Abstract:
A support structure has a number of posts with flanges and slots formed in the flanges. The support structure also has a number of aprons with end tabs that are inserted into respective post flange slots. A gap defined by the apron end tabs and an edge of the apron creates an interference fit with a slot lip of the flange slot. The disclosed interlock of the aprons to the posts creates a stable support structure that has aesthetic value. The disclosed interlock further provides the capability of creating various support structures (e.g., shelving assemblies, workbenches, cabinets, storage assemblies).

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims the priority date benefit of Provisional U.S. Patent Application Serial No. 60/292,152, filed May 18, 2001, entitled “Shelving Apparatus and Method of Assembly”, which is hereby incorporated by reference. 
     
    
     
       BACKGROUND  
         [0002]    Readily assembled support or work structures, such as shelving units or workbenches, have been in the market and in use for years. Various forms of assembly techniques have been employed in these support structures. A common form of shelving unit uses a nut and bolt type assembly for post and apron connections. Such assemblies, though effective, have several limitations. Each unit has a number of parts that need to be assembled. Each bolt, nut and washer, if provided, needs to be assembled and tightened. Each part that needs to be put together and tightened or fastened creates additional assembly time. Also, such assemblies require an assortment of tools that the shelf builder has to have, such as screwdrivers (Phillips or flat-head), pliers, wrenches, etc. Without the required tools, the shelf builder is unable to build the shelf. Further, the connections of such nut and bolt assemblies have a tendency to loosen over time, making the shelving unit unstable.  
           [0003]    Nut and bolt assemblies and other types of assemblies, such as rivet-type assemblies, also tend to lack aesthetic appeal because the fastener in these types of assemblies passes through the vertical post and is exposed to someone viewing the shelving unit. As such, these assembly types are usually only used in utilitarian work spaces. Present assembly types also lack necessary flexibility. Due to the design and structure of most present assembly structures, they are usually not reconfigurable (i.e., cannot be converted from a shelving unit to a workbench or other structure or vice versa). Even when such assemblies are reconfigurable, they are very difficult to reconfigure from a shelving unit to a workbench or some other structure without considerable effort.  
           [0004]    Accordingly, there is a need for a readily assembled support structure that is easy to assemble, using minimal tools, aesthetically pleasing and incorporating a degree of flexibility to be configured and used in different ways.  
         SUMMARY  
         [0005]    According to one aspect of the present invention, a kit for forming a support structure includes a number of posts, a number of aprons and a support panel. Each post has a pair of flanges with each flange having a series of slots formed in it such that each slot defines a slot lip. Each apron has two ends with each end having at least one end tab extending from it, wherein each tab and respective apron edge define a gap. When assembled, each end tab is disposed in a respective post flange slot such that the slot lips of the flange are disposed in the gaps formed between the end tabs and the edge of the apron. The support panel is placed on a set of the aprons.  
           [0006]    According to one aspect of the present invention, a support structure has a number of posts and a number of aprons. Each post has a pair of flanges, and each flange has a series of slots formed in it such that each slot defines a slot lip. Each apron has two ends, and each end has an edge and at least a pair of end tabs extending from the edge. Each tab and respective apron edge define a gap, such that the end tabs of each end of an apron are disposed in respective post flange slots such that the slot lips of the flange are disposed in the gaps formed between the end tabs and the edge of the apron. The support structure further includes a support panel. The support panel rests on a set of the aprons.  
