WELDLESS SUPPORT BEAM FOR RACK SHELVING

A shelving support member includes a unitary member of a bent sheet material and defining a support portion extending along an axis to a first end and a retention portion disposed at the first end of the support portion. The retention portion defines a base extending congruently with the support portion at least partially along the axis and to a first fold in the member. A reinforcement portion extends from the first fold along and in contact with the base. A first punched area is defined in an aligned manner through both the base and the reinforcement portion of the retention portion.

BACKGROUND

The present device generally relates to a support member for use in a shelving system. In particular, the support member includes ends thereof that are reinforced for retaining the support member in the related system without the use of welding.

Rack-type shelving systems are used in heavy-duty storage scenarios. These types of shelving systems typically use elongated metal components that are assembled together to give the resultant shelving units their shape, mechanical support, and to position the associated shelves. Typically, these components are assembled at 90° angles that extend relative to each other in various directions, depending on the particular component. Variations of this shelving include components that can be assembled together without separate fasteners or tools by use of interlocking tabs, slots, and the like. Further, the components of these types of shelving are often fabricated from bent sheet material or various extrusions, to give the desired strength at a reduced weight and cost compared to solid or cast materials.

Because of the structure of the assembled shelving units, in which various components are relied upon in the assembly for providing strength along the various axes, relatively thin materials can be used with profiles that generally resist bending along the lengths of the components. However, in the areas where the components are assembled together, such thin material may not be able to withstand the loads imparted thereon due to shelf loading or the like. Accordingly, coupling ends of these components, particularly longer shelving support members or beams, are often made of thicker material that is welded onto the ends of the component. The additional material and components associated with this construction can add to manufacturing time and overall cost. Accordingly, further advances may be desired.

SUMMARY

According to an aspect of the present disclosure, a shelving support member includes a unitary member of a bent sheet material and defining a support portion extending along an axis to a first end and a retention portion disposed at the first end of the support portion. The retention portion defines a base extending congruently with the support portion along the axis to a first fold in the member. A reinforcement portion extends from the first fold toward the first end of the support portion in contact with the base. A first punched area is defined in an aligned manner through both the base and the reinforcement portion of the retention portion.

According to another aspect of the present disclosure, a shelving system includes a first vertical member and a shelf support beam. The shelf support beam includes a unitary member defining a support portion including sheet material extending along an axis from a first end and a retention portion disposed at the end of the support portion. The retention portion defines a base extending congruently with the support portion along the axis to a first fold in the member. A reinforcement portion extends oppositely from the base along the axis in contact with the base. A first punched area is defined in an aligned manner through both the base and the reinforcement member of the retention portion. The shelf support beam is coupleable with the first vertical member at the retention portion thereof such that the shelf support beam extends perpendicularly from the first vertical member.

According to another aspect of the present disclosure, a method for making a shelving support member includes bending an extension tab extending from a support portion along an axis to a first end. The extension tab initially extends along the axis beyond the first end of the support portion and is bent to form a first fold separating the extension tab into a base extending congruently with the support portion and a reinforcement portion extending oppositely from the base along the axis in contact with the base. The method further includes forming a first punched area in an aligned manner through both the base and the reinforcement member.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring to the embodiment illustrated inFIGS. 1-7, reference numeral10generally designates a shelving support member. Shelving support member10includes a unitary sheet material member12that is bent or otherwise formed to define a support portion14extending along an axis16to a first end18. Unitary member12further defines a retention portion20disposed at the first end18of the support portion14. Retention portion20further defines a base22extending congruently with the support portion14along the axis16to a first fold24in unitary member12. A reinforcement portion26extends oppositely along axis16from the first fold24in contact with base22. A first punched area28is defined in an aligned manner through both base22and reinforcement portion26of the retention portion20.

As illustrated inFIGS. 1 and 3, the punched area28included in the retention portion20of the present embodiment is defined by a generally U-shaped or C-shaped cut through both retention portion20and reinforcement portion26. In particular, the cut defining punched area28includes a first cut edge72and respective upper and lower74and76cut edges extending away from first cut edge72. In this manner, a coupling tab78can be formed integrally with retention portion20by bending the remaining portions of base22and reinforcement portion26defined within punched area28along a folded edge80extending between ends of cut edges74and76opposite cut edge72. Further, coupling tab78can be bent back toward reinforcement portion26such that at least a portion thereof extends generally parallel with reinforcement portion26. Coupling tab78can facilitate coupling of support member10with an associated component of a shelving system34(FIG. 2), as discussed further below.

