240,1246 might be connected to the vertical supports 1104,1106 in other fashions. For example, the exterior of the body of the inserts might be threaded for engagement with threads on the interior of the vertical supports 1104,1106 (or vice versa). In yet other embodiments, the vertical support 1104,1106 might be directly connected to the sleeves 1123 (such as by a fastener which extends through wall of the sleeve 1123 into engagement with the vertical support), via threading engagement directly to the sleeve, etc. Inserts 1240,1246 may be caps located at a top or a bottom of the rack assembly 1102 when rack assembly 1102 is in an ASSEMBLED position and disposed on a horizontal ground. See for example, FIG. 33.
[0081] Inserts 1240,1246 may be disposed at a top of (see FIG. 35) rack assembly 1102 and may function to provide surfaces for a table to advantageously be formed on rack assembly 1102. Inserts 1240,1246 may couple to rack assembly 1102 in similar manners as inserts 240,342,442. For example, inserts 1240,1246 may be press fit inserts, notched inserts, threaded inserts, etc. As shown in FIGS. 34 and 35, inserts 1240,1246 function to provide a foot for rack assembly 1102, so that it can more stably be positioned in an upright manner when in an ASSEMBLED position and located on a horizontal ground. As shown in FIGS. 34 and 35, rack assembly may have corner support feet 1251,1252,1253,1254 disposed at each corner. While depicted for illustrative purposes in FIGS. 33 and 34 as casters, it should be appreciated that the corner support feet 1251,1252,1253,1254 may alternatively be fixed feet, as described in more detail below with respect to FIGS. 43 and 44. In one embodiment, sleeve-style inserts may be located at each corner, each of which may define an aperture for receiving a stem element of a corresponding foot. These inserts might be welded to the rack assembly 1202 (such as the bottom shelf 1180), such as at the corners thereof. Of course, the feet might be connected to the rack assembly 1202 in other manners (threading engagement, one or more fasteners, etc.)
[0082] FIG. 35 illustrates a cross-sectional side view of a portion of the rack assembly 1102. Elongated shelves 1120,1140,1160,1180 may be placed at various intervals along the height of rack assembly 1102. Elongated shelves 1120,1140,1160,1180 may be coupled to vertical supports 1104,1106 similarly to how elongated shelves 20,40,60,80 are secured to vertical supports 4,5,6,7. While illustrated as having four elongated shelves evenly spaced, it is understood that rack assembly 1102 may comprise any number of elongated shelves disposed at various and adjustable locations along vertical supports 1104,1106.
[0083] FIG. 36 is an enlarged view of a portion of the rack assembly 1102. Elongated shelf 1120 is secured at a first height along vertical support 1106. Press fit members 1110 and 1111, similar to press fit members 10,11 are configured to be coupled to one another, be disposed within sleeve member 1123, and receive vertical support 1106 in order to secure vertical support 1106 within sleeve member 1123 in a press fit manner.
[0084] As shown in FIGS. 37 and 38, elongated shelves 1140,1160 may be sandwiched between elongated shelves 1120,1180 when rack assembly 1102 is in a COLLAPSED state in a similar manner to elongated shelves 20,40,60,80 as illustrated in FIGS. 6-10. This is shown most clearly in FIG. 38, although since all elongated shelves 1120,1140,1160,1180 are preferably structured the same, it will be appreciated that the numbering of shelves are interchangeable. As shown in FIG. 38, rail 1144 of elongated shelf 1040 is nested within notch apparatuses (e.g., bent rails 1126, 1136) of elongated shelf 1120, by longitudinally and transversely offsetting, and inverting, alternating shelves. This translates into a significant space savings. More specifically, elongated shelves 1140,1160 are structured to nest within elongated shelves 1120,1180 in the COLLAPSED position such that a combined height H3 of elongated shelves 1120,1140,1160,1180, when nested, is less than a combined height 4*H4 of elongated shelves 1120,1140,1160,1180, individually, where H4 is the height of each of elongated shelves 1120,1140,1160,1180 individually.