           [0007]    According to another aspect of the present invention, the interaction of the slot lip with the gap formed by the end tab and the apron edge is an interference fit. The pair of flanges of the post may define a channel. The channel retains the edge of the support panel. The support structure may also have a back stop that may be retained vertically in the channel. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:  
         [0009]    [0009]FIG. 1 illustrates the interlock mechanism of the present invention;  
         [0010]    [0010]FIG. 2 is an apron and post assembly diagram of the present invention;  
         [0011]    [0011]FIG. 3 illustrates an embodiment of an assembled shelving unit of the present invention;  
         [0012]    [0012]FIG. 4 is an assembly diagram illustrating a joiner and the interconnection of an upper assembly;  
         [0013]    [0013]FIG. 5 illustrates an embodiment of an assembled workbench of the present invention;  
         [0014]    FIGS.  6 A-C illustrate a further embodiment of an assembled workbench of the present invention having a work tray and a drawer assembly;  
         [0015]    [0015]FIG. 7 illustrates an embodiment of an assembled cabinet of the present invention; and  
         [0016]    [0016]FIG. 8 illustrates an embodiment of an assembled storage assembly of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]    Referring now to FIG. 1, the interlock mechanism used in the support structures of the present invention is depicted. The interlock mechanism of the present invention utilizes a post edge interlock, which, as explained in detail below, allows the flexibility to form different structures using this interlock. The structural elements of the structures formed using such interlock mechanism include posts  12  and braces or aprons  14 . The posts  12  and braces and aprons  14  are usually formed metal pieces. Each post  12  is formed into a right angled portion  20  integral with two C-flange segments  22 . Each C-flange  22  and the right angle portion  20  define a pocket  24 . In this embodiment, the C-flanges  22  define a channel  26  between them. Also, formed along the length of each C-flange  22  are a series of slots  28 . Each slot  28  defines a slot lip  40 . Each apron  14  of an assembly has a number of end tabs  30  formed at each end of the apron  14 . In this embodiment, each apron has two tabs on each end. The end tabs  30  form a gap  34  between the tab  30  and the apron edge  36 . The apron  14 , as depicted, may be formed to have two flanges  32  along its edges. The flanges  32  provide the apron  14  with greater strength and resistance to bending.  
         [0018]    When assembling a structure using the interlock mechanism of the present invention, the posts  12  and aprons  14  are interconnected by aligning the tabs  30  of an apron  14  with corresponding post slots  28  and then inserting the tabs  30  into such slots  28 . Once inserted, the gaps  34  formed by the apron end tabs  30  and the apron edges  36  are aligned with a respective slot lip  40 , and the apron end tabs  30  are then forced down into the slot  28 . The clearance of the gap  34  and the thickness of the slot lip  40  are manufactured such that when the tabs  30  are forced down into the slots  28 , an interference fit is created between the tab  30 , the slot lip  40  and the apron edge  36 . The interference fit between the apron and the post can be of varying degree, but in a preferred embodiment it is such that a force no greater than a mallet tap is required to interlock each post  12  and apron  14 . The interference fit between the end tabs  30 , the slot lip  40  and the apron  14  creates a strong and stable interface between the post  12  and the apron  14 . With the end tabs  30  in position, the end tabs  30  are disposed behind the right angle portion  20  of the post  12  and are hidden from someone looking at a finished assembly from an exterior view point. The interlock mechanism of the present invention, therefore, also enhances the aesthetic appeal of finished assemblies incorporating it.  
         [0019]    After one end of the apron  14  is inserted into one of the posts  12 , the other end of the apron  14  is inserted into another post  12  and the apron end tabs  30  are forced into the post slot  28 . As depicted in FIG. 2, once one apron  14  is connected, the structure assembler continues to connect the aprons  14  to the posts  12  in a similar manner until the provided aprons  14  are connected to the provided posts  12 .  
         [0020]    Referring to FIG. 3, an embodiment of an assembled stand alone shelving unit  10  using the interlock mechanism of the present invention is depicted. The shelving unit  10  has a number of posts  12  and a number of braces or aprons  14 . The aprons  14  interlock with the posts  12 , as described in detail above, to form a stable, self-supporting shelving structure. The interlocking of the aprons and the posts creates such a stable platform that it is not necessary to use cross bracing with the unit of the present invention. In the assembled unit, the aprons  14  at each level support a shelf  16 . The posts  12 , due to their configuration, described above, act as channel guides to hold the shelves  16  in place. The shelving unit may be distributed as a disassembled kit with the kit including the necessary post, apron and shelving pieces.  
