Storage system

A storage system comprises a rail having a protrusion including a first flange and a second flange. An accessory mount for mounting to the rail includes a top hook for engaging the first flange and a resilient bottom hook for engaging the second flange. The rail comprises a back rail portion comprising a substantially planar member and a front rail portion substantially coextensive with the back rail portion and secured to the back rail portion. The protrusion may be symmetrical about the longitudinal axis. The first flange and the second flange define first and second recesses. A method of assembling a support is also provided where a first hook is inserted the first flange and a second hook deforms to engage the second flange.

BACKGROUND

Such wall mounted storage systems are sold by Newell Rubbermaid Inc. under the trademarks FASTTRACK and 300X. These systems comprise a rail or a plurality of rails that are mounted to a substantially vertical supporting surface such as a wall. The rail supports a variety of organizing and storage accessories such as hooks, shelving units and tool holders. The accessories can be removed from and attached to the rail along its length such that the system provides a flexible, reconfigurable storage and organizing system.

SUMMARY OF THE INVENTION

A storage system is provided comprising a rail having a protrusion including a first flange and a second flange. An accessory mount for mounting to the rail includes a top hook for engaging the first flange and a resilient bottom hook for engaging the second flange.

A rail is also provided for supporting an accessory mount comprising a back rail portion comprising a substantially planar member and a front rail portion substantially coextensive with the back rail portion and secured to the back rail portion. A protrusion is formed on the front rail portion and extends along a longitudinal axis of the rail. The protrusion comprises a first flange and a second flange extending along the longitudinal axis where the protrusion is symmetrical about the longitudinal axis. The first flange and the second flange are formed with rounded outer peripheries and define a first recess located behind and extending along the first flange and a second recess located behind and extending along the second flange.

A method of assembling a support is also provided comprising providing a rail having a protrusion comprising a first flange and a second flange where the protrusion extends for substantially the length of the rail. The first flange defines a first recess and said second flange defines a second recess. The rail is mounted to a surface. An accessory mount is provided having a first hook and a second hook. The first hook is inserted on the first flange such that the first hook extends into the first recess. The bottom of the accessory mount is pushed towards the rail forcing the second hook into engagement with the second flange to deform the second hook. The second hook passes transversely under the second flange and snaps back toward its original shape to engage the second flange.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

A rail for use in a wall mounted storage system is shown generally at100in the Figures. The rail100is constructed of two components—a front rail portion102and a back rail portion104. The back rail104portion comprises a substantially planar member constructed of full hard steel or other structurally rigid material. The back rail portion104is dimensioned so as to extend for substantially the length and width of the finished rail100. While the rail may be dimensioned to in a variety of sizes in one embodiment the rail has a horizontal length that is substantially greater than the vertical height. For example, the rail may have a height of approximately 2 to 3 inches and a length of approximately 4 to 6 feet. A plurality of mounting apertures106are provided along the length of the back rail portion104.

The front rail portion102may also comprise full hard steel formed to have the shape shown in the drawings. The finished dimensions of the front rail portion102substantially conform to the dimensions of the back rail portion104such that the front rail portion102is substantially coextensive with the back rail portion104. While in the illustrated embodiment the front rail portion102is coextensive with the back rail portion104, these components do not necessarily have to be coextensive. A plurality of mounting apertures108are provided along the length of the front rail portion102that are aligned with the apertures106on the back rail portion104when the front rail portion is secured to the back rail portion. The apertures may also be formed in the rail after the front and back rail portions are joined together. The apertures receive fasteners for securing the rail to the wall or other vertical surface. In one embodiment the front rail portion102is secured to the back rail portion104by welding. Other mechanisms may also be used to secure the front rail portion102to the back rail portion104such as rivets or other fasteners, adhesive, a mechanical joint such as crimping or the like.

The front rail portion102has a protrusion110formed therein that in one embodiment extends for the length of the rail. When joined together the front rail portion102and the back rail portion form a rail100that has a box section that is very rigid and resists twisting and bending. The protrusion110is configured to mate with accessories that are to be mounted on rail100as will hereinafter be described. In one embodiment the protrusion110is substantially symmetrically disposed on front rail portion102such that the rail100may be properly secured to the wall or other vertical surface with either longitudinal side on the top. Making the rail symmetrical also facilitates its use as a ceiling mounted support because accessories can grip both protrusions112and114. The protrusion110has a first upwardly facing flange112and a second downwardly facing flange114where both flanges extend for the length of the front rail portion102. The flanges112and114create longitudinally extending recesses116and118, respectively, that extend for the length of the front rail portion102. Because the rail is symmetrical it can be mounted on a vertical surface with either flange112or114facing upward. In explaining operation of the rail, reference is made to an upper flange and a lower flange. It is to be understood that either flange112or flange114may function as the upper or lower flange depending on the orientation of rail100.

