Shelf system for elongated articles

A modular shelf system comprising: (i) at least two panels comprising a set of modular inserts of a predetermined size and shape, having holes disposed in said modular inserts; and (ii) means for maintaining said panels substantially parallel to one another at a predetermined distance apart, wherein said holes is dimensioned to accept a plurality of articles to be stored, in a substantially planer form even when placed under a load.

FIELD OF THE INVENTION

This invention relates to shelf systems, in particular shelf systems which are used to support, display and/or organize articles having a length substantially greater than their width or diameter. Such elongated articles include, but are not limited to, the following: construction materials, such as pipes, moldings, lumber, extrusions and the like; garden tools, such as rakes, hoes, shovels, picks and the like; and home cleaning tools, such as brooms, mops and the like.

DESCRIPTION OF THE RELATED ART

In any retail business, storage and display of merchandise and inventory is a fundamental concern. While it is usually desirable to maximize the exposure of merchandise and inventory to potential customers seeking to purchase, it is just as important to preserve and maintain the quality and integrity of such articles. Moreover, it is also important to ensure the most efficient use of space within the business. Similar considerations attach in other situations, including industrial settings, offices and homes and residences, where it is often necessary to store and/or organize articles.

These concerns are magnified in the case of elongated articles, i.e. items having a length substantially greater than their width or diameter. Such elongated articles include, but are not limited to, the following: construction materials, such as pipes, rods, moldings, extrusions, boards, dowels and the like; gardening tools, such as rakes, shovels, hoes and the like; household cleaning tools, such as mops, brooms and the like; office articles, such as rolled plans, spreadsheets, blueprints and the like; bolts of fabric; coils of fibers or wire; etc.

These elongated articles are, of course, too long to fit comfortably into any conventional drawer. Accordingly, these articles are generally stored by being stood on end in a corner or in a rack of some type, or by hanging them on a wall rack or a nail, or simply laying them in a pile on the floor. Each of these approaches has problems.

For example, if the articles are stood on end in a corner, then elongated articles with enlarged ends, such as rakes or brooms, will not fit well. If there are many articles, then they will look messy and will not be easily accessible or even viewable. It is also quite possible that the articles will get damaged, for example by rubbing or bumping against one another. Moreover, if unsupported, one or more articles may topple over and injure someone and/or damage the item(s). Articles stored vertically can also be damaged and/or cause damage or injury when being handled, for example when being removed for purchase.

Similarly, if piled on the floor, the articles will look messy and will not be easily accessible or even viewable. Also, to get an article at the bottom of the pile, one would need to disassemble and then reassemble the whole pile. It is also likely that one or more articles may get damaged in the pile. Moreover, articles stored in a pile, such as pipe and the like, can roll over and fall on someone.

If the articles are hung a hook or nail on the wall or ceiling, the items may still fall and possibly injure someone. Moreover, most construction materials, such as pipes, dowels, molding and the like, do not have a hole or similar recess to hold them on a hook or nail, or even a bulge to hold them between such supports.

Each of these proposed solutions, however, has one or problems which have limited their acceptance and/or use by the industry. Accordingly, there remains a need for a shelf system for supporting, displaying and/or organizing elongated articles.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the deficiencies of known and available racks and shelf systems. It is further an object of the present invention to provide a shelf system for supporting, displaying and/or organizing elongated items.

In accordance with these and other objects, a first embodiment of the present invention is directed to a shelf system comprising: (i) at least two modular panels of predetermined size and shape, each modular panel having a plurality of modular inserts, each insert having at least one hole, and (ii) means for maintaining said panels substantially parallel to one another at a predetermined distance apart, wherein each of the panels has a first surface and a second surface and an edge and contains a plurality of holes extending completely through the panel from the first surface to the second surface, wherein each of the plurality of holes is dimensioned to accept a plurality of articles to be stored, wherein each of the panels comprises a material having a bending modulus sufficient to maintain said panel in a substantially planer form even when placed under a load, and wherein the panels are arranged such that at least one hole on one of said panels is substantially aligned with at least one hole on the other of said panels.

