Stackable and collapsible shelf assembly

A coated wire shelf assembly capable of free standing support and collapsible to a reduced size to facilitate shipping and storage thereof. The shelf assembly includes a shelf and a pair of laterally spaced shelf supports connected by hinge joints to the shelf. Separate locking mechanisms releasably secure each shelf support in a shelf supporting position and allows each shelf support to be rotated about a respective hinge joint to a storage position to substantially reduce the size of the shelf assembly thereby facilitating shipping and storage thereof.

TECHNICAL FIELD OF THE INVENTION 
The present invention generally relates to plastic-coated wire structures 
and, more particularly, to a plastic-coated wire shelf assembly which is 
capable of stacking on a like shelf assembly or collapsing to a 
substantially reduced size to facilitate shipping and storage thereof. 
BACKGROUND OF THE INVENTION 
Plastic-coated metal wire structures have become very popular consumer 
items. A wide variety of such products are available, including shelves, 
racks, baskets, and like arrangements, which facilitate convenient storage 
of articles where desired. Because various colors and types of plastic 
coatings can be applied to such structures, they can be used in a myriad 
of locations throughout the home. 
Because of their light weight, strength and durability, baskets, shelves, 
and racks formed of coated wire material have proven convenient and 
useful, particularly around the home. One type of such a coated wire 
product is a shelf which is suitable for use in the kitchen, bathroom, and 
other areas where there is a need for shelving to store or stack various 
articles. While some metal wire shelves may be affixed to a wall, others 
are adapted to be free standing and may be placed in cabinets, pantries, 
closets, or the like. 
Wire structure shelving units come in a variety of shapes and sizes. U.S. 
Pat. No. 4,444,320 to J. P. Chap discloses a stackable shelf unit formed 
of wire coated material. Such a shelf unit readily lends itself to various 
uses, such as for supporting a variety of containers, articles, or boxes 
thereon. 
One desirable feature of a free standing shelf is the capability of the 
shelf to stack upon a like shelf and preferably interlock therewith. The 
ability to stack the shelves upon each other allows a user to efficiently 
make use of space at a selected location and readily arrange the shelves 
into a multi-tiered arrangement. This feature allows the user to 
"customize" shelf arrangements. As will be understood, the ability to 
interlock the shelves with each other reduces the likelihood that they 
will separate, e.g., and fall when the containers or articles stored 
thereon are slidably removed from the shelf. 
The ability to effect compact storage of a shelf when not in use is another 
desirable feature. Compact storage is an important consideration during 
shipment where volume of the item to be shipped is usually directly 
related to shipping costs. Compact storage of a shelf will likewise 
enhance inventory and storage. While the ability to "nest" such wire shelf 
structures within each other is advantageous, the ability to further 
reduce the shipping size of such shelf structures would provide further 
benefits. 
Thus, there is a need and a desire for a coated wire shelf structure which 
is capable of interlocking with a like shelf structure and yet is 
collapsible upon itself to minimize its size thereby facilitating shipping 
and storage thereof. 
SUMMARY OF THE INVENTION 
In accordance with the present invention, there is provided a shelf 
assembly, typically made of coated wire, capable of free standing support, 
which is collapsible to a reduced size to facilitate shipping and storage 
thereof. The shelf assembly of the present invention includes a shelf 
having a plurality of parallel laterally spaced and joined shelf members 
defining a supporting surface and a pair of laterally spaced shelf 
supports rotatably connected to the shelf. Locking mechanisms releasably 
lock the shelf supports in a shelf supporting position generally 
transverse to the supporting surface. When released, each of the shelf 
supports is rotatable to a storage position adjacent the supporting 
surface to substantially reduce the size of the shelf assembly thereby 
facilitating shipping and storage thereof. 