The flanges112and114are formed with rounded outer peripheries112aand114athat facilitate the mounting and removal of accessories on the rail. The center portion of protrusion110has a longitudinally extending recess120formed therein that is used to reinforce the rail along its length. A pair of flat surfaces122and124are formed between the recess120and flanges112and114, respectively.

An accessory mount130for mounting to the rail100is shown inFIGS. 4 through 11. The accessory mount130is intended to support any accessory127that may be mounted to the rail including, but not limited to, hooks, shelves, cabinets, tool holders, equipment holders, tools, power strips or the like. The accessory mount includes support portions132that support the specific accessory. For example, support portions132may have a hook, shelf support, cabinet, tool holder, equipment holder, tool, power strip or the like connected thereto such as by welding. The accessory may also be removably connected to the support portions132. Further, the accessory and the support portions132may be integrally formed with one another such that the transition from the support portion to the accessory is seamless.

The support portions132are connected to a top hook support131that may be made of sheet metal or other rigid material. Top hook support131includes a body portion133that terminates at its top end in a first hook134that is open in a downward direction. Hook134has an inner shape that closely corresponds to the outer peripheries112aand114aof flanges112and114, respectively. Further, the lip134aof hook134has a length sufficient to extend into recesses116or118for a major portion of the depth of the recesses as shown inFIG. 9. Hook134has a thickness and width sufficient to support the weight of the accessory and any articles intended to be supported by the accessory. The hook134may comprise an outer portion136made of a substantially rigid material such as sheet metal. In one embodiment outer portion136is formed integrally with body portion133. Hook134may also comprise an inner sleeve138made of a more resilient material such as plastic or rubber. The inner sleeve138may be connected to the outer portion136such as by sonic welding, fasteners or other connection mechanism. The exposed surface138aof the inner sleeve138is shaped and dimensioned to closely receive outer peripheries112aand114aof flanges112and114. The inner sleeve138ensures a tight fit with the rail100and prevents marring or scraping of the rail surface. Another pad139may also be attached to the body portion133so as to contact the front of the rail when the accessory is mounted on the rail. The pad139may be made of plastic or rubber sonically welded or otherwise secured to hook support131and also prevents marring or scraping of the rail surface.

A flange140extends from hook support131near the bottom of body portion133. Flange140fits under the lower flange but does not extend into the recess formed by the lower flange. In one embodiment the flange140is formed of the same material as the body portion133and may be formed integrally therewith.

A resilient bottom hook142is mounted on the hook support131for engaging the lower flange in a snap fit connection. Bottom hook142extends generally transverse to flanges112and114when the accessory is mounted on rail100. Bottom hook142is formed with protrusions146at either end thereof where the protrusions extend into recesses116or118a minor portion of the depth of the recesses. Protrusions146have a rounded outer surface146ato facilitate the mounting of the accessory on rail100. Because the member144is relatively thin and made of a resilient material such as plastic, the hook142can flex relative to the hook support131to allow the accessory to be removably mounted to the rail100. In the illustrated embodiment, bottom hook142includes a portion142a(FIGS. 6,7and8) that is connected to the front of hook support131and forms a decorative fascia on the front of the support. Portion142amay be molded to include designs, logos, words, symbols or other indicia143.

To mount an accessory on the rail100, the top hook134is inserted on flange112or114such that the hook extends into the top recess116or118. The bottom of the accessory mount130is pushed towards the rail100forcing bottom hook142into engagement with the bottom flange112or114. The bottom flange112or114engages surfaces146ato slightly deform the bottom hook142and push the bottom hook142away from the top hook134. The bottom hook142deforms until it can pass transversely under the bottom flange112or114. The bottom hook142then snaps back to its original shape forcing protrusions146into recess116or118and locking the accessory mount130on the rail100.

To remove the accessory mount130from rail100the process is reversed. A force is applied to the bottom of the accessory mount130pulling the accessory mount away from the rail100. The protrusions146aengage the bottom flanges causing the bottom hook142to deform and spread away from top hook134. The rail can then be removed from between the top hook134and the bottom hook142. The accessory mount and its associated accessory can be positioned and repositioned any where along the rail100.

Specific embodiments of an invention are disclosed herein. One of ordinary skill in the art will recognize that the invention has other applications in other environments. Many embodiments are possible. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described above.