As shown inFIG. 4, coupling tab78includes a first portion82extending integrally with reinforcement portion26and a second portion84extending integrally with base22. In this manner, the inclusion of coupling tab78integral with retention portion20can serve to at least partially secure reinforcement portion26against base22due to the presence of folded edge80and the additional end of coupling tab78itself (or at least increase the resistance of retention portion20from being un-bent at fold24). Further, as shown inFIGS. 3 and 4, folded edge80can be angled with respect to, for example, first fold24. This arrangement may further facilitate retention of reinforcement portion26against base22. By providing retention portion20with two material layers (base22and reinforcement portion26) that together retain coupling tab78, support member10can be strengthened in the area of connection with a related vertical shelving member32(FIG. 2) without the need for an additional welded component. Accordingly, support member10can include a single sheet material comprising unitary member12, as described above, while providing desired strength in the area of coupling tab78.

Referring now toFIG. 2, a shelving system34is illustrated that includes a number of support members10coupled with a set of four vertical members32. As illustrated, support members10can extend horizontally between two respective vertical numbers32and can be arranged in horizontally-aligned pairs between respective sets of such vertical members32. In this arrangement, the horizontally-aligned pairs of support members10can support a shelf33thereon. As depicted, additional structural elements can extend perpendicularly to support members10between adjacent vertical members32to fully retain system34together. These structural elements can include, for example, braces35, shelf supports37, additional braces, or the like. As further shown inFIG. 2, the vertical members32can include a plurality of slots36arranged along a height thereof at regular intervals. Such slots36can be spaced apart at intervals to allow for varied, user-selected spacing between the pairs of horizontally-aligned support members and, accordingly, the shelves supported thereon.

As further shown inFIGS. 5-7, the plurality of slots36included in vertical member32can be shaped to receive coupling tab78therethrough by movement of support member10toward vertical member32in a generally horizontal direction. Slots36can further provide an interengaging arrangement, in which a portion of vertical member32is captured between reinforcement portion26and coupling tab78when support member10is moved in a generally vertical direction70along vertical member32. As shown inFIGS. 6 and 7, slots36are generally angled to match the angle of folded edge80and may include a tapered portion86to a lower end thereof to guide a portion of vertical member32between reinforcement portion26and coupling tab78during the above-described vertical movement of support member10with respect to vertical member32.

FIG. 8shows another support member11that is shown in the assembled shelving system34ofFIG. 2along the top and bottom of the system34in place of the beams10discussed above with respect toFIGS. 1 and 3-7. In particular, support member11includes a unitary sheet material member13defining a support portion15and retention portions21on opposite ends thereof, including first end19. As illustrated, retention portion21includes a two part-base including a first portion23athat extends from support portion15along axis17and a second portion23bjoined with the first portion23aat a bend25asuch that second portion23bis approximately perpendicular to and extends away from first portion23a.Fold25bis positioned along the end of second base portion23bwith reinforcement portion27extending therefrom back toward first portion23ain a doubled-over manner similar to reinforcement portion26and base22of support member10, discussed above. As further shown inFIG. 8, a coupling tab79that is generally similar to coupling tab78is present within retention portion21extending from a punched area73through second base portion23band reinforcement portion27. Coupling tab79, accordingly, includes respective portions83and85extending congruently from reinforcement portion27and second base portion23b.

As shown inFIG. 2, the positioning of coupling tab79along second base portion23band the associated reinforcement portion27can position coupling tab79so as to engage with one of the slots36positioned toward the outside of the support member11(i.e. ones of slots36that are perpendicular to those of slots36engaged by the coupling tabs78of support members10). This may be advantageous for the joining of vertical members32in the locations in which support members11are illustrated, including for structural and assembly purposes. Further, variations of assembly34are possible with support members11in place of one or all of the support members10. Conversely, an assembly34with additional ones of support members10in place of support members11is also contemplated.

As discussed above, support member10comprises a bent or otherwise formed structure of metal (such as steel, for example) sheet material. Accordingly, in a method of fabricating support member10, a blank of sheet material of metal having appropriate properties, and of appropriate size for the particular support member10being fabricated, can be cut into a shape that can be bent and folded in the form shown inFIGS. 1, 3, and 4. Suitable materials may include galvanized or stainless steel, various aluminum alloys, or the like. In general, the cut form will include a two-dimensional shape with areas thereof corresponding to vertical portion48, upper flange50, and lower flange52of support portion14, as well as areas for base22and reinforcement portion26. The cut material may be formed using stamping, sawing, laser cutting, or the like.