Each shelf support includes a length of metal wire, which combines with the 
wire structure of the shelf to form a hinge joint pivotally connecting the 
shelf support to the shelf. The hinge joint also includes a pivot member 
which extends generally parallel to and is located at opposite ends of the 
shelf supporting surface to permit arcuate movement of a respective shelf 
support relative to the shelf through an angle of about 90.degree.. The 
hinge joint is configured to minimize projections from either side of the 
shelf supporting surface and thereby economize on the storage size of the 
shelf assembly. 
More specifically, each shelf support takes the form of a generally 
U-shaped single length of metal wire having leg portions and a support or 
foot portion. The free ends of the metal wire have eyelets configured to 
accommodate and allow a wire structure or pivot member disposed below and 
attached to the shelf to pass therethrough to form the hinge joint. Such a 
design provides a substantially clear and generally planar shelf 
supporting surface for the shelf assembly by maintaining the shelf 
supports below the shelf supporting surface in both the shelf supporting 
and collapsed positions. To promote stability for the shelf assembly when 
the shelf supports are locked in a shelf supporting position, the 
generally horizontal foot or support portion of each shelf support is 
extends laterally outwardly from the shelf assembly. The foot or support 
portion of the shelf support promotes stability upon stacking of a shelf 
assembly vertically one upon the other. 
The leg portions of each U-shaped shelf support are resiliently flexible 
and join the support portion to pivot member at the hinge joint. Each leg 
portion is configured to normally position the support portion laterally 
outward of a vertical plane passing through the corresponding pivot member 
and the hinge joints to establish an outwardly directed resilient force 
which holds the support portion in interlocking engagement with a like 
shelf assembly therebelow. 
The locking mechanism for releasably locking a shelf support in a 
supporting position preferably includes a wire locking member extending 
across opposite ends and beneath the supporting surface of the shelf. The 
locking member is configured to releasably entrap an upper end of each leg 
portion in a manner inhibiting pivotal movement of the shelf support about 
a respective hinge joint. The locking mechanism further provides a surface 
on which another shelf assembly is supported in a vertical stacking 
relationship therewith. 
The shelf assembly is preferably fabricated from vinyl or plastic-coated 
metal wire for corrosion resistance and in a pleasing resilient finish. 
When the shelf supports are in their shelf supporting position, they 
depend from the shelf and can be interconnected to a like shelf assembly 
to provide customized storage solutions throughout the household. 
When not in use, the shelf assembly of the present invention may be 
collapsed to a substantially reduced size. As indicated above, the leg 
portions of each shelf support are normally resiliently biased into 
engagement with the locking mechanisms. The leg portions of each shelf 
support are released from entrapment with their respective locking 
mechanism by sliding the free ends of the leg portions inwardly along the 
corresponding pivot member until they are clear of the locking mechanism. 
Each shelf support can then be rotated about a respective hinge joint to a 
storage position in which it lies underneath and generally parallel to the 
supporting surface to minimize the size of the collapsed shelf assembly. 
Numerous other features and advantages of the present invention will become 
readily apparent from the following detailed description of the invention 
and an embodiment thereof, from the claims, and from the accompanying 
drawings in which the details of the invention are fully and completely 
disclosed as a part of this specification.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
While the present invention is susceptible to embodiment in various forms, 
there is shown in the drawings, and will hereinafter be described, a 
presently preferred embodiment, with the understanding that the present 
disclosure is to be considered as an exemplification of the principles of 
the present invention and is not intended to limit the invention to the 
specific embodiment illustrated. 
Referring now to the drawings, wherein like reference numerals indicate 
like parts throughout the several views, there is shown a shelf assembly 
10 including a shelf 12 and a pair of laterally spaced shelf supports 14 
and 16 which are connected near opposite ends of the shelf 12. Preferably, 
shelf 12 and supports 14, 16 are fabricated from plastic coated metal wire 
members which are appropriately shaped to form the assembly of the present 
invention in its desired configuration. 
The shelf assembly is fabricated with known methods typically comprising 
suitable interconnection of the various members, such as by welding, with 
the entire assembly thereafter being coated. The plastic coating may 
comprise vinyl or a like material which is suitably durable and corrosion 
resistant, and which is typically available in a wide variety of colors 
for enhancing the aesthetic appeal of the resultant product. 
