Abstract:
A post coupler is provided with a pair of coupler flanges having rivet receiving apertures for receiving rivets extending from horizontal shelf-supporting beams to facilitate vertical shelf placement in a shelving unit unfettered by the vertical disposition of the post couplers. Apertures in the coupler index with apertures in abutting corner post sections to permit rivet extension therethrough. The reverse bend flanges of the coupler have a length shorter than the overall length of the coupler.

Description:
PRIORITY CLAIM 
       [0001]    This application is a Continuation-in-Part of U.S. patent application Ser. No. 11/044,689 filed Jan. 27, 2005, published under Publication No. US2006/0163438, entitled “POST COUPLER”, both of which are expressly incorporated herein by reference in their entirety. 
       RELATED PATENT APPLICATIONS 
       [0002]    This application is related to applications filed on even date herewith and including:
       U.S. application Ser. No. ______ entitled “DESIGN FOR WRAPPED POST COUPLER”, attorney docket number EDSM-47;   U.S. application Ser. No. ______ entitled “DESIGN FOR POST COUPLER WITH SCALLOPED EDGES”, attorney docket number EDSM-48;   U.S. application Ser. No. ______ entitled “DESIGN FOR POST COUPLER WITH KEYHOLE OPENING”, attorney docket number EDSM-50;   U.S. application Ser. No. ______ entitled “OUTSIDE WRAP POST COUPLER WITH ASSEMBLY ASSIST”, attorney docket number EDSM-51;   U.S. application Ser. No. ______ entitled “DESIGN FOR POST COUPLER WITH INSIDE WRAP”, attorney docket number EDSM-52;   U.S. application Ser. No. ______ entitled “DESIGN FOR POST COUPLER WITH SCALLOPED EDGES AND INSIDE WRAP”, attorney docket number EDSM-53;   U.S. application Ser. No. ______ entitled “DESIGN FOR POST COUPLER WITH KEYHOLES AND INSIDE WRAP”, attorney docket number EDSM-55;   U.S. application Ser. No. ______ entitled “INSIDE WRAP POST COUPLER ACCOMMODATING BEAM RIVET”, attorney docket number EDSM-55A;   U.S. application Ser. No. ______ entitled “INSIDE WRAP POST COUPLER WITH ASSEMBLY ASSIST”, attorney docket number EDSM-56; and   U.S. application Ser. No. ______ entitled “DESIGN FOR INNER POST COUPLER”, attorney docket number EDSM-57.       
 
         [0013]    All these related applications are herewith expressly incorporated herein by reference as if fully set out herein. 
     
    
     FIELD OF THE INVENTION 
       [0014]    This invention relates to shelving and post couplers used in coupling shelf supporting columns end-to-end and accommodating horizontal shelf-supporting beams. 
       BACKGROUND OF THE INVENTION 
       [0015]    Prior post couplers have been used to couple post ends together to form an elongated, unitary corner post or column used with other corner posts to support a plurality of shelves mounted on elongated brackets or beams connected to and extending horizontally between the corner posts. Typically, the posts are of angled construction defined by flanges at 90° to each other and are provided with keyhole-shaped slots for receiving rivets extending from the elongated shelf beams which are oriented horizontally between the posts. The rivets interlock the beams to the posts to define a ladder-like shelf frame on which shelves are supported. 
         [0016]    These beams can thus be adjusted vertically, up and down the posts, to provide for a desired vertical spacing between shelf members supported by the beams. This range of vertical adjustability is limited, however, by the post couplers, which serve to interconnect post members in vertical alignment to form a unitary post used as a column. 
         [0017]    It will be appreciated that in a shelving apparatus formed by composite posts which are defined by two or more post sections, coupled end-to-end by such couplers, the length of the couplers is typically long enough that the coupler covers at least two levels of rivet-receiving keyhole slots in each of two adjacent post members. The prior couplers then cover, mask or obstruct four levels of slots in the assembled post. This prevents location of shelf-supporting brackets at the vertical height where the post members are joined by the couplers, since no beam supporting rivets can be extended through slots of the post at the ends of the vertical post members and which are covered by the couplers. There is thus a vertically-oriented void area in a prior shelving unit defined by the vertical extent of the useful, but slot-blocking, post couplers. 
         [0018]    In addition, it is desirable to enhance or facilitate the combination of a post coupler with a post so that obstruction from linear or flat edges of the components is eliminated. 
         [0019]    Accordingly, it is desirable to provide a shelving unit with an unlimited vertical spacing capacity for the shelves where the corner posts are each defined by at least two end-to-end post members. 
         [0020]    A further objective of the invention has been to provide a post coupler in combination with corner post members in a shelving unit wherein the couplers may be integrated with the shelf-supporting beams to provide unlimited vertical positioning of the shelf along the length of the shelving unit corner posts. 