Subsequently, the material can be bent to form upper flange50and lower flange52of support portion14, including by bending the designated area corresponding thereto with respect to vertical portion48such that upper flange50and lower flange52extend inwardly away therefrom at the desired angle (e.g., 90°). Additionally, if desired, shelf recess54can be bent into upper flange50. Subsequently, retention portion20can be formed by bending the cut material along the desired area of first fold24to define base22and reinforcement portion26. Subsequently, the above-described punched area28can be formed through retention portion20by stamping or punching of base22and reinforcement portion26in a single operation, according to the various techniques described above. Coupling tab78can be defined within punched area28by forming folded edge80between cut edge74and76by bending, stamping, or the like, with coupling tab78being further shaped by bending or folding. In one embodiment, punched area28and coupling tab78can be simultaneously formed by a combined punching and stamping operation in which a single tool and die arrangement is used to form cut edges72,74, and76in a single operation in which the portion of retention portion20defined within cut edges72,74, and76is then bent to define folded edge80and the desired shape of coupling tab78. Support members11can be fabricated in a similar manner, with an additional fold25abeing incorporated between respective portions23aand23b.

Turning now toFIG. 9, a variation of a support member110that is generally similar in some respects to support member10discussed above with respect toFIGS. 1-7is shown. Support member110includes a general structure, as described above, including a unitary sheet material member112defining a support portion114and retention portions120on opposite ends thereof, including first end118. As illustrated, retention portion120includes a base122having a first fold124on an end thereof opposite support portion114, such a fold124joining base122with a reinforcement portion126extending generally therealong in a doubled-over manner, thereby providing additional support for retention portion120in the same manner as discussed above.

As further shown inFIG. 9, shelving support member110can include at least one attachment rivet130coupled with the unitary member112through the first punched area128. In this manner, rivet130is secured through both base122and reinforcement portion126, thusly helping secure reinforcement portion126in contact with base122. Further, rivet130may be configured to a facilitate coupling between retention portion120and a vertical support member132, as part of a shelving system134that is generally similar to that which is discussed above with reference toFIG. 2. Thusly, the doubling over of unitary member112within retention portion120can provide beneficial additional structural strength. Particularly, in a similar manner to that which is discussed above, this reinforcement helps prevents deflection, weakening, or even rupture of retention portion20due to load concentration thereon due to the coupling and support provided by rivet130.

With additional reference toFIG. 10, the present embodiment of support member110is shown having a second punched area138beneath first punched area128, second punched area138having a second attachment rivet140extending therethrough to couple with both base122and reinforcement portion126of retention portion120. This arrangement can give additional support and stability for the coupling between retention portion120and vertical member132, and can also facilitate an arrangement in which support member110extends from vertical member132in a generally horizontal manner (i.e. generally perpendicular to vertical member132). As shown inFIG. 10, first rivet130and second rivet140can be spaced apart vertically at an interval generally equal to an interval between slots136in vertical member132. This arrangement can provide for an adjustment interval of support member110that is equal to the spacing between first rivet130and second rivet140.

As further shown inFIG. 9, the present embodiment of support member110can include a second fold142at an end of reinforcement portion126opposite first fold124, the second fold142positioning a stabilizer tab144in a generally perpendicular relationship with reinforcement portion126and with base122. Stabilizer tab144can provide additional rigidity for retention portion120. In particular, stabilizer tab144can make retention portion120further resistant to bending along axis116.

Further, as shown inFIG. 9, within support portion114support member110can define a generally C-shaped cross-sectional profile146. In such a profile, support portion114can define a generally vertical mid portion148, from which base122extends congruently, as discussed above. An upper flange150and a lower flange152can extend away from vertical mid portion148, thereby providing structural rigidity for support portion114and, further, providing an area154that is recessed to receive, for example, a substrate used to form the associated shelf (similar to shelf33inFIG. 2). As shown inFIG. 9, upper flange150and lower flange152can define respective edges156and can be arranged such that adjacent upper and lower edges158,160of stabilizer tab144extend, at least partially, therealong. As shown, this arrangement can include stabilizer tab144being inset with respect to upper flange150and/or lower flange152, which can help resist twisting or other deformation of support member110, particularly at a junction between support portion114and retention portion120. It is to be understood that a second retention portion may be present along support member110at an end of support portion114opposite first end118, such second retention portion120being generally a mirror-image of retention portion120depicted inFIG. 9.

As shown inFIG. 10, support member110can be assembled with respective vertical members132in a shelving system that may be similar to that which is described above with respect toFIG. 2. In particular, vertical member132can include slots136appropriately sized and positioned to receive and retain rivet130therein. As shown inFIG. 10, when retention portion120is coupled with vertical member132, reinforcement member126generally contacts a first surface162of vertical member132. In some embodiments, stabilizer tab144may contact an edge163of vertical member132adjacent to first surface162. In other embodiments, a second surface of vertical member132may extend away from first surface162such that stabilizer tab144is in contact therewith when support member110is assembled with vertical member132. In particular, In this manner, a lower portion136bof slot136can be generally narrower than the upper portion thereof such that rivets130and140, which can be generally T-shaped in a rotational cross section, can capture a portion of vertical member132outside of slot136after movement thereof in the vertical direction170. The relatively larger upper portion136acan allow rivets130and140to pass through and into respective slots136during movement of support portion120toward vertical member132.

