Abstract:
A shelf is defined by a tempered glass panel bonded to opposing flanges of a pair of metal shelf brackets carrying hooks for connection to and adjustment along vertical trackways in refrigerator compartments. Adhesive constitutes the sole means for maintaining the shelf substantially rigidly united. Each shelf bracket includes at least one abutment surface for engaging an edge of the shelf panel or a handgrip member carried thereby to assure perfect alignment between the components during curing of the adhesive. Each shelf bracket is defined by a shelf arm and a flange with the flanges having pockets housing the adhesive. The shelf arms may additionally include uppermost projections for engaging side edges of the shelf panel and/or at least one additional flange, such that side edge portions of the shelf panel can be housed between the pair of vertically spaced longitudinally offset flanges of each shelf bracket.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to shelving for refrigerators and the like, though it is equally capable of being utilized as a bookshelf or a shelf associated with most any type of furniture as a cantilevered shelf defined by a pair of shelf brackets and a shelf panel supported therebetween.  
         [0002]     Shelves specifically designed for refrigerators are well known, and typical thereof is the cantilevered shelf of  FIG. 1  of U.S. Pat. No. 5,362,145 issued on Nov. 8, 1994 to Kevin C. Bird et al. The cantilevered shelf is formed by a planar tempered glass shelf member or panel and a pair of metal support brackets which are united to each other by a molded polymeric/copolymeric synthetic resinous thermoplastic material encapsulation or rim. The rim is molded around the entire peripheral edge of the glass shelf member or panel and forms a spill dam for containing product spills occurring when the shelf or shelf assembly is in use in an associated refrigerator compartment. Such encapsulated shelves have been exclusively manufactured and sold by the assignee of the present application and are generally utilized in high-end/expensive refrigerators because of shelf rigidity, product drip/spillage protection and the extremely attractive aesthetic appearance achieved through the injection molding or encapsulation of the shelf brackets to the glass shelf panel.  
         [0003]      FIG. 46  of the latter patent discloses another cantilevered shelf assembly in which a rim or encapsulation of polymeric/copolymeric synthetic plastic material totally encompasses an edge of a piece of tempered glass and is snap-attached by clips of the encapsulation or rim to front and rear frame members of a generally polygonal wire frame which includes side frame brackets and associated hooks for securing the shelf assembly to conventional slotted vertical tracks of a refrigerator compartment. The aesthetics of the latter shelf assembly are inferior to those of the shelf assembly first described herein, but the cost of manufacture and assembly can be less, particularly if assembled manually in countries outside the United States having lower wages, benefits, etc. However, the latter shelf assembly retains the liquid dam or anti-drip function which is a desirable feature, particularly for cantilevered shelves upon which might be supported products tending to drip or leak, particularly when the shelf is vertically adjusted.  
         [0004]     In lieu of the metal shelf brackets or polygonal metal wire frame of U.S. Pat. No. 5,362,145, U.S. Pat. No. 6,488,347 issued on Dec. 3, 2002 in the name of Craig Bienick discloses a refrigerator shelf formed of but two pieces of material, namely, a glass shelf panel bounded by an integral, injection-molded, one-piece frame/encapsulation/rim of polymeric/copolymeric synthetic plastic material which includes integral shelf brackets and suspension hooks defined by the encapsulation/rim. This shelf assembly includes all of the advantages of the shelf assembly first described with respect to U.S. Pat. No. 5,362,145 and desirably excludes separate metal shelf brackets. However, the entire periphery of the encapsulation and particularly the side shelf arms must be reinforced to prevent adverse torquing characteristics which would occur if the polymeric/copolymeric shelf arms were made extremely thin. Therefore, though the shelf assembly of the latter patent excludes manual assembly costs, the latter could be offset by the added cost of the polymeric/copolymeric material utilized in the injection molding of the rim/encapsulation to effect rigidity/reinforcement thereof. Obviously, such conventional material is derived from petroleum and both availability and price stability thereof have always been a problem, particularly when quoting manufacturing costs of shelves one or more years into the future, as is customary under long-term customer purchase agreements.  