[0085] As also illustrated in FIG. 38, the vertical supports 1104,1106 may comprise multiple connectable portions, where the lengths of those portions do not exceed the greatest dimension of the shelves 1120,1140, 1160,1180, allowing them to be packaged with the shelves (such as in the space between two or more of the shelves) without increasing the dimensions (height, width or length) of the disassembled rack beyond the dimensions of the stacked shelves.
[0086] FIG. 43 illustrates an isometric view of a rack assembly 1302, shown in an ASSEMBLED position, in accordance with another non-limiting embodiment of the disclosed concept, wherein like numbers represent like features. FIG. 44 illustrates an exploded isometric view of a portion of the rack assembly 1302. FIG. 45 illustrates a side view of the rack assembly of 1302.
[0087] As depicted in FIGS. 43-45, collapsible rack assembly 1302 may comprise similar features as previously disclosed rack assemblies, such as end caps, inserts, sleeves, elongated sleeves, solid rails, cutouts, etc. It should be appreciated that, for brevity, such features may not be repeated or may not be repeated below in as much detail, but these features are also compatible with the rack assembly 1302.
[0088] Rack assembly 1302 may be a compact version of rack assembly 1102. Rack assembly 1302 may have a more compact wire decking arrangement as compared to rack assembly 1302. Rack assembly 1302 may comprise three elongated shelves 1320,1340,1360 rather than four.
[0089] FIGS. 42-45 illustrate alternative corner support feet 1451,1452,1453,1454. Corner support feet 1451,1452,1453,1454 are fixed feet. Corner support feet 1451,1452,1453,1454 may be individually adjustable so as to assist in creating level shelves on slightly uneven or sloped ground. Corner support feet 1451,1452,1453,1454 may be threaded, have slots, or other adjustment mechanisms to iteratively or smoothly adjust a height of each foot. It should be appreciated that corner support feet 1251,1252,1253,1254 are interchangeable between rack assemblies 1102 and 1302. Similarly, corner support feet 1451,1452,1453,1454 are interchangeable between rack assemblies 1102 and 1202.
[0090] Rack assembly 1302 may comprise inserts 1440,1446 similar to inserts 1240,1246. For illustrative purposes, inserts 1440,1446 are depicted as similar to insert 240 of FIG. 14. However, it should be understood that any insert disclosed herein is compatible with rack assembly 1302.
[0091] As illustrated in FIGS. 43-45, adjustable rack assembly 1202 may comprise at least one wall mount 1410 for securing at least one elongated shelf 1320,1340,1360 to a wall. It should be appreciated that wall mount 1410 is compatible with any of the previously described rack assemblies in addition to rack assembly 1202.
[0092] One advantage to the racks 1102,1302 just described is that the shelves may be supported by just two vertical supports, such as vertical supports 1104,1106 which are located at opposing ends of the rack and at the midpoint region of the shelves. The reduced number of vertical supports reduces the material cost for the rack, reduced the costs of shipping and storage due to the reduced weight and space occupied thereby, and reduces the complexity of assembly to a user. In one embodiment, the midline rail 1124 serves as a load beam for mass which is supported by the associated shelf, transmitting that load to the vertical supports 1104,1106 at each end thereof.
[0093] In the embodiment which is illustrated, notches are defined by bent rail sections 1136,1148 at the sides of the shelves. However, as indicated above relative to the embodiment illustrated in FIG. 1, the bent rail sections and notches could be located at the ends of the shelves. An advantage of locating the bent rails sections 1136,1148 at the sides of the shelves in this embodiment (where sleeves are not located at the corners as in the rack illustrated in FIG. 1) is that it allows the top and bottom side rails 1163,1164 to be joined (such as by a weld) at additional locations along the sides (near the corners in this example), which greatly increases the strength of the trussed front and rear sides of the shelves (in the embodiment illustrated in FIG. 1, this issue is addressed by having the top and bottom rails join to the corner-located sleeves). However, it is possible (such as for lighter load racks) for the rack assembly 1202 to utilize bend end rail sections which define notches (along with notches in the center or midline rail 1124) which again allows the shelves to be stack in a reduced height-dimension configuration similar to the rack assembly illustrated in FIG. 1.
[0094] This description uses examples to describe embodiments of the disclosure and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. For example, it will be appreciated that suitable alternative embodiments of the disclosed concept include elongated shelves have different aspects from any of the different aforementioned embodiments.