Alternatively, the shelf assembly may be plated with a suitable metal 
coating in lieu of the plastic coating. The shelf 12 and supports 14, 16 
may also be molded and thereafter connected together. If molded, multiple 
elements may be molded as a unitary component rather than welding the 
various elements together to form the assembly. 
In the illustrated embodiment, shelf 12 has a generally rectangular 
configuration and includes a plurality of generally parallel laterally 
spaced and joined shelf members 18 which combine to define a supporting 
surface 20. The opposite ends of the shelf members 18 are connected to a 
frame comprised of a pair of spaced apart, laterally extending, generally 
parallel left and right wire frame members 22, 24. The supporting surface 
20 of shelf 12 may also include one or more stiffening members 25 attached 
to and extending across a number of shelf members 18 intermediate their 
ends. 
The shelf supports 14, 16 are rotatably connected near opposite lateral 
ends of the shelf 12 to pivot members or rods 28, 30. Each pivot rod 28, 
30 extends generally parallel to and is either coplanar with or spaced 
slightly beneath the supporting surface 20 to allow rotation of a 
respective shelf support 14, 16, respectively, relative thereto. In the 
illustrated embodiment, each pivot rod 28, 30 permits rotation of a 
respective shelf support 14, 16 beneath and relative to the shelf 12 
through an angle of about 90.degree.. 
In the illustrated embodiment, the shelf supports 14, 16 are mirror images 
of each other. Accordingly, only shelf support 14 and its connection to 
pivot rod 28 will be discussed in detail with the understanding that shelf 
support 16 and pivot rod 30 are substantially similar in construction. 
As seen in FIG. 2, the shelf support 14 is comprised of a single piece of 
metal wire 32 which is pivotally connected to the pivot rod or wire member 
28, which, as indicated above, extends between and is secured to the left 
and right frame members 22 and 24 adjacent the ends thereof. In the 
preferred embodiment, the metal wire 32 forming the shelf support 28 is 
generally U-shaped. The free ends of the metal wire 32 are configured as 
eyelets 36, 38 which receive and are pivotally or rotatably supported by 
wire member or pivot rod 28. 
As shown in FIG. 2, the metal wire 32 of the shelf support 14 includes a 
pair of resiliently flexible left and right leg portions 40, 42 which are 
integral with and extend between the left and right eyelets 36 and 3 
formed integrally therewith and the free ends thereof, to a bottom portion 
44, formed at the lower ends thereof. As seen in FIGS. 3 and 4, the bottom 
portion 44 extends transversely to the plane of the leg portions 40, 42 to 
define a foot portion which adds free standing stability to the shelf 
assembly. 
The shelf assembly is furthermore provided with shelf support locking 
members 50 and 52. Each locking member 50, 52 releasably locks a 
respective shelf support 14, 16 in a shelf supporting position in which 
the shelf supports 14, 16 depend from the shelf 12. When released, each of 
the shelf supports 14, 16 can be rotated about the respective pivot rods 
28, 30 from its supporting position (FIGS. 1-4) to a storage position 
(FIG. 5). In both the shelf supporting and collapsed or storage positions, 
the shelf supports 14, 16 are arranged beneath, and provide a 
substantially clear, shelf supporting surface 20. 
The locking members 50, 52 are mirror images of each other. Accordingly, 
only locking member 50 is described below in detail with the understanding 
that locking member 52 is constructed substantially similar thereto. 
The locking member 50 is positioned at the end of and beneath the support 
surface of shelf 12. In the illustrated embodiment, each locking member 50 
includes a central bracing portion 56 and end hook portions 58 which are 
configured to releasably entrap an upper end of each leg portion 40, 42 of 
the shelf support 14 in a manner inhibiting pivotal movement of the shelf 
support about its respective pivot rod 28. 
