Abstract:
The present invention is a modular stacking system for continuous stack drying of millwork that is easily transported and takes up a minimal amount of floor space when assembled. The modular stacking system is comprised of modular stabilizing stackable blocks and lightweight cross members which allow the user to create multiple stacking layers. The design of the stackable blocks ensures that the stacking system remains stable even with a large number of layers.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/258,121 filed on Nov. 4, 2009. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates to the field of support racks and more particularly to modular stacking systems. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]      FIG. 1  illustrates a perspective view of an exemplary embodiment of an assembled modular stacking system with five stacking layers in use. 
           [0004]      FIG. 2  illustrates a perspective view of an exemplary embodiment of an assembled modular stacking system with fifteen stacking layers in use. 
           [0005]      FIG. 3  illustrates an exploded view of an exemplary embodiment of a modular stacking device and millwork. 
           [0006]      FIG. 4   a  illustrates a perspective view of one exemplary embodiment of an assembled modular stacking system with one stacking layer. 
           [0007]      FIG. 4   b  illustrates a perspective view of a second exemplary embodiment of an assembled modular stacking system with one stacking layer. 
           [0008]      FIG. 5  illustrates a perspective view of an exemplary embodiment of an assembled modular stacking system in use. 
           [0009]      FIG. 6   a  illustrates a perspective view of the back of an exemplary embodiment of a stackable block for a modular stacking system. 
           [0010]      FIG. 6   b  illustrates a perspective view of the front of an exemplary embodiment of a stackable block for a modular stacking system. 
           [0011]      FIG. 7   a  illustrates a bottom view of an exemplary embodiment of a stackable block for a modular stacking system. 
           [0012]      FIG. 7   b  illustrates a bottom view of an exemplary embodiment of a stackable block for a modular stacking system with a cross member. 
           [0013]      FIG. 8  illustrates a cross-sectional view of an exemplary embodiment of a stackable block for a modular stacking system. 
           [0014]      FIG. 9  illustrates a perspective view of the front of two stacked stackable blocks for a modular stacking system. 
       
    
    
     GLOSSARY 
       [0015]    As used herein, the term “continuous stack drying” refers to a task in which a user assembles a plurality of cross members, places an object to be dried onto the cross members, and repeats the process by assembling additional cross members above the object to be dried during the drying/processing operation. A continuous stack drying operation does not require the user to place the object which must be dried in a horizontal space between pre-assembled, stacked cross members. 
         [0016]    As used herein, the term “cross member” refers to a component secured horizontally between two stackable blocks on which millwork rests. 
         [0017]    As used herein, the term “flange” refers to a rim, band, collar, ring or other structural configuration molded or formed to give additional strength or support or to provide an area to engage other components. 
         [0018]    As used herein, the term “friction rib” refers to a protruding or contoured component shaped to provide friction against another component. 
         [0019]    As used herein, the term “horizontal stabilizing member” refers to a component placed through a bottom stackable block that rests on the ground and extends parallel to the floor, and which provides additional support to a modular stacking system. 
         [0020]    As used herein, the term “knit line” refers to the point where two or more flow fronts join during the molding process, typically after flowing around holes or other obstructions, resulting in a weak area. 
         [0021]    As used herein, the term “millwork” refers to woodwork, trim, other construction materials known in the art used to decorate or border openings or wall surfaces, such as casings, moldings, baseboards, cornices, and window frames, or any other object requiring painting, staining, finishing, chemical treatment, or cleaning, and subsequent air drying. Millwork includes items such as canvasses, pottery, manufactured items, and may be made of wood, metal, plastic, fabric, canvas, or any other material that requires drying. 
         [0022]    As used herein, the term “self-stabilizing” means not requiring additional support components. 
         [0023]    As used herein, the term “stabilizing strut” refers to a component that extends between a horizontal stabilizing member and a cross member to provide additional support to a modular stacking system. 
         [0024]    As used herein, the term “stop lip” refers to the component of a stackable block that prevents a cross member from passing completely through the stackable block. 
       BACKGROUND 
       [0025]    Residential and commercial construction projects typically involve finishing and installing millwork. Millwork, such as trim and doors, is typically stained, varnished or painted before it is installed, which is commonly done at the building site. Before the millwork can be installed it must be allowed to dry. The time it takes for the millwork to air dry ranges from an hour to four hours or more depending on the material and the finishing; however, drying overnight is usually recommended. It is also desirable to dry indoors to protect the millwork and finishing from dust and debris. 
         [0026]    For drying, millwork may be leaned against a wall or placed on a set of sawhorses; however, both methods of drying are problematic. Leaning millwork, such as trim, against a wall allows a large amount to be dried at once; however, the trim is not secure and may fall over preventing the trim from drying or requiring that that one or more pieces be refinished or replaced. This method of drying also prevents other phases of the construction project from being completed. 
         [0027]    Sawhorses on the other hand, require a large amount of floor space when usually only a limited amount of space is available. In addition, sawhorses allow only one layer of millwork to be dried at a time; therefore, many sets of sawhorses are usually required to dry the amount needed to be dried. Sawhorses also vary in size and weight and take up a lot of space while in use and during transportation and storage. For example, each sawhorse may weigh approximately five pounds. In addition, depending on the size, sawhorses may be difficult to transport and/or require the use of a truck or van. 
         [0028]    Examples of rack systems are known in the art; however, these rack systems are not desirable because they contain one or more large pieces that are difficult to transport and/or require extensive assembly. In addition, millwork can be heavy and some of these rack systems are not capable of accommodating and supporting multiple layers of heavy millwork. Rack systems that do accommodate multiple levels usually require that the individual pieces of millwork be horizontally slