Abstract:
A roller rail system includes an adjustment bracket including a first roller rail assembly support portion and a second roller rail assembly support portion adjacent the first roller rail assembly support portion. The first and second roller rail assembly support portions are each configured to receive a roller rail assembly such that the roller rail assembly slides within the respective first and second roller rail assembly support portion relative to the adjustment bracket. A first roller rail assembly is received by the first roller rail assembly support portion. A second roller rail assembly is received by the second roller rail assembly support portion. The roller rail system has a retracted configuration where leading ends of the first and second roller rail assemblies are closer together and an extended configuration where the leading ends of the first and second roller rail assemblies are further apart.

Description:
TECHNICAL FIELD 
       [0001]    The present specification generally relates to roller rail systems and, more particularly, to roller rail systems including adjustment brackets. 
       BACKGROUND 
       [0002]    Various shelving systems and conveyors may utilize a roller-type element, such as a roller wheel or ball, to facilitate movement of goods or parts from one location to another along the shelving systems or conveyors. One example is a gravity feed shelving system that allows a rearward located good to feed forward once a forward located good is removed from the shelving system. 
       SUMMARY 
       [0003]    In one embodiment, a roller rail system includes an adjustment bracket including a first roller rail assembly support portion and a second roller rail assembly support portion adjacent the first roller rail assembly support portion. The first and second roller rail assembly support portions are each configured to receive a roller rail assembly such that the roller rail assembly slides within the respective first and second roller rail assembly support portion relative to the adjustment bracket. A first roller rail assembly is received by the first roller rail assembly support portion. A second roller rail assembly is received by the second roller rail assembly support portion. The roller rail system has a retracted configuration where leading ends of the first and second roller rail assemblies are closer together and an extended configuration where the leading ends of the first and second roller rail assemblies are further apart. 
         [0004]    In another embodiment, a shelving system includes multiple shelving regions. The shelving system includes a front horizontal support member and a rear horizontal support member. A roller rail system spans the front horizontal member and the rear horizontal member. The roller rail system includes an adjustment bracket including a first roller rail assembly support portion and a second roller rail assembly support portion adjacent the first roller rail assembly support portion. The first and second roller rail assembly support portions are each configured to receive a roller rail assembly such that the roller rail assembly slides within the respective first and second roller rail assembly support portion relative to the adjustment bracket. A first roller rail assembly is received by the first roller rail assembly support portion. A second roller rail assembly is received by the second roller rail assembly support portion. The roller rail system has a retracted configuration where leading ends of the first and second roller rail assemblies are closer together and an extended configuration where the leading ends of the first and second roller rail assemblies are further apart. 
         [0005]    In another embodiment, a method of assembling a roller rail system is provided. The method includes positioning a first roller rail assembly in a first roller rail assembly support portion of an adjustment bracket; positioning a second roller rail assembly in a second roller rail assembly support portion of an adjustment bracket; and moving the first roller rail assembly relative to the second roller rail assembly with the first roller rail assembly located in the first roller rail assembly support portion to increase an overall length of the roller rail system. 
         [0006]    These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
           [0008]      FIG. 1  is a perspective view of a shelving system including multiple roller rail systems according to one or more embodiments described herein; 
           [0009]      FIG. 2  illustrates a single shelving region with roller rail system according to one or more embodiments described herein; 
           [0010]      FIG. 3  is a side view of the roller rail system of  FIG. 2  according to one or more embodiments described herein; 
           [0011]      FIG. 4  illustrates an end, section view of a roller rail assembly for use in the roller rail system of  FIG. 3  according to one or more embodiments described herein; 
           [0012]      FIG. 5  illustrates a perspective, side view of the roller rail assembly of  FIG. 4  according to one or more embodiments described herein; 
           [0013]      FIG. 6  illustrates a perspective, end view of an adjustment bracket for use in the roller rail system of  FIG. 2  according to one or more embodiments described herein; 
           [0014]      FIG. 7  illustrates a perspective, side view of the adjustment bracket of  FIG. 6  according to one or more embodiments described herein; 
           [0015]      FIG. 8  illustrates a bottom view of the adjustment bracket of  FIG. 6  according to one or more embodiments described herein; 
           [0016]      FIG. 9  illustrates a top view of the roller rail system of  FIG. 3  in a retracted, shortened configuration according to one or more embodiments described herein; 
           [0017]      FIG. 10  illustrates a top view of the roller rail system of  FIG. 3  in an expanded configuration; and 
           [0018]      FIG. 11  illustrates a method of assembling the shelving and roller rail systems of  FIG. 1  according to one or more embodiments described herein. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    Embodiments described herein generally relate to roller rail systems utilizing an adjustment bracket that allows for adjustment of one or more roller rail assemblies relative to another roller rail assembly. In some embodiments, one of the roller rail assemblies may be adjusted along a length of the other roller rail assembly in order to adjust an overall length of the roller rail system. Such an adjustable roller rail system allows for use of the roller rail system with a plurality of shelving systems or conveyors having various dimensional requirements. Additionally, the adjustable roller rail systems can reduce the amount of scrap roller rail assemblies resulting from cutting the roller rail assemblies to a desired length to fit the various dimensional requirements of the shelving systems and conveyors. 