Support member110can be fabricated in a manner generally similar to that used in fabricating support member10, described above with respect toFIGS. 1-7. Specifically, support member110can be bent into the general shape shown inFIGS. 9 and 10, including support portion114and retention portion120. In particular, the portion of the unitary sheet material112within retention portion120can be bent along first fold124to define base122extending congruently with support portion114and reinforcement portion126extending back along axis126in contact with base120. Further, second fold142can be formed prior to formation of first fold124, although the particular order may vary. Further, in a variation, retention portion120can be formed prior to formation of support portion114.

After the desired forming of the sheet material has been completed to form the unitary support member110, first and second punched areas128and138can be formed through retention portion120, including by stamping or punching holes or the like through both base122and reinforcement portion126, simultaneously. Alternatively, punched areas128can be formed by cutting holes through retention portion120and reinforcement portion26, including by laser cutting or the like. Subsequently, first rivet130and second rivet140can be coupled, respectively, with first punched area128and second punched area138. Variations of support member110including additional or fewer rivets130can be fabricated by a similar process with the desired number of punched areas and rivets being formed in and assembled with support member110.

Turning now toFIGS. 11 and 12, a further embodiment of a support member210is shown that is, similar to support member110, discussed above with respect toFIGS. 9 and 10, respectively. Support member210includes a general structure, as described above, including a unitary sheet material member212defining a support portion214and retention portions220on opposite ends thereof, including first end218. As illustrated, retention portion220includes a base222having a first fold224on an end thereof opposite support portion214, such a fold224joining base222with a reinforcement portion226extending generally therealong in a doubled-over manner, thereby providing additional support for retention portion220in the same manner as discussed above. A second fold242can define a stabilizer tab244generally perpendicularly arranged with respect to reinforcement portion226. This stabilizer tab244can extend along portions of an upper flange250and a lower flange252that extend inwardly from a vertical portion248of support portion214.

As further shown inFIG. 11, retention portion220includes a first punched area228and a second punched area238therein that extend through both base222and reinforcement portion226. However, such punched areas228and238have generally rectangular shapes. As further shown, retention tabs266aand266bcan be respectively coupled within first and second punched areas228,238so as to extend generally inwardly from retention portion220(i.e. in the same direction as stabilizer tab244). Further, retention tabs266a,266bcan each have a hooked or bent shape such that at least a portion thereof extends generally in the direction of axis216so as to be spaced apart from reinforcement portion226.

As shown inFIG. 12, such a support member210can be used in connection with a related vertical member232of a shelving system that can be generally similar to that which is described above with respect toFIG. 2. Vertical member232may be adapted to receive both retention tabs266aand266bin specifically-adapted slots268formed therein. Further, support member210can be coupled with vertical member232by movement of support member210in the vertical direction270indicated inFIG. 12.

Tab slot268can be similarly configured with the respective upper268aand lower268bportions receiving retention tab266therethrough during movement of support member210in a horizontal direction toward vertical member232. Further, lower portion168bcan be narrower such that a portion of vertical member232is captured between respective portions of retention tabs266aand266band reinforcement portion226after movement of support member210in the vertical direction270. In this arrangement, the narrower lower portion268bcan be horizontally offset with respect to the upper portion, as opposed to being centered in the case of slot136, discussed above.

A method for fabricating support member can be generally similar to the above-described method of fabricating support member10and support member110. However, retention tabs266aand266bcan be coupled with retention portion220as a separate element with the use of mechanical fasteners, adhesives, welding, or the like. Alternatively, first and second punched areas228and238can be formed using a three-sided punch or cut through both base222and reinforcement portion226with retention tabs266aand266bbeing bent from respective portions of base222and reinforcement portion226and being defined within punched areas228and238in a similar manner to that which is discussed above with respect to coupling tab78.

A further variation of a support member310with a doubled over retention portion320is shown inFIG. 13. In such a variation, the base322associated with retention portion320is joined with portion314by first fold324in the unitary shape material312such that base322extends generally perpendicularly from support portion314. The associated reinforcement portion326is then joined with base322by a second fold242such that reinforcement portion326extends back along base322to generally align with first fold324and support portion344. A plurality of punched areas328,338, can be formed within retention portion320, by cutting, punching, stamping, or the like through both base322and reinforcement portion326, including through second fold342. Remaining portions of retention portion320outside of the punched areas328and228, including second fold342can, accordingly, define retention hooks388and390that can engage with corresponding slots in a vertical member similar to vertical members32,132, and232, discussed above.