         [0005]     A relatively simplistic refrigerator shelf is found in U.S. Pat. No. 4,923,260 issued on May 8, 1990 to Douglas Poulsen. The refrigerator shelf includes a pair of metal cantilevered shelf supports or brackets which are rigidly interconnected to each other by a rigid rear support rod or cross member. The glass shelf is inserted into a rear shelf retainer which carries a downwardly opening U-shaped clip which engages the rear rod. A U-shaped front cross member is also rigidly secured between front or free ends of the cantilevered shelf supports. Though relatively simplistic with respect to the various parts required to form the shelf, the welding of the front and rear cross members to the shelf brackets is expensive, as is the complex nature of the extruded rear clip.  
         [0006]     The latter patents and those additionally specified in U.S. Pat. No. 6,488,347 establish the state of the cantilevered shelf art over which the present disclosure is considered to be a novel and unobvious departure.  
       SUMMARY OF THE INVENTION  
       [0007]     In keeping with the foregoing, a novel shelf, particularly a cantilevered shelf which is adapted to be hooked to and vertically adjusted with respect to conventional slotted trackways in a refrigerator compartment, is manufactured from a pair of metal shelf brackets, a shelf panel preferably made of tempered glass, and adhesive for uniting the latter three shelf components in a substantially rigid manner. Through the utilization of but two metal shelf brackets which are appropriately blanked or severed from a planar piece of sheet metal, contoured/bent and, if desired, painted, bonding material is utilized to rigidly adhere upper surfaces of opposing flanges of the shelf brackets to an underside of the tempered glass panel. The flanges of each shelf bracket preferably include an upwardly opening reservoir or pocket in which the adhesive or bonding material can be located such that upon assembly of the glass panel side edges to the flanges, the adhesive/bonding material will not extrude laterally inwardly or outwardly of the flanges whereby aesthetics is enhanced due to the absence of visible extruded adhesive/bonding material inboard or outboard of the flanges.  
         [0008]     In further accordance with the present invention, each cantilevered shelf arm of each bracket includes at least one projection which projects upwardly beyond its associated flange such that the projections engage side edges of the tempered glass panel to rigidify the assembly along the shelf bracket length thereof thereby precluding undesired torquing of the rigidly adhesively united shelf.  
         [0009]     In further accordance with the present invention, each of the shelf arms includes at least a second flange spaced above the first flange and longitudinally offset therefrom which collectively afford upper and lower support to side edge portions of the tempered glass panel housed therebetween. The shelf of the present invention also includes means for locating the tempered glass shelf panel relative to each of the shelf brackets to assure perfect alignment of the components as the adhesive dries/bonds which thereby assures substantially perfect parallelism between the metal shelf arms or brackets which enhances the anti-torquing characteristics and rigidity of the shelf.  
         [0010]     With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  is a top perspective view of a novel cantilevered refrigerator shelf constructed in accordance with this invention, and illustrates a pair of metal shelf brackets spanned by a transparent tempered glass shelf panel which in turn carries a front grip member and a rear product retention member each formed of synthetic polymeric/copolymeric synthetic plastic material.  
         [0012]      FIG. 2  is an exploded front perspective view of the shelf of  FIG. 1 , and illustrates each shelf arm in the form of a relatively flat side shelf bracket having a hook and reinforcement at a rear end thereof, and an inwardly directed shelf panel support flange defining along its length an upwardly opening pocket.  
         [0013]      FIG. 3  is a side elevational view of the shelf of  FIG. 1 , and illustrates a front edge of the shelf bracket and the shelf panel support flange and a rear edge of the shelf panel support flange abuttingly engaging the respective front grip and rear product retention members to accurately locate the glass shelf or glass panel relative to the shelf bracket incident to a bonding operation.  
         [0014]      FIG. 4  is a fragmentary enlarged cross-section view taken generally along line  4 - 4  of  FIG. 3 , and illustrates structural adhesive in the pocket of the flange for rigidly bonding an upper surface of the shelf panel support flange to a lower surface of the tempered glass shelf panel.  
         [0015]      FIG. 5  is longitudinal cross-sectional view taken generally along line  5 - 5  of  FIG. 1 , and more clearly illustrates the manner in which front and rear edges of the shelf bracket engage the respective front grip and rear product retention members to locate each of the shelf brackets relative to the tempered glass panel during curing of the adhesive.  