A further embodiment of the present invention is directed to a shelf system comprising: (i) at least two modular panels of predetermined size and shape, each modular panel having a plurality of modular inserts, each insert having at least one hole, wherein each of the panels has a first surface and a second surface and an edge, wherein each edge contains at least one notch, (ii) rigid support members configured to receive said notch in said edge of said panels to maintain said panels substantially parallel to one another, and (iii) wherein each panel contains a plurality of holes extending completely through the panel from the first surface to the second surface, wherein each of the plurality of holes is dimensioned to accept a plurality of articles to be stored, wherein each of the panels comprises a material having a bending modulus sufficient to maintain said panel in a substantially planer form even when placed under a load, and wherein the panels are arranged such that at least one hole on one of said panels is substantially aligned with at least one hole on the other of said panels.

DETAILED DESCRIPTION OF THE FIGURES

As used herein the term “about” means within 10% of a stated number.

As used herein, terms such as “a,” “an,” and “the” include singular and plural referents unless the context clearly demands otherwise.

Referring now to the drawings,FIG. 1shows an exemplary panel10that may be used in the inventive shelf system. This exemplary panel is shown to have a substantially square shape, but any suitable shape may be employed including circles, ellipses and polygons. As shown inFIG. 1, the exemplary panel10has a first surface100and a second surface200and a plurality of edges301-304.

The exemplary panel10contains a plurality of holes1001-1009that extend completely through the panel10from the first surface100to the second surface200. The size of the panel(s) used in the inventive shelf system may be determined empirically depending, for example, on the number of holes desired and the width or diameter of the articles intended to be stored, displayed and/or organized.

Each of the plurality of holes1001-1009is dimensioned to accept a plurality of articles to be stored, displayed and/or organized. Each of the plurality of articles is an elongated article which has a length substantially greater than its width or diameter. Such elongated articles include, but are not limited to, the following: construction materials, such as pipes, moldings, lumber, extrusions and the like; garden tools, such as rakes, hoes, shovels, picks and the like; and home cleaning tools, such as brooms, mops and the like.

Each of the plurality of holes1001-1009is dimensioned to accept an elongated articles. Suitable diameter for each of the plurality of holes in any given panel in the present invention, such as holes1001-1009in exemplary panel10, is from about 1 mm to about 1000 mm, or about 10 mm to about 100 mm, or about 100 mm to about 500 mm, or about 10 mm to about 50 mm. The size of such hole may be determined empirically by one skilled in the art depending, for example, on the width or diameter of the articles intended to be stored, displayed and/or organized and the overall size of the panel.

The panels used in the inventive shelf system, such as the exemplary panel10shown inFIG. 1, may be made of any suitable material having a bending modulus sufficient to maintain the panel in a substantially planer form even when placed under a load. That is, the panels may be made of any material, or combination of materials, which does not bend or distort excessively when assembled into the inventive shelf system and a plurality of articles are placed in at least one of the plurality of holes. Illustrative examples of suitable materials for the panels include, but are not limited to, the following: woods, plastics, resins, polymers, metals, alloys, laminates, composites, fibers, papers and combinations of any two or more thereof. The panels in the inventive shelf system are all preferably made from the same material(s), although in certain embodiments they can be made from different materials. The panels may have a length and a width of about 4 inches to about 96 inches, or about 8 inches to about 48 inches, or about 8 inches to about 24 inches, or about 8 inches to about 16 inches. The panels may also be circular, elliptical, triangular, or polygonal in shape. The diameter of a circular or elliptical is about 4 inches to about 96 inches, and the length of any one side of a triangle or polygon is similar about 4 inches to about 96 inches.

FIG. 2shows an exemplary shelf system of the present invention, which has three panels10,11, and13and four substantially rigid members21-24as the means for maintaining said panels substantially parallel to one another at a predetermined distance apart. According to embodiments such as this, substantially rigid members21-24may be attached to either an edge or a surface of panels10,11by any suitable method.

Suitable methods for attaching substantially rigid members21-24to panels10,11may be determined empirically by one skilled in the art through routine experimentation. For example, substantially rigid members21-24may be attached to an edge301of panels10,11by use of a combination of bolts, washers and free nuts fastened through holes in substantially rigid members21-24aligned with holes in the edge(s) of panels10,11. Alternatively, substantially rigid members21-24may be attached to a surface of panels10,11by use of a bracket, with screws or bolts and nuts, or an adhesive, such as a glue or epoxy. Still other ways of attaching substantially rigid members21-24to panels10,11include, but are not limited to, one or more of the following: captured nuts in combination with bolts, nuts (free or captured) in combination with screws, screws, rivets, welding, glues, epoxys, resins, acrylates and the like.