         [0020]    Referring to  FIG. 1 , a shelving system  10  includes a frame  12  that supports a plurality of shelving regions  14   a - 14   c.  While only three shelving regions  14   a - 14   c  are illustrated, one over another, more or less than three shelving regions may be employed in a single column or multiple columns in a side-by-side arrangement. In the embodiment of  FIG. 1 , however, a single column of shelving regions  14   a - 14   c  is shown for illustration. 
         [0021]    The frame  12  includes front vertical support members  16  and  18  and rear vertical support members  20  and  22  that are located at corners of the shelving system  10 . Additional vertical support members may be located between the vertical support members  16 ,  18 ,  20  and  22 , as needed depending on size, load requirements, etc. The front vertical support members  16  and  18  support front horizontal support members  24 ,  26  and  28  and the rear vertical support members  20  and  22  support rear horizontal support members  30 ,  32  and  34 . In the illustrated exemplary embodiment, the rear horizontal support members  30 ,  32  and  34  are offset vertically above the front horizontal support members  24 ,  26  and  28 . In other embodiments, the rear horizontal support members  30 ,  32  and  34  may be at about the same elevation as the front horizontal support members  24 ,  26  and  28  and/or the front horizontal support members  24 ,  26  and  28  may be offset vertically above the rear horizontal support members  30 ,  32  and  34 . Side rails  36  and  38  may be provided for each of the shelving regions  14   a - 14   c.  Side rail  36  may be supported by the vertical support members  16  and  20  and the side rail  38  may be supported by the vertical support members  18  and  22 . In other embodiments, no side rails may be provided or only one or some of the shelving regions  14   a - 14   c  may include side rails. 
         [0022]    A roller rail system  40   a - 40   c  is located at each shelving region  14   a - 14   c.  Referring to  FIG. 2  illustrating one shelving region  14 , the roller rail system  40  includes a first roller rail assembly  41  and a second roller rail assembly  42  adjacent the first roller rail assembly  41  in a side-by-side arrangement. The first roller rail assembly  41  extends from the front horizontal support member  24  to an adjustment bracket  44  and the second roller rail assembly  42  extends from the adjustment bracket  44  to the rear horizontal support member  30 . In some embodiments, the adjustment bracket  44  is supported on a bracket support member  46  that extends between side horizontal support members  48  and  50  and is located between the front horizontal support member  24  and the rear horizontal support member  30 . In the arrangement of  FIG. 2 , the roller rail system  40  spans the distance between the front horizontal support member  24  and the rear horizontal support member  30 . 
         [0023]    Referring to  FIG. 3 , in some embodiments, at least a portion of the second roller rail assembly  42  extends vertically above at least a portion of the first roller rail assembly  41 . The first roller rail assembly  41  may include a leading end  52  and a trailing end  54  ( FIG. 2 ). The leading end  52  of the first roller rail assembly  41  may be engaged with the front horizontal member  24 . In some embodiments, a connecting tab  53  or other structure may be provided to connect the leading end  52  of the first roller rail assembly  41  to the front horizontal member  24 . In some embodiments, the leading end  52  of the first roller rail assembly  41  may be connected to the front horizontal member  24 , e.g., using fasteners, welding, adhesives, etc. In some embodiments, the first roller rail assembly  41  may include a hook-like member that is used to hook or mate with the front horizontal member  24  in a releasable fashion without use of any tools. The second roller rail assembly  42  may include a leading end  56  and a trailing end  58 . The leading end  56  of the second roller rail assembly  42  may be engaged with the rear horizontal member  30 . In some embodiments, the leading end  56  of the second roller rail assembly  42  may be connected to the rear horizontal member  30 , e.g., using fasteners, welding, adhesives, etc. In some embodiments, a connecting tab  55  or other structure may be provided to connect the leading end  56  of the second roller rail assembly  42  to the rear horizontal member  30 . As used herein, the term “leading end” of the roller rail assemblies  41  and  42  refers to the associated ends that are extended outwardly from the adjustment bracket  44  and located furthest from the adjustment bracket  44 . Accordingly, the leading ends of the roller rail assemblies  41  and  42  may change depending on the direction they are extended relative to the adjustment bracket  44 . In some embodiments, the second roller rail assembly  42  may include a hook-like member that is used to hook or mate with the rear horizontal member  30  in a releasable fashion without use of any tools. 