         [0016]      FIG. 6  is a top perspective view of another novel cantilevered refrigerator shelf constructed in accordance with this invention, and illustrates a pair of metal shelf brackets spanned by a transparent tempered glass shelf panel which in turn carries a front grip member and a rear product retention member each formed of synthetic polymeric/copolymeric synthetic plastic material.  
         [0017]      FIG. 7  is a side elevational view of the shelf of  FIG. 6 , and illustrates a front edge of the shelf bracket and the shelf panel support flange and a rear edge of the shelf panel support flange abuttingly engaging the respective front grip and rear product retention members to accurately locate the glass shelf or glass panel relative to the shelf bracket incident to a bonding operation.  
         [0018]      FIG. 8  is a fragmentary enlarged cross-section view taken generally along line  8 - 8  of  FIG. 7 , and illustrates structural adhesive in a pocket of the flange for rigidly bonding an upper surface of the shelf panel support flange to a lower surface of the tempered glass shelf.  
         [0019]      FIG. 9  is a fragmentary enlarged cross-section view taken generally along line  9 - 9  of  FIG. 7 , and illustrates structural adhesive in the pocket for rigidly bonding the shelf panel support flange to a lower surface of the tempered glass shelf and an uppermost projection of the shelf bracket for effecting edge abutting alignment of the glass panel.  
         [0020]      FIG. 10  is a longitudinal cross-sectional view taken generally along line  10 - 10  of  FIG. 6 , and more clearly illustrates the manner in which front and rear edges of the shelf bracket engage the respective front grip and rear product retention members to accurately locate each of the shelf brackets relative to the tempered glass panel during curing of the adhesive.  
         [0021]      FIG. 11  is a top perspective view of another novel cantilevered refrigerator shelf constructed in accordance with this invention, and illustrates a pair of metal shelf brackets spanned by a transparent tempered glass shelf panel which in turn carries a front grip member formed of synthetic polymeric/copolymeric synthetic plastic material and a rear locating tab of the shelf brackets engaging a rear edge of the shelf panel.  
         [0022]      FIG. 12  is a side elevational view of the shelf of  FIG. 11 , and illustrates a front edge of the shelf bracket and the shelf panel support flange and a rear edge of the shelf panel support flange abuttingly engaging the respective front grip member and shelf panel rear edge to locate the glass shelf or glass panel relative to the shelf bracket incident to a bonding operation.  
         [0023]      FIG. 13  is a fragmentary enlarged cross-section view taken generally along line  13 - 13  of  FIG. 12 , and illustrates structural adhesive in a pocket of the shelf panel support flange for rigidly bonding the shelf panel support flange to a lower surface of the tempered glass shelf and an uppermost overlying flange engaging an upper surface of the glass shelf.  
         [0024]      FIG. 14  is a fragmentary enlarged cross-section view taken generally along line  14 - 14  of  FIG. 12 , and illustrates structural adhesive in the pocket at a longitudinal portion of the shelf bracket which excludes the uppermost overlying flange.  
         [0025]      FIG. 15  is a longitudinal cross-sectional view taken generally along line  15 - 15  of  FIG. 11 , and more clearly illustrates the manner in which front and rear edges of the shelf bracket engage the respective front grip member and shelf panel rear edge to locate each of the shelf brackets relative to the shelf panel during curing of adhesive and longitudinally alternating relationship of the shelf panel support and overlying flanges.  
         [0026]      FIG. 16  is a fragmentary enlarged cross-sectional view taken generally along line  16 - 16  of  FIG. 12 , and illustrates the manner in which the locating projection or tab formed from the shelf bracket material is aligned for abutment with the rear terminal edge of the tempered glass shelf or panel. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0027]     A novel cantilevered shelf or shelf assembly constructed in accordance with this invention which is particularly adapted for utilization in fresh food or frozen food compartments of a refrigerator in association with slotted vertical trackways thereof is illustrated in  FIGS. 1 through 5  of the drawings and is generally designated by the reference numeral  10 .  
         [0028]     The shelf  10  is constructed from three primary components, namely, a shelf panel  11  and a pair of metal cantilever side shelf brackets  12 ,  13  and secondary components in the form of a front grip or gripping member  14  and a rear product retention member  15  carried by the shelf panel  11 .  