         [0021]    A further objective of the invention has been to provide a post coupler for accommodating the horizontal shelf supporting beams at their interface with shelf unit corner posts. 
         [0022]    A further objective has been to facilitate the combination of a post coupler to a post section. 
       SUMMARY OF THE INVENTION 
       [0023]    To these ends, a preferred embodiment of the invention contemplates a shelving unit having corner posts, each comprising at least two corner post members coupled end-to-end with a post coupler and a plurality of shelf-supporting beams coupled to the corner posts via fasteners, the post coupler having apertures aligned with fastener-accepting apertures in the respective corner post members for receiving such fasteners, wherein the beams can be connected along the corner posts at selected positions, including positions traversed by the post couplers of the corner posts. Apertures in the post coupler are indexed or aligned with apertures in adjacent corner post members so the aperture spacing in the couplers is cooperative with the spacing of apertures in the connected-together corner post members. 
         [0024]    Moreover, in a preferred coupler embodiment, the coupler has two main flanges and two inwardly directed, reverse bend flanges for disposition around edges of the post sections from the outside. These reverse bend flanges are of such limited width that they do not extend across any portions of the apertures in either the coupler or the post section. In this way, such couplers provide for unobstructed pass-through of the rivets extending from the beams into and through the couplers and the posts. 
         [0025]    In one embodiment of a shelving unit provided with such coupler, a beam is disposed to interface with a post or coupling on the interior side thereof. In another embodiment, the beam is disposed on one exterior side of the coupling post. 
         [0026]    These and other features and advantages of the invention will be further readily understood from the following written description and from the drawings in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  is an isometric view of a shelving unit according to the invention; 
           [0028]      FIG. 2  is an enlarged isometric view of a portion  2  of  FIG. 1  from the interior area of the shelving unit and at the juncture of beam, post and coupler; 
           [0029]      FIG. 2A  is an isometric view of the post coupler of the invention; 
           [0030]      FIG. 3  is a plan view in partial cross-section taken along lines  3 - 3  of  FIG. 2  with an offside portion of the coupler broken away with the beams mounted inside the post and the coupler; 
           [0031]      FIG. 4  is an elevational view in partial cross-section of the coupler, posts and beams taken along lines  4 - 4  of  FIG. 2 ; 
           [0032]      FIG. 5  is a cross-sectional view taken along lines  5 - 5  of  FIG. 3 ; 
           [0033]      FIG. 6  is an enlarged view of the encircled area  6  of  FIG. 5 ; 
           [0034]      FIG. 7  is a cross-sectional view taken along lines  7 - 7  of  FIG. 3 ; 
           [0035]      FIG. 8  is an enlarged view of the encircled area  8  of  FIG. 7 ; 
           [0036]      FIGS. 9-15  are similar to  FIGS. 2-8  but show an alternate position of the shelf-supporting beams; 
           [0037]      FIG. 9  is an isometric view similar to  FIG. 2  but showing an alternate embodiment with beams mounted on the outside of the coupler; 
           [0038]      FIG. 10  is a plan top view taken along lines  10 - 10  of  FIG. 9 ; 
           [0039]      FIG. 11  is a cross-sectional view similar to  FIG. 4  but is taken along lines  11 - 11  of  FIG. 9 ; 
           [0040]      FIG. 12  is an elevational view in partial cross-section taken along lines  12 - 12  of  FIG. 10 ; 
           [0041]      FIG. 13  is an enlarged view of the encircled area  13  of  FIG. 12 ; 
           [0042]      FIG. 14  is a cross-sectional view taken along lines  14 - 14  of  FIG. 10 ; and 
           [0043]      FIG. 15  is an enlarged view of the encircled area  15  of  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0044]    Turning now to the drawings and in particular, to  FIGS. 1-8 , one embodiment of the invention comprises a shelf unit  10  having a plurality of shelves  11 - 15 . Four composite corner posts or columns  16 - 19  define the corners of unit  10 , each comprising at least two post sections (could be more) joined by a coupler as at  20  (three appear in  FIG. 1  for posts  16 ,  17  and  18 , respectively). Each shelf  11 - 15  is supported by four horizontally-oriented shelf-supporting brackets or beams as at side beams  21 , and front and rear beams  22 , with front and rear beams  22  being longer than side beams  21 . The rear beam and offside beams not shown in  FIG. 1  are respectively identical to the front ( 22 ) and side ( 21 ) beams as shown in  FIG. 1 . Side beams  21  on one hand and the front/rear beams  22  on the other hand differ essentially only in length and are otherwise identical. 
         [0045]    With attention to  FIG. 2 , there is shown from the perspective of the interior of the unit  10  a representative corner structure as at post  17 , comprised of lower post section  25  and upper post section  26 , coupled in end-to-end abutting relationship via coupling or coupler  20  to form a unitary post. The posts, post sections, coupling  20 , and the end structure of the beams at each corner of unit  10  are essentially identical, so only one corner structure, coupler, post section and beam intersection as in  FIG. 2  will be described. 