Each of the methods of for attaching substantially rigid members21-24to panels10,11may be used alone or in combination with another way. For example, if substantially rigid members21-24are attached to a surface of panels10,11by a weld, a bracket with bolts and nuts may also be used to further strengthen the shelf system.

FIG. 2further shows the substantially rigid members21-24having a notch14, for securing to panels10,11, and13. Accordingly, the use of a notch14, at end of each substantially rigid member21-24aids in maintaining the panels substantially parallel to one another at a predetermined distance apart. These substantially rigid members21-24may be made of any suitable material(s), i.e. any material or combination of materials that will maintain the panels substantially parallel to one another at a predetermined distance apart, and may be made from the same material(s) or from different material(s). Illustrative examples of suitable materials for the substantially rigid members include, but are not limited to, the following: woods, plastics, resins, polymers, metals, alloys, laminates, composites, fibers, papers and combinations of any two or more thereof.

Suitable equivalents of each of these various embodiments described above may also be used as the means for maintaining the panels substantially parallel to one another at a predetermined distance apart. The suitability of any potential equivalent may be determined empirically by one skilled in the art, for example by constructing a model shelf system using the potential equivalent and testing it under the intended load(s).

As noted above, the panels of the inventive shelf system are maintained at a predetermined distance apart. Distances between panels are about 4 inches to about 96 inches. In other embodiments distances between panels are about 4 inches to 48 inches, or about 8 inches to about 24 inches. This predetermined distance may be any distance suitable for storing, displaying and/or organizing the intended elongated articles. The suitability of any potential distance may be determined empirically by one skilled in the art based on the length of the articles to be stored, displayed and or organized or by constructing a model shelf system using the potential distance and testing it with the intended article(s).

FIG. 3identifies an embodiment of a panel12of the invention described herein, having notches16in the corner of the panels. These notches16allow for substantially rigid members21-24(FIG. 2) to secure to the corner of the panels. Further, this provides a means to secure multiple panels12to substantially rigid members21-24. The notches16guide the substantially rigid members21-24and provide a means for aiding in the alignment and securing of the substantially rigid members21-24to said panels12.

In certain embodiments of the shelf system of the present invention, the means for maintaining the panels12substantially parallel to one another at a non-predetermined distance apart is adjustable, i.e. the non-predetermined distance may be changed if desired. For example, one mechanism for maintaining the panels substantially parallel to one another at a non-predetermined distance apart utilizes a panel12having grooves16for accepting a substantially rigid member. Said grooves16are situated on the edges301-304of said panel12, and are located, in particular on the corners of said panel12. Said grooves16having a length and a width to correspond to the dimensions of a substantially rigid member21-24, to facilitate securing said panels12to said substantially rigid member21-24.

In other embodiments, the panels may or may not have grooves16, but the substantially rigid members21-24have grooves. In such an embodiment, a predetermined distance may be changed by moving one or both panels from one groove to another. Similar modifications may be performed on other embodiments of the inventive shelf system. Embodiments may include one or both of the substantially rigid member and the panels having grooves.

FIG. 4shows an exemplary shelf system of the present invention, which has two panels50,51and four panel support holes30, in each panel. The panel support holes30extending from one side of the panel to the other, allowing a panel50or51to freely move along the substantially rigid members52. The panel support holes30allowing a substantially rigid member52to be secured to the panel50or51, to maintain the panels50and51substantially parallel to one another. The panel holes have a panel hole lock53, such as a screw or nail or other fastening mechanism, to secure the panel50or51to the substantially rigid member52. Additional panels, can be inserted onto substantially rigid members52, and secured at non-predetermined distances between panels50and51, by securing the panel to the rigid members52, with the panel hole lock53.

The panel hole lock53may be any number of locking mechanisms or typical fastening devices to secure one panel to a member inserted into said panel. Typical features include threaded fasteners or nails situated in a pocket hole of said panel50,51, such that the panel hole lock53secures the panel50,51, to a particular point on the substantially rigid member52. Other locking means may also be utilizes as is known to one of ordinary skill in the art.