         [0029]     The shelf panel  11  is preferably constructed from a polygonal piece of transparent tempered glass defined by side edge portions  16 ,  17  having respective side edges  18 ,  19  in substantially parallel relationship to each other and front and rear edge portions  20 ,  21  having respective front and rear edges  22 ,  23  ( FIGS. 3 and 5 ) also in substantially parallel relationship to each other. The shelf panel  11  also includes an upper substantially planar surface  24  and a lower substantially planar surface  25 . Each of edges  18 ,  19 ,  22 ,  23  is preferably ground and, if desired, either or both of the members  14 ,  15  can be eliminated.  
         [0030]     The metal shelf brackets  12 ,  13  are substantially identical to each other and are each cut or blanked from a sheet of planar metallic material and formed to the configurations and cross-sections best illustrated in  FIGS. 2 and 4  of the drawings. Each shelf bracket  12 ,  13  includes a cantilevered relatively flat shelf arm  30 ,  31  having a respective rear end portion  32 ,  33  and a respective front end portion  34 ,  35 . The rear end portions  32 ,  33  of the respective shelf arms  30 ,  31  carry respective reinforced hooks  36 ,  37  and projections  38 ,  39  which are utilized in a conventional manner to secure the shelf  10  in slots of vertical trackways of a refrigerator compartment (not shown) in a conventional manner, particularly as is illustrated in  FIG. 1  of U.S. Pat. No. 5,362,145.  
         [0031]     Each shelf bracket  12 ,  13  additionally includes a shelf panel support flange  40 ,  41 , respectively, which project laterally toward each other, as is most apparent from  FIG. 2  of the drawings. Since the shelf panel support flanges  40 ,  41  are identical, the immediate description of the shelf panel support flange  40  is equally applicable to the shelf panel support flange  41 . The shelf panel support flange  40  ( FIG. 4 ) includes an inboard flange portion  42  most adjacent an upper longitudinal portion (unnumbered) of the shelf arm  30 , an outboard flange portion  43  terminating at a lateral terminal edge  44  and a medial flange portion  45  between the flange portions  42 ,  43  of a generally upwardly opening U-shaped transverse cross-sectional configuration defining a reservoir or pocket  46  in which structural adhesive means A is introduced incident to assembling and bonding together the shelf panel  11  and the shelf brackets  12  and  13 , as will be described more fully hereinafter.  
         [0032]     A plane P 1  ( FIG. 4 ) is common to upper surfaces (unnumbered) of the inboard and outboard flange portions  42 ,  43 , respectively, and is also common to the lower surface  25  of the shelf panel  11 .  
         [0033]     Each of the shelf panels support flanges  40 ,  41  include means  50 ,  51  ( FIGS. 2, 3  and  5 ) defined by forwardmost and rearwardmost edges of the respective shelf panel support flanges  40 ,  41 , for locating the shelf panel  11  accurately relative to the shelf brackets  12 ,  13  until such time as the adhesive A has cured to assure parallelism between the shelf brackets  12 ,  13 , parallelism of the side edges  18 ,  19  of the shelf panel  11  relative to the shelf brackets  12 ,  13 , and substantial normalcy between the shelf arms  30 ,  31  and the shelf panel  11 .  