As shown in FIGS. 1, 2, and 3, the free end 60 of each shelf frame member 
22, 24 is bent downwardly depending 58 extending beneath the support 
surface 20. The locking member 50 is secured to the depending ends 60 of 
the frame members 22, 24 and, extends therebetween. Each hook end 58 of 
the wire locking member 50 defines elongated open-ended locking channel 62 
(See FIG. 4). Each locking channel 62 is generally vertically aligned with 
the pivot rod 28 disposed thereabove. The channel 62 is appropriately 
sized to releasably entrap an upper end of the resilient leg portions 40, 
42 of the shelf support 14 therein to inhibit rotational movement of the 
leg portions. In a preferred form of the invention, the locking channel 
has a width equal to or slightly greater than the cross-sectional 
thickness of the upper end of the leg portion on each shelf support. 
When the shelf supports 14, 16 are locked in their shelf supporting 
position, the leg portions thereof normally position the respective foot 
portion 44 outwardly of a vertical plane passing through the respective 
hinge rod 28. As depicted in FIG. 2, the leg portions 40 and 42 slightly 
converge toward each other such that the width of the foot portion 44 is 
somewhat less than the distance separating the eyelets 36 and 38. Such 
configuration facilitates interconnecting like shelf assemblies when 
vertically stacked upon each other. 
To facilitate stacking of the shelf assemblies upon each other, and as 
depicted in FIG. 4, the outermost shelf member 18 is laterally spaced 
inwardly from pivotrods 28, 30 a distance sufficient to allow the foot 
portion 44 of another shelf support 12, 14 to pass therebetween. 
The central portion 56 of the locking member 50 acts as a support for the 
foot portion 44 of another shelf assembly allowing it to be stacked 
thereupon. Configuring the leg portions 40 and 42 such that the foot 
portion 44 extends laterally outward, when combined with arranging the 
locking rod 50 in general vertical alignment with the hinge rod 28, 30, 
facilitates locking engagement of vertically stacked shelf assemblies by 
imparting a outwardly directed bias force to the foot portion 44 of each 
shelf support 14, 16 in the direction of arrow 66 (FIG. 3) when the shelf 
supports are in shelf supporting position. 
Overall resiliency of each shelf support coupled with the elongation and 
resiliency of the leg portions 40 and 42 allows each shelf support 44 to 
be quickly and readily locked in a shelf supporting position with minimum 
effort and time. Moreover, the resilient nature of the plastic coating on 
the wires enhances engagement between the wire structures so as to 
facilitate the locking relationship between the wires when the shelf 
support is moved into a shelf supporting position. 
When it is desired to store the shelf assembly 10 of the present invention, 
the leg portions 40, 42 are quickly and readily collapsible. As will be 
understood, the resiliency of the leg portions 40 and 42 allows them to be 
moved inwardly towards each other along pivot rod 28 and released from 
within the locking channels 62 of the respective hook ends 58. The support 
shelf supports 14, 16 may thus be pivoted about the respective hinge rods 
28, 30. Accordingly, as illustrated in FIG. 5, the shelf support may be 
rotated about their respective hinge rod into a position extending 
substantially parallel to the support surface of the shelf. 
Thus, there has been disclosed a conveniently stowable shelf assembly 
capable of being easily and rapidly erected and used and is likewise 
capable of compact storage without requiring significant space allocations 
or the use of tools. Notably, the shelf supports are configured to 
establish a resilient force facilitating interconnection of the shelf 
assemblies when stacked upon each other. Moreover, by arranging the hinge 
rods, locking mechanisms, and shelf supports beneath the shelf 12, a clear 
and unobstructed support surface is provided for each shelf assembly. 
From the foregoing, it will be observed that numerous modifications and 
variations can be effected without departing from the true spirit and 
scope of the novel concept of the present invention. It will be 
appreciated that the present disclosure is intended as an exemplification 
of the invention, and is not intended to limit the invention to the 
specific embodiment illustrated. The disclosure is intended to cover by 
the appended claims all such modifications as fall within the scope of the 
claims.