         [0021]    To assemble the shelving unit, the post  12  is held upright on a shelving unit support surface, such as a floor. Some form of material (e.g., a cardboard or a rag) may be placed between the post  12  and the support surface to keep the support surface from being damaged. The tabs  30  of an apron  14  are then aligned with and inserted into a post slot  28 . Once inserted, the gaps  34  formed by the apron end tabs  30  are aligned with the respective slot lip  40 , and the apron end tabs  30  are then forced down into the slot  28 . The apron tabs  30  engage the slot lips  40  of the slots  28  as described above.  
         [0022]    As depicted in FIG. 2, after one end of the apron  14  is inserted into one of the posts  12 , the other end of the apron  14  is inserted into another post  12  and the apron end tabs  30  are forced into the post slot  28 . Once one apron  14  is connected, the shelf assembler continues to connect the aprons  14  to the posts  12  in a similar manner until all of the aprons  14  at the first level  50  are connected to the posts  12  of the first level  50 . In the embodiment depicted in FIG. 3, the shelving assembly  10  has two levels  50 ,  52 . Once the first level  50  is complete, the shelf assembler adds the second, vertical level  52 . The second level  52  may be connected to the first level  50  in a number of ways. In one embodiment, to add the second level  52 , the shelf assembler first inserts joiners  54 , as depicted in FIG. 4, into the pockets  24  formed in the lower posts  12 L of the first level  50 . The joiners  54  interact with a dimple  58  on the post  12 L to keep the joiner  54  from sliding all the way into the post  12 L. With the joiners  54  in place, upper posts  12 U and additional aprons  14  are added to the upper level of the assembly in the same manner as described above for adding posts  12  and aprons  14  to the lower level of the assembly. In another embodiment, the second level  52  is added using aprons  14  to connect the upper posts  12 U to the lower posts  12 L. In this embodiment, the lower end tabs  30  of four aprons  14  are inserted into the top slots  28  of the lower posts  12 L. To connect the upper posts  12 U, the upper end tabs  30  of the same four aprons  14  are inserted into the bottom slots  28  of the upper posts  12 U.  
         [0023]    With all of the aprons  14  and posts  12  connected, the shelves  16  are then inserted into the shelving unit to complete the shelving assembly. At each level of aprons  14 , a shelf  16  is placed on top of the top apron flanges  32 . The channels  26  formed by the C-flanges  22  of each post  12  act to keep each shelf  16  firmly in place so the shelf does not shift during use.  
         [0024]    Other embodiments of the present invention demonstrate the flexibility of the shelving unit of the present invention. Instead of building an upper, second level of the shelf assembly in a vertical arrangement as depicted in FIG. 3 and described above, the shelving unit may be assembled as horizontal side-by-side sections.  
         [0025]    The present invention may also be used to configure a workbench. Referring to FIG. 5, an embodiment of an assembled workbench  60  using the interlock mechanism of the present invention is depicted. The workbench  60 , as with the shelving unit  10 , has a number of posts  12  and a number of braces or aprons  14 . The workbench  60  has set of short posts  12 W which provide the back section  62  of the workbench  60  with added height.  
