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 and wrap around edges of post sections, to be coupled, from the inside to the outside.

Description:
PRIORITY CLAIM 
       [0001]    This application is a Continuation-in-Part of co-pending U.S. patent application Ser. No. 11/044,689, filed Jan. 27, 2005, published under Publication No. US2006/0163438, both of which are incorporated herein by reference in their entirety. 
       RELATED PATENT APPLICATIONS 
       [0002]    This application is related to co-pending 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 ACCOMMODATING BEAM RIVET”, attorney docket number EDSM-50A;   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 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 a related application, there is provided a post coupler of an outside wrap configuration wherein the coupler wraps around post sections edges from the outside to inside reverse bend flanges of the coupler and is provided with rivet receiving apertures indexed with like apertures in the post sections and to accommodate universal beam mount even at the coupler locations. In instances where alternative couplers which wrap around post edges from the inside to outside reverse bend flanges, it is desired to provide improved couplers of this configuration which also accomplish universal or unlimited beam mounting even at the coupler positions. 
         [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 joined by a coupler disposed on the inside of the post members and which wraps around post edges from the inside to reverse bend flanges disposed along the outside of the 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, whether mounted on the inside or outside of the coupled post members. 
         [0021]    A further objective of the invention has been to provide an inside-to-outside wrap post coupler for accommodating the horizontal shelf supporting beams at their interface with shelf unit corner posts. 
       SUMMARY OF THE INVENTION 
       [0022]    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. 
         [0023]    Moreover, in a preferred coupler embodiment, the coupler has two main flanges and two outwardly directed, reverse bend flanges for disposition around edges of the post sections from the inside around to 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 inside wrap couplers provide for unobstructed pass-through of the rivets extending from the beams into and through the couplers and the posts. For purposes of this application, the term “inside wrap” as applied to post couplers refers to post couplers having major coupler flanges and additional reverse bend flanges extending from the major flanges and wrapping around post edges from the inside of the post section to the outside thereof. Specifically, the reverse bend flanges are oriented proximate outside surfaces of the respective post sections as shown in the drawings. 
         [0024]    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. 
         [0025]    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 
         [0026]      FIG. 1  is an isometric view of a shelving unit according to the invention; 
           [0027]      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 post sections and coupler; 
           [0028]      FIG. 3  is an exploded isometric view of the components of  FIG. 2 , excluding the shelf; 
           [0029]      FIG. 4  is an elevational view of the components of  FIG. 2  from the interior of the shelving unit; 
           [0030]      FIG. 5  is an elevational view of the components of  FIG. 2  from the exterior of the shelving unit; 
           [0031]      FIG. 6  is a cross-sectional view taken along lines  6 - 6  of  FIG. 5 ; 
           [0032]      FIG. 6A  is a view like that in  FIG. 6  but omitting the post section for clarity; 
           [0033]      FIG. 7  is a cross-section view taken along lines  7 - 7  of  FIG. 5 ; 
           [0034]      FIG. 8  is an elevational view in partial cross-section similar to  FIG. 4  but showing preferably inside mounted beams and shelf therein in combination with the elements of  FIG. 4 ; and 
           [0035]      FIG. 9  is an enlarged view in partial cross-section of the encircled area  9  of  FIG. 8   
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0036]    Turning now to the drawings and in particular, to  FIGS. 1-7 , one embodiment of the invention comprises a shelf unit  10  having a plurality of shelves  11 - 16 . Four composite corner posts or columns  17 - 20  define the corners of unit  10 . Each post  17 - 20  comprises at least two post sections (could be more) joined by a coupler as at  21 . 
         [0037]    Each shelf  11 - 16  is supported by four horizontally-oriented shelf-supporting brackets or beams as at side beams  22 , and front and rear beams  23 , with front and rear beams  23  being longer than side beams  22 . The rear beam and offside beams not shown in  FIG. 1  are respectively identical to the front ( 23 ) and side ( 22 ) beams as shown in  FIG. 1 . Side beams  22  on one hand and the front/rear beams  23  on the other hand differ essentially only in length and are otherwise identical. 