         [0034]     The front grip member  14  and the product retention member  15  can either be injection molded upon the respective front and rear edge portions  20 ,  21  of the shelf panel  11  or can be manufactured and post-assembled by sliding the same upon the respective edge portions  20 ,  21  of the shelf panel  11 . Members  14 ,  15  have lower transverse edges  52 ,  53  ( FIGS. 3 and 5 ) which are spaced a distance D 1  from each other. The distance D 1  corresponds to the substantially identical distance D 1  ( FIG. 2 ) between the locating means  50 ,  51  of the shelf panel support flanges  12 ,  13 . Therefore, as the shelf panel  11  is assembled relative to the shelf brackets  12 ,  13 , as is readily visualized in  FIG. 2  by imagining the latter components being moved toward one another to the position shown in  FIG. 1 , the transverse edges  52 ,  53  of the transverse members  14 ,  15 , respectively, will abuttingly engage and thereby be located by the locating means or edges  50 ,  51 , respectively, of the respective shelf brackets  12 ,  13 . The adhesive A is preferably deposited in the pockets  46  of each of the shelf panel support flanges  40 ,  41  before the lower surface  25  of the glass shelf panel  11  is moved to the position shown in  FIG. 4 . The adhesive A can extend the entire length of each of the reservoirs or pockets  46  and slightly above the plane P 1  ( FIG. 1 ) before assembly. A bead of the adhesive A of a generally cylindrical cross-sectional configuration, as viewed in  FIG. 4  though not illustrated therein, with an uppermost surface slightly above the plane P 1  will be maintained in the latter configuration by surface tension. Thereafter, as the lower surface  25  of the glass shelf panel  11  moves toward the flange portions  42 ,  43  and in contact therewith the bead of adhesive A will flatten and expand laterally in both lateral directions, but will not be extruded or squeezed laterally outwardly and inwardly beyond either flange portions  42  or  43 , respectively. The latter is highly desirable to preclude the necessity of cleaning extruded adhesive A from areas inboard of the shelf supporting flange edge  44  and/or outboard of the juncture between the shelf edges  18 ,  19  and the respective bracket arms  30 ,  31 . However, such extrusion will not occur in accordance with this invention by placing beads of adhesive A in spaced relationship to each other along each of the pockets or reservoirs  46  in the manner illustrated in  FIG. 2  of the drawings. In the latter case, should there be an excess of adhesive A in the pockets  46  of the shelf panel support flanges  40 ,  41 , the same will be pushed, extruded or squeezed lengthwise along the pockets  46  because of the lesser longitudinal resistance to flow as opposed to lateral resistance to flow/friction offered by the U-shaped flange wall portion  45 . Hence, the pockets  46  define means for preventing lateral extrusion or flow in either direction of the adhesive A therefrom and promoting longitudinal extrusion or flow along the length of the pockets  46 , thus assuring an aesthetically appearing shelf  10 .  
         [0035]     The adhesive A is preferably a structural adhesive/sealant, such as AM-47, which provides high strength and excellent adhesion while being tough, elastic and waterproof, all characteristics being requisite for utilization of the shelf  10  in refrigerator compartments, particularly in view of the moisture normally associated therewith, both by way of normal condensation and product spillage. The AM-47 adhesive can be used absent primers, is fast curing, is of extremely low shrinkage, is paint/enamel compatible and, when cured, satisfies all U.S. Federal Regulations, such as OSHA Hazardous Communication Standards.  
         [0036]     Another novel cantilevered shelf or shelf assembly constructed in accordance with this invention which is also particularly adapted for utilization in fresh food or frozen food compartments of a refrigerator in association with slotted vertical trackways thereof is illustrated in  FIGS. 6 through 10  of the drawings and is generally designated by the reference numeral  100 . Components of the shelf assembly  100  which correspond to like components of the shelf assembly  10  have been prefixed by “100” to identify identical structure without specifically describing the same. However, as in the case of the shelf or shelf assembly  10 , the shelf  100  is constructed from three primary components, namely, a shelf panel  111  and a pair of metal cantilevered side shelf brackets  112 ,  113  and secondary components in the form of a front grip or gripping member  114  and a rear product retention member  115  carried by the shelf panel  11 .  
         [0037]     The most significant difference between the two shelves  10 ,  100  resides in the fact that while the shelf brackets  12 ,  13  each included a single relatively long shelf panel supporting flange  40 ,  41 , respectively, the corresponding shelf brackets  112 ,  113  of the shelf  100  each include a pair of shelf panel supporting flanges  140 ,  140 ;  141 ,  141 ; respectively. The shelf panel supporting flanges  140 ,  141  are in opposite opposing relationship to the shelf panel supporting flanges  141 ,  141 , as is most readily visualized by comparing  FIGS. 7 and 10  of the drawings. Upper surfaces (unnumbered) of the shelf panel support flanges  140 ,  141  lie in a common plane corresponding to the plane P 1  of  FIG. 4  which lies in the plane of the lower surface  125  of the glass panel  111  ( FIGS. 8 and 9 ). Each shelf panel support flange  140 ,  141  defines an upwardly opening reservoir or pocket  146  in which the structural adhesive A is introduced incident to an assembling and bonding operation corresponding to that heretofore described with respect to the shelf  10 . However, the shelf or shelf assembly  100  also includes means  147 ,  148  and  149  in the form of upper edge portions or upper projections of the respective shelf arms  30 ,  31  which end in an uppermost common longitudinal edge or edge portion  160 .  