         [0026]    To assemble the workbench  60 , a front post  12 L or a back, short post  12 W is held upright on a support surface, such as a floor. Some form of material (e.g., a cardboard or a rag) may be placed between the post  12  and the support surface to keep the support surface from being damaged. The tabs  30  of an apron  14  are then aligned with and inserted into a post slot  28 , as described above. After one end of the apron  14  is inserted into one of the posts  12 , the other end of the apron  14  is inserted into another post  12  (either a front post  12 L or a back, short post  12 W) and the apron end tabs  30  are forced into the post slot  28 . The shelf assembler continues to connect the aprons  14  of the first shelf  16 A to the posts  12  in a similar manner until all of the aprons  14  and posts  12 L,  12 W for the first shelf  16 A are connected. To add back posts  12 B to the assembly, the shelf assembler first inserts joiners  54  into the back, short posts  12 W and then slides the back posts  12 B onto the joiners  54 . The shelf assembler then connects the aprons  14  for a second, work surface level to the front posts  12 L and the back posts  12 B. With all of the aprons  14  and posts  12  connected, the shelves  16  are then inserted into the workbench unit. A back stop  64  is inserted into the channels  26  of the back posts  12 B to create a workbench back stop surface which may be designed to hold tools or other equipment. The back stop  64  may be made from pegboard material or some other appropriate material. Support brackets  66  and a utility shelf  68  may also be provided. With a pegboard back stop  64 , the support brackets  66  hook into holes in the pegboard, and the utility shelf  68  rests on top of the support brackets  66 . The workbench  60 , as with the shelving unit, may be distributed as a disassembled kit with the kit including the necessary post, apron, shelving and back stop pieces.  
         [0027]    Referring to FIGS.  6 A- 6 B, another embodiment of an assembled workbench  70  using the interlock mechanism of the present invention is depicted. The workbench  70  is assembled similar to the workbench  60  described above. The workbench  70  includes a heavy duty work tray  72 , in place of the utility shelf  68  of the previously described embodiment, and also includes a drawer assembly  74 . As FIG. 6C depicts, the work tray  72  includes a support frame  76  which interlocks with the back posts  12 B using the interlock mechanism of the present invention. Tabs  30  of the support frame  76  are inserted into and engage post slots  28  of the posts  12 B. The work tray  72  also includes a support surface  78  which is supported by the support frame  76 . The drawer assembly  74  includes outer slide rails  80 , inner slide rails  82  and a drawer  84 . The outer slide rails  80  have tabs that insert into slots  28  on the posts  12 B,  12 L to connect the outer slide rails  80  to the workbench  70 . The inner slide rails  82 , in turn, connect to the drawer  84 , and in the assembled workbench, the inner slides  82  of the drawer  84  are disposed within the outer slide rails  80  as illustrated in FIG. 6B.  
         [0028]    The present invention may also be used to configure a cabinet. Referring to FIG. 7, an embodiment of an assembled cabinet  90  using the interlock mechanism of the present invention is depicted. The cabinet  90 , as with the workbenches  60 ,  70  and the shelving unit  10 , has a number of posts (or support corners)  12  and a number of braces or aprons  14 . To assemble the cabinet  90 , the aprons  14  are connected to the support corners  12  in the same manner as aprons  14  are connected to the posts  12  for the shelving assembly and workbench assembly configurations. With all of the aprons  14  and support corners  12  connected, shelves  16 , a top  92  and side panels  94  are then inserted into the cabinet unit. A door  96  is then attached to the front of the unit by attaching hinges to the door  96  and a front support corner  12 . The cabinet  90 , as with the shelving unit and the workbenches, may be distributed as a disassembled kit with the kit including the necessary support corners, apron, shelving, top, side panel and door pieces.  
         [0029]    Referring to FIG. 8, in another embodiment of the present invention, the interlock mechanism of the present invention may be used to configure a storage assembly  100 . In the storage assembly  100 , a set of posts  12  and aprons  14  are assembled in the manner described above in another embodiments to form a support structure. A bottom support surface  16 A is placed on the bottom level of aprons  14 . In this embodiment, the top level of aprons  14  do support a shelf or support surface. In this embodiment, storage bags  102 , when stored, are disposed within the support structure. The top portion of the storage bags  102  have a flap  104  that folds over the outer aprons  14  and attaches back to the bag  102  (e.g., with Velcro or some other attachment means). When someone wants to take a storage bag  102  out of the storage assembly  100 , he or she detaches the flap  104  and pulls the bag  102  out.  
         [0030]    While the invention has been discussed in terms of preferred and specific embodiments, it should be appreciated by those of skill in the art that the invention is not so limited. The embodiments are explained herein by way of example, and there are numerous modifications, variations and other embodiments that may be employed that would still be within the scope of the present invention.