         [0024]    Referring to  FIG. 4 , the roller rail assembly  41  includes a U-shaped housing member  60  including a first sidewall  62 , a second sidewall  64  and a bottom wall  66  that extends between the first and second sidewalls  62 ,  64 . Rotatably mounted between the first sidewall  62  and the second sidewall  64  are a plurality of roller wheels  68 . The roller wheels  68  may be mounted between the first and second sidewalls  62 ,  64  in a linear fashion where each roller wheel  68  is in front of and/or behind an adjacent roller wheel  68 . In some embodiments, axle pins  71  may be used to rotatably connect the roller wheels  68  to corresponding axle receiving structures  73 . Any suitable connection may be used between the roller wheels  68  and the housing member  60  that allows for rotation of the roller wheels  68  relative to the housing member  60 . In other embodiments, there may be multiple columns of roller wheels mounted in the housing member  60 . 
         [0025]    Referring to  FIG. 5 , the roller rail assembly  41  includes the roller wheels  68  that extend above the sidewalls  62  and  64  to provide a dynamic roller surface that facilitates movement of an object thereon. The sidewalls  62  and  64  may each include openings  70  that extend through the sidewalls  62  and  64 . The openings  70  may be located at least partially between adjacent roller wheels  68 . In some embodiments, the openings  70  of the first sidewall  62  may be aligned across from or facing the openings  70  of the second sidewall  64 . Such an aligned arrangement can facilitate passing a fastener or rod through each of the openings  70 , between adjacent roller wheels  68 . In other embodiments, the openings  70  of the first sidewall  62  may be offset from the openings  70  of the second sidewall  64 . 
         [0026]    Referring to  FIG. 6 , the exemplary adjustment bracket  44  includes a first roller rail assembly support portion  72  and a second roller rail assembly support portion  74  that is adjacent the first roller rail assembly support portion  72 . The first roller rail assembly support portion  72  includes an outer sidewall  76 , an inner sidewall  78  and a floor  80  that extends between the outer sidewall  76  and the inner sidewall  78  thereby forming a somewhat U-shaped first roller rail assembly support portion  72 . Similarly, the second roller rail assembly support portion  74  includes an outer sidewall  82 , an inner sidewall  84  and a floor  86  that extends between the outer sidewall  82  and the inner sidewall  84  thereby forming a somewhat U-shaped first roller rail assembly support portion  74 . In some embodiments, the first roller rail assembly support portion  72  may be formed separately from the second roller rail assembly support portion  74 . The first and second roller rail assembly support portions  72  and  74  may then be connected together, for example, by welding, adhering or otherwise fastening the two roller rail assembly support portions  72  and  74  together such that their inner sidewalls  78  and  84  are side-by-side. In other embodiments, the adjustment bracket  44  may be formed as a single piece, for example, by molding, machining, etc. 
         [0027]    Referring also to  FIG. 7 , each sidewall  76 ,  78 ,  82  and  84  may include openings  90  that extend through the sidewalls  76 ,  78 ,  82  and  84 . In some embodiments, the openings  90  of each of the sidewalls  76 ,  78 ,  82  and  84  may be aligned with openings  90  of the other sidewalls  76 ,  78 ,  82  and  84 . Such an aligned arrangement can facilitate passing a fastener or rod through each of the openings  90  between aligned openings  90 . In other embodiments, the openings  90  of the sidewalls  76 ,  78 ,  82  and  84  may be offset. Each sidewall  76 ,  78 ,  82  and  84  may include bent overhang ledges  95  that extend over a length of the sidewalls  76 ,  78 ,  82  and  84 . The bent overhang ledges  95  of each roller rail assembly support portion  72  and  74  may extend toward one another and overhang their respective floors  80  and  86 . The bent overhang ledges  95  may be used to impede vertical movement of the roller rail assemblies  41  and  42  and facilitate sliding movement of the roller rail assemblies  41  and  42 . 