         [0046]    For clarity, a shelf such as shelf  13  is shown in phantom lines only in  FIGS. 2 and 3 . 
         [0047]    For purposes of this application, the terms “inner”, “inside”, or “interior” refer to a post or coupler as viewed from within a shelving unit, while the terms “outer”, “outside” or “exterior” refer to the post or coupler as viewed from without a shelving unit. 
         [0048]    Each lower and upper post section  25 ,  26  is provided with a series of keyhole-shaped apertures  30  as shown, each preferably identically spaced in each post section, one from the other. Preferably, the endmost aperture  30  in each post section  25 ,  26  is spaced from the section ends at one-half pitch so that when sections  25 ,  26  are abutted, the two endmost apertures  30  are spaced from each other at the same pitch as each aperture  30  is spaced from other apertures  30  in the same post section. Apertures  30  have enlarged and narrower portions as shown. 
         [0049]    Each post section  25 ,  26  is preferably in the form of an angle, formed by two post flanges  34 ,  35  at a preferred included angle A of about 90° with respect to each other. Each post flange has an elongated edge  34   a ,  35   a  as shown. 
         [0050]    Post sections  25 ,  26  preferably abut each other end-to-end at section ends  25   a ,  26   a.    
         [0051]    As noted, beams  21 ,  22  are generally identical except for length in this embodiment; the length of such beams being variable to accommodate the width and depth of a desired shelving unit  10 . Beams  21 ,  22  each incorporate a beam web  40 , an upper reverse bend at  41 , a flange  42  bent to reside alongside an upper margin of web  40 , and a 90° bend defining a shelf-supporting flange  43 , all as clearly shown in  FIGS. 2-5  and  7 . 
         [0052]    As perhaps best seen in  FIG. 3 , flanges  42 ,  43  are terminated short of ends  21   a  and  22   a  of webs  40 . Shelf-supporting flanges  43  are relieved or tapered at an angle, as shown in plan view in  FIG. 3 , in a direction away from ends  21   a ,  22   a , so as not to interfere with any proximate beam end. 
         [0053]    Each beam  21 ,  22  is provided proximate its ends  21   a ,  22   a , with two beam supporting lugs or rivets  45 ,  46  ( FIG. 4 ), one above the other. The cross-sectional views of  FIGS. 5-6  illustrate one suitable shape of the rivets  45 ,  46 . 
         [0054]    Rivets  45 ,  46  extend through coupling  20  and through respective holes  30  in the post end sections  25   a ,  26   a  described above, and as will be described. 
         [0055]    Post coupling  20  is best seen in  FIG. 16 . The coupling comprises two major integral coupler flanges  50 ,  51  disposed at an included angle (at bend  56 ) to each other at preferably 90°, preferably similar to angle A between the post flanges  34 ,  35 . 
         [0056]    Each major flange has a reverse bend or fold  52 ,  53  and an inwardly directed reverse bend flange  54 ,  55  respectively turned inwardly, each flange  54 ,  55  lying parallel to the respective flanges  50 ,  51  from which they extend. 
         [0057]    A gap G is defined by the respectively adjacent flanges  50 ,  54  and  51 ,  55  respectively, this gap being approximately equal to the thickness of post flanges  34 ,  35  respectively. 
         [0058]    At each end of the bend  56 , the coupler  20  includes a rounded projection  58 ,  59  projecting outwardly from the ends of flanges  50 ,  51  at bend  56 . 
         [0059]    Coupler  20  also includes a plurality of keyhole-shaped apertures  60 - 63  as shown in  FIG. 16 , one above the other respectively, so apertures  60 ,  62  are respectively above apertures  61 ,  63  at the same distance or pitch as separate apertures  30  in the post end sections  25   a ,  26   a . Apertures  60 - 63  are preferably in the same shape as apertures  30  in the post sections  25 ,  26 . 
         [0060]    Coupler  20  is also provided with a plurality of detents or projections  65  in the respective reverse bend flanges  54 ,  55 . These extend inwardly into the respective gaps G, and serve to frictionally engage post end sections  25   a ,  26   a  in gaps G when the post end sections are inserted into the coupler  20 . 
         [0061]    In this regard, it will be appreciated the rounded projections  58 ,  59  serve to aid in the introduction of respective post end sections into the coupler. Thus, projections  58 ,  59  serve to help guide and facilitate the introduction of the post sections into coupler  20 . 
         [0062]    Projections  58 ,  59  extend from coupler flanges  50  and  51  respectively, at opposite ends of the coupler, the distance between their outermost edges defining an overall coupler length. it will be appreciated that the respective reverse bend flanges are shorter longitudinally than said overall length, each terminating short of an end of the coupler defined by the projection. 