         [0038]    For purposes of this application, the terms “inner” or “inside” or “interior” refer to the post or coupler as viewed from within a shelving unit. The terms “outer” or “outside” or “exterior” refer to the posts or couplers as viewed from without a shelving unit. 
         [0039]    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  21  to form the unitary post  17 . The posts  17 - 20 , post sections  25 ,  26 , coupling  21 , 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  FIGS. 2 and 3  will be described. 
         [0040]    Each lower and upper post section  25 ,  26  is in the form of an angle and is provided with a series of keyhole-shaped apertures  32  as shown, in each flange thereof, each aperture preferably identically spaced in each post section, one from the other. Preferably, the endmost aperture  32  in each post section  25 ,  26  is spaced from the section ends at one-half pitch so that when sections  25 ,  26  are abutted as at junction  27 , the two endmost apertures  32  are spaced from each other at the same pitch as each aperture  32  is spaced from other apertures  32  in the same post section  25 ,  26 . Apertures  30  and  32  have enlarged and narrower portions as shown. 
         [0041]    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. Each post section  25 ,  26  has a respective post section end  25   a ,  26   a  as shown in  FIG. 3 . 
         [0042]    Post sections  25 ,  26  preferably abut each other end-to-end at section ends  25   a ,  26   a  defining junction  27 . 
         [0043]    As noted, beams  22 ,  23  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  22 ,  23  each incorporate, as best seen in  FIGS. 8 and 9 , a beam web  40 , an upper reverse bend at  41 , an upper vertical flange  42 , a lower vertical flange  44 , and a  90 ′ bend from flange  42  defining a shelf-supporting flange  43 , all as clearly shown in  FIGS. 8-9 . 
         [0044]    Shelf-supporting flanges  43  are relieved or tapered at an angle, as shown in  FIG. 8 , in a direction away from the beam ends, so as not to interfere with any proximate beam end. 
         [0045]    Each beam  22 ,  23  is provided proximate its ends, with two beam supporting lugs or rivets  45 ,  46 , one above the other. The views of  FIGS. 8 and 9  illustrate one suitable shape of the respective rivets  45 ,  46 . 
         [0046]    For purposes of this embodiment, it will be appreciated the spacing of the upper and lower rivets  45 ,  46  is equal to twice the distance between the sequential apertures  30 ,  32 , respectively. In other words, the rivets in this embodiment are spaced vertically apart at a distance twice that of the pitch between vertical apertures, one from the next, in the couple and post, as shown in  FIGS. 8 and 9 . 
         [0047]    Upper rivets  45  extend through apertures  30  in coupling  21  and through respective holes  32  in the post end sections  25   a ,  26   a  described above, and as will be described. 
         [0048]    Post coupling  21  is best seen in  FIGS. 2-7 . The coupling  21  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 . 
         [0049]    Each major flange  50 ,  51  has a reverse bend or fold  52 ,  53  and an inwardly directed reverse bend flange  54 ,  55  respectively turned inwardly, from flange bends  52 ,  53 . Each flange  54 ,  55  lies parallel to the respective flanges  50 ,  51  from which they extend, and on the outside thereof. 
         [0050]    A gap G is defined between the respectively adjacent flanges  50 ,  54  and  51 ,  55  respectively, this gap being approximately equal to the thickness of post flanges  34 ,  35  respectively. See  FIG. 6A . 
         [0051]    At each end of the bend  56 , the coupler  21  includes an extended projection  58 ,  59  projecting outwardly from the ends of major coupler flanges  50 ,  51  at bend  56 . The ends of the respective projections define the length of the coupler  21 . The projections  58 ,  59  have tapered or cured edges  61 ,  62 . 
         [0052]    The keyhole-shaped apertures  30 , as shown, of the coupler, are oriented in flanges  50 ,  51  one above the other respectively, at the same distance or pitch as separate apertures  32  in the post end sections  25   a ,  26   a . Apertures  30  are preferably in the same shape as apertures  32  in the post sections  25 ,  26 . 