         [0028]    The distance D b  between the sidewalls  76  and  78 ,  82  and  84  may be greater than a distance D r  between sidewalls  62  and  64  of the roller rail assembly  41 . The distance D b  between the sidewalls  76  and  78 ,  82  and  84  may be selected to allow the roller rail assemblies  41  to slide horizontally between the sidewalls  76  and  78 ,  82  and  84  relative to each other. 
         [0029]    Referring to  FIG. 8 , a connecting bracket  92  may be located at a bottom  94  of the adjustment bracket  44 . In some embodiments, the connecting bracket  92  is a U-shaped member having sidewalls  96  and  98  that are sized to fit about the bracket support member  46 . The connecting bracket  92  may include the sidewalls  96  and  98  that span both of the roller rail assembly support portions  72  and  74  and may be used to engage the connecting bracket  92  to limit movement of the adjustment bracket  44  away from the bracket support member  46  once engaged therewith. In some embodiments, the connecting bracket  92  may be configured for slidable engagement with the bracket support member  46  such that the adjustment bracket  44  can be slid along a length of the bracket support member  46  while engaged therewith. 
         [0030]      FIG. 9  illustrates the adjustment bracket  44  with the first roller rail assembly  41  and the second roller rail assembly  42  adjacent the first roller rail assembly  41  in the side-by-side arrangement. In the embodiment of  FIG. 9 , the roller rail system  40  is in a retracted, shortened configuration where the ends of the first roller rail assembly  41  and the second roller rail assembly  42  are aligned, side-by-side such that a maximum length of the roller rail system  40  is about the same length as one of the first and second roller rail assemblies  41  and  42 . 
         [0031]    Referring to  FIG. 10 , the adjustment bracket  44  allows for individual adjustment of the first roller rail assembly  41  and the second roller rail assembly  42  relative to each other in the directions of arrows  100  and  102 . In some embodiments, both roller rail assemblies  41  and  42  may be adjustable along the same adjustment plane. In other embodiments, the first roller rail assembly  41  and the second roller rail assembly  42  may be adjustable along different planes. In the embodiment of  FIG. 10 , the roller rail system  40  is illustrated in an extended, elongated configuration where both of the roller rail assemblies  41  and  42  are moved relative to the other such that their ends are not aligned. In this elongated configuration, the total length of the roller rail system  40  measured between the ends of the first and second roller rail assembly  41  and  42  is greater than the length of one of the first and second roller rail assemblies  41  and  42 . In some embodiments, for example, the roller rail system  40  may be expandable from about 1500 mm to about 3000 mm. 
         [0032]    Referring to  FIG. 11 , a method  110  of assembling the roller rail system  40  is illustrated. At step  112 , the first roller rail assembly  41  and the second roller rail assembly  42  may be placed in the first and second roller rail assembly support portions  72  and  74  in the side-by-side arrangement. The adjustment bracket  44  may then be engaged with the bracket support member  46  using the connecting bracket  92  at step  114 . At step  116 , the first roller rail assembly  41  may be slid forward in the first roller rail assembly support portion  72  relative to the second roller rail assembly  42  until the free end of the first roller rail assembly  41  engages the front horizontal support member  24 . At step  118 , the second roller rail assembly  42  may be slid rearward in the second roller rail assembly support portion  74  relative to the first roller rail assembly  41  until the free end of the second roller rail assembly  42  engages the rear horizontal support member  30 . In some embodiments, the first and/or second roller rail assembly  41 ,  42  may be fastened to the front horizontal support member  24  and/or the rear horizontal support member  30  at step  120 . At step  122 , a fastener  124  ( FIG. 3 ) may be inserted through one or more of the openings  70  and  90  to fix the positions of the first roller rail assembly  41  and the second roller rail assembly  42  relative to each other and relative to the bracket  44 . The fastener  124  may be sized and located so as to not interfere with rolling of the roller wheels  68 . 
         [0033]    The above-described roller rail systems may include the roller rail assemblies that may be adjusted along a length of the other roller rail assembly in order to adjust an overall length of the roller rail system. Such adjustable roller rail systems can allow for use of the roller rail system with a plurality of shelving systems or conveyors having various dimensional requirements. Additionally, the adjustable roller rail systems can reduce the amount of scrap roller rail assemblies resulting from cutting the roller rail assemblies to a desired length to fit the various dimensional requirements of the shelving systems and conveyors. 
         [0034]    While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.