         [0063]    Finally, note the reverse bend flanges  54 ,  55  have respective edges  54   a ,  55   a . These define the inward extent of flanges  54 ,  55  so the flanges do not extend over and block apertures  60 - 63 . The reverse bend flanges thus do not subtend apertures  60 - 63 , as would block them for passage of rivets as will be discussed. 
         [0064]    Turning now to the relationship of the components as coupled and connected in an erected shelving unit,  FIGS. 2-8  reflect such a unit where the beams  21 ,  22  are disposed on the inside of post sections  25 ,  26  (and posts  16 - 19 ).  FIGS. 9-15  reflect another embodiment wherein beams  21 ,  22  reside outside post sections  25 ,  26  and posts  16 - 19 . 
         [0065]    It will be appreciated the concepts shown in  FIGS. 9-16  above are identical to those of  FIGS. 2-8  and  16 , excepting for the relative dispositions, and excepting the length of the respective rivets  45 ,  46  in  FIGS. 2-8  and shorter rivets  75 ,  76  in  FIGS. 9-15 . 
         [0066]    In  FIGS. 2-8 , beams  21 ,  22  are located inside of posts  16 - 19 . Coupler  20  is disposed substantially outside the posts.  FIG. 2  broadly illustrates this embodiment while remaining  FIGS. 3-8  show its details. 
         [0067]    Referring to  FIG. 3 , coupler  20  is disposed proximate the bottom end  26   a  of upper post section  26 , coupler  20  in secure contact with post section  26 . Detents  65  frictionally engage and hold post section  26   a  in gap G, it being appreciated there is some flexibility in flanges  54 ,  55 . Webs  40  of beams  21 ,  22  lie against reverse bend flanges  55 ,  54  respectively. 
         [0068]    Rivets  45  ( FIG. 3) and 46  ( FIG. 4 ) extend through webs  40 , post section  25 ,  26  and coupler  20 . Interior rivet heads  47  seat on webs  40 . Exterior rivet heads  48  are positioned to pass through the enlarged portions of the post section  25  and coupler  20 , allowing shanks  49  to seat in the narrower sections of apertures  30 , and  60 ,  62 , securing the components together. Exterior rivet heads  48  rest against those portions of post section  26  surrounding the narrow portions of apertures  60 ,  62 . 
         [0069]    The same is true of lower rivets  46  respecting apertures  30  in lower post section  25  and coupler apertures  61 ,  63 . It will here be appreciated that since edges  54   a ,  55   a  of coupler  20  do not block apertures  60 - 63  in coupler  20 , and the rivet heads  48  may pass therethrough in the enlarged portions of the apertures to facilitate erection of shelving unit  10 . 
         [0070]    Turning now to  FIGS. 9-15 , beams  21 ,  22  are disposed on the outside of coupler  20  and of posts  16 - 19  as shown. Components of this embodiment numbered as the same components of  FIGS. 2-8  are the same except for relative disposition. 
         [0071]    In this embodiment, upper and lower rivets  70 ,  71  are somewhat shorter than rivets  45 ,  46  of  FIGS. 2-8 . Rivets  70 ,  71  have respective exterior and interior heads  72 ,  73  ( FIG. 10 ). Interior heads  73  pass through enlarged apertures  60 - 63  respectively of coupler  20  and post sections  25 ,  26  respectively, resting on the portions of posts  25 ,  26  surrounding the narrower portions of apertures  30 . Exterior heads engage the webs  40  of the beams  21 ,  22 . 
         [0072]      FIGS. 10-15  illustrate in respective cross-section the details of this embodiment. A shelving unit as in this embodiment will have the appearance of unit  10  of  FIG. 1 , excepting the ends of beams  21 ,  22  will be positioned outside posts  16 - 19  and couplers  20 . 
         [0073]    It will also be appreciated that the invention may include other configurations of the beams  21 ,  22  suitable with end structures as depicted herein. Other shelf-supporting elements formed in other such beams can be provided to produce shelving units of other configurations, such as where the surfaces of the shelves are disposed below the upper edges of the beams, for example. 
         [0074]    Accordingly, this invention contemplates a post coupler in outside wrap form with flanges wrapping around the edges of an angular post from the outside and accommodate shelf-supporting beams disposed at their ends interiorly of the posts or alternately on the outside of the posts, and the couplers accommodating beam supporting rivets without limit to the vertical beam position and shelves supported thereby within the height of the shelf unit corner posts including the areas where composite sections of the post are coupled. 
         [0075]    These and other modifications and variations of the invention will be readily appreciated by the foregoing to those of ordinary skill in the art without departing from the scope of the invention and applicant intends to be bound only by the claims appended hereto.