         [0053]    Coupler  21  is also provided with a plurality of detents or projections  65  ( FIG. 5 ) 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  21 . 
         [0054]    In this regard, it will be appreciated the projections  58 ,  59  serve to aid in the introduction of respective post end sections  25   a ,  26   a  into the coupler  21 . Thus, projections  58 ,  59  serve to help guide and facilitate the introduction of the post sections into coupler  21 . 
         [0055]    In use, a post section  25 ,  26  is introduced to coupler  21  at slight angle thereto. Engagement of ends  25   a ,  26   a  with the coupler  21  tend to slide over or along the coupler projection  58  or  59  and continue the joining motion of these components without hanging up one against the other, thus facilitating engagement and positioning of the post section into the coupler, i.e. the post flange edges are easily guided into the gaps G. 
         [0056]    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  54 ,  55  are shorter longitudinally than said overall length, each terminating short of an end of the coupler defined by the projection. In other words, while the reverse bend flanges extend along major flanges  50 ,  51 , they terminate short of the overall coupler length. 
         [0057]    Finally, note the reverse bend flanges  54 ,  55  have respective edges  54   a ,  55   a . These define the inward extent of flanges  54 ,  55  ( FIG. 5 ) so the flanges  54 ,  55  do not extend over and block apertures  30  or  32 . The reverse bend flanges  54 ,  55  thus do not subtend apertures  30  or  32 , as would block them for passage of rivets  65 . 
         [0058]    Turning now to the relationship of the components as coupled and connected in an erected shelving unit.  FIGS. 2-9  reflect such a unit where the beams  22 ,  23  are disposed on the inside of post sections  25 ,  26  (and posts  17 - 20 ). 
         [0059]    In  FIGS. 2-8 , beams  22 ,  23  are located inside posts  17 - 20 . Coupler  21  is disposed substantially on the side of the posts against post flanges  34 ,  35 , with bends  52 ,  53  wrapped around edges  34   a ,  35   a  of the post sections.  FIG. 2  broadly illustrates this embodiment while remaining  FIGS. 3-8  show its details. 
         [0060]    Referring to  FIGS. 2-5 , coupler  21  is disposed proximate the bottom end  26   a  of upper post section  26 , coupler  21  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  22 ,  23  lie against coupler flanges  50 ,  51  respectively. 
         [0061]    Rivets  45  ( FIGS. 8 ,  9 ) extend through beams  22 ,  23  and coupler flanges  50 ,  51  respectively and post section  26 . Interior rivet heads seat on flanges  42  of the beams. Exterior rivet heads are positioned to pass through the enlarged portions of the post section  26  and coupler  21 , allowing rivet shanks to seat in the narrower sections of apertures  30  and  32 , securing the components together. The exterior rivet heads rest against those outer surfaces of post section  26  flanges  34 ,  35 . 
         [0062]    Lower rivets  46  have a similar orientation. They extend from the outer surface of the post flanges and through lower flange  44  of a beam. It will here be appreciated that since edges  54   a ,  55   a  of coupler  21  do not block apertures  30  in coupler  21 , and the rivet heads may pass therethrough in the enlarged portions of the apertures  30  to facilitate erection of shelving unit  10 , including mounting o the beam onto the composite posts  17 - 20  even at the location of couplers  21 . Flange  44  of beam  23 , for example, in  FIG. 8 , is slightly spaced from the post flange by the partial intervention of the projection  59  therebetween. 
         [0063]    It will also be appreciated that the invention may include other configurations of the beams  22 ,  23  suitable with end structures as depicted herein. For example, these beams and rivets so configured to be fitted onto the outside of the posts  17 - 20 , with the beams lying on the reverse bend flanges  54 ,  55 , for example. 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. 
         [0064]    Accordingly, this invention contemplates a post coupler in inside wrap form with flanges wrapping around the edges of an angular post from the inside and accommodates 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. 
         [0065]    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.