         [0038]     As is best illustrated in  FIG. 9  of the drawings, a plane horizontally passing through the upper surface  124  of the glass panel  11  also passes through the common edge  160  of the upwardly projecting portions  147 ,  148 ,  149 . The panel support flanges  140 ,  141  at the forward end portions  134 ,  135  of the respective shelf brackets  112 ,  113  are located between the upward projecting portions or upwardly projecting edges  147 ,  148 , while the shelf panel support flanges  140 ,  141  at the rear end portions  30 ,  33  of the respective shelf brackets  112 ,  113  are positioned between the upwardly directed projections or projecting edge portions  147 ,  149 . The projecting portions  147  through  149  define abutment means or locating means for the shelf panel  111  incident to bonding the same to the adhesive A upon the flanges  140 ,  140 ;  141 ,  141 . The side edges  118 ,  119  of the glass panel  111  are brought into contiguous or contacting relationship with inner surfaces (unnumbered) of the flat shelf arms  130 ,  131  of the respective shelf brackets  112 ,  113 , in the manner best illustrated in  FIG. 9  of the drawings. The latter contact assures that the side shelf brackets  112 ,  113  are in parallel relationship to each other and are also normal to a horizontal plane through the glass panel  111  until such time as the adhesive A sets or cures. Once the latter occurs, an extremely rigid right-angle connection is effected along the length of each shelf bracket  112 ,  113  and the side edge portions  116 ,  117  of the shelf panel  111  to form an extremely rigid shelf  100  which is not subject to distortion, cocking, torquing, etc., during vertical adjustment and/or when under product loading.  
         [0039]     Another novel cantilevered shelf or shelf assembly constructed in accordance with this invention is illustrated in  FIGS. 11 through 16  of the drawings and is generally designated by the reference numeral  200 . Components of the shelf assembly  200  which correspond to like components of the shelf assemblies or shelves  10  and  100  have been similarly designated to avoid duplication of description.  
         [0040]     The shelf or shelf assembly  200  differs from the shelves  10 ,  100  in three aspects, namely, ( 1 ) each metal shelf bracket  212 ,  213  includes only a pair of upwardly projecting edge portions or projections  248 ,  249  which results in three spaced shelf panel support flanges  239 ,  240  and  241  along each shelf bracket  212 ,  213 , ( 2 ) upper most edge portions  260  of the upper edge projections  248 ,  249  are bent inwardly in aligned opposing relationship with each other ( FIG. 11 ) in overlying relationship to the glass panel  211 , and ( 3 ) each shelf bracket  212 ,  213  includes locating means  251  in the form of a tab disposed at an angle of approximately  45  degrees ( FIG. 17 ) to its associated shelf panel support flange  240 ,  241  into alignment with and being abutted by the rear edge  223  of the glass panel  211 .  
         [0041]     As is most readily apparent from  FIG. 13  of the drawings, since the flanges  260 ,  239 ;  260 ,  240  and  260 ,  241  snugly receive therebetween the side edge portions  216 ,  217  of the glass panel  211 , added rigidity is provided the shelf  200  upon the setting/curing of the adhesive A. The latter is augmented by additional adhesive which can be located in the reservoirs of all three shelf panel support flanges  239 ,  240  and  241  associated with each shelf bracket  212 ,  213 , thereby providing additional rigidity than that of the shelf  100  which includes only the two pair of relatively short shelf panel supporting flanges  140 ,  141  ( FIGS. 7 and 10 ). Finally, the locating flanges or tabs  250  assure that the glass shelf  211  cannot move leftward from the position shown in  FIGS. 12 and 15  with respect to the shelf brackets  212 ,  213 , thereby additionally assuring that all components are assembled in the desired parallel/normal relationships heretofore described.  
         [0042]     Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined by the appended claims.