FIG. 5shows a modular panel32having a first surface100and a second surface200, and holes1001-1009between said panel32. The modular panel, having nine modular inserts37, that make up the modular panel32. Each modular insert37, may be located at any one of the nine positions, allowing the panel32to be modified based on consumer needs. Each insert37, may have a single hole,1001, or, as shown inFIG. 7have more than one hole in each insert37. Each insert may have from 0 to 16 holes. Typically inserts have about 1 to 9 holes, and about 1 to 4 holes per insert. The holes on each insert may be the same size or different sizes (see insert39inFIG. 7).

FIG. 6shows additional modular panels31, having four inserts33-36, having between one and three holes per insert. The four inserts33-36combine to from the modular panel31. Each insert33-36may include the same number of holes or different number of holes as is necessary. Each insert has a first surface and a second surface, and has four sides. In essence, each insert is a small panel, that can be combined together to form a larger single panel. The sides of each insert comprise a locking mechanism to secure each insert to one another. Further, means to secure each insert to one another may also be on said first and second surfaces.

FIG. 7shows two variations of modular panel inserts,33-36and37-40, being part of a 2×2 modular insert panel, or a 3×3 modular panel insert.FIG. 7further shows two variations of attachment mechanisms between the panel inserts. The panel inserts may utilize a key6and keyhole5type locking mechanism, or use a notch mechanism41. Other attachment mechanisms to lock the panels together are widely known in the art, such as tongue and groove, clips, post and hole, latches, etc. The panel on the left can combine all four panels inserts33-36together, to create a single panel31. The panel on the right, in contrast, combines the panel inserts37-40together with a panel support7, that surrounds and attaches to the panel inserts, to create a secure panel31.

Modular panels allow for a completely customizable panel based on the needs of an end user. Thus, different sized holes, different shapes, and various number of holes in each panel are possible. Thus, an end user may customize a panel based on the needs of each individual user.

FIG. 8identifies two panel supports7, for various embodiments of a modular panel. Each panel support7has attachment mechanisms compatible with the panel inserts33-36and37-40, to allow the panel to be locked together. The panel on the left further includes notches14, on the corners of the panel, whereas the panel on the right has no notches on the edges of the panel.

FIG. 9identifies a modular shelf system comprising at least two modular panels and substantially rigid support members21-24, each having notches14disposed at the end of each rigid member. In certain embodiments the notches14on the substantially rigid support member21-24may be eliminated.

FIG. 10identifies a notches on a substantially rigid support member21, having notches14disposed at each end of the rigid support member as well as notches15disposed at intervals over the length of the substantially rigid support member21. The notches15have a dimension that is slightly larger than the dimension of the edge of the panel, which allows for panels to be secured at these locations and to maintain each panel substantially parallel to the other panels.

FIG. 11further identifies a modular panel60, having four inserts61-63, that may be secured together to create a modular panel60. Each insert61-63has different sized holes to allow for a customizable panel.

Although the detailed description of preferred embodiments above contain many details and specifics, these should not be construed as limiting the scope of the invention in any way, but rather as merely providing illustrative examples of some of the presently preferred embodiments of this invention. For example, the holes in the panels may be any suitable shape, including round, square, rectangular, or irregularly shaped holes depending upon the article(s) being stored, displayed and/or organized. There may be three or four or more panels in the shelf system. And the system may comprise various inserts33-40in combination with insets61-63as is practicable. Accordingly, the invention is a modular system that comprises a plurality of inserts to form a modular, customizable panel, for storing elongated articles.

The foregoing description and the following examples are illustrative only and are not intended to limit the scope of the invention as defined by the appended claims. It will be apparent to those skilled in the art that various modifications and variations can be made in the methods of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Among the advantages of the present invention are: (a) simple, i.e. typically made of few parts and easy to assemble; (b) inexpensive to manufacture; (c) sturdy when free standing; (d) adjustable; (e) easy to store, organize and/or display elongated articles in a neat arrangement in which all articles are equally accessible and protected from damage; (f) versatile; (g) easy to mass produce; (h) lightweight, i.e. typically made of plastics or light metal composite material; (i) corrosion resistant, i.e. typically made of light metal composite material or plastics; and (j) and fully modular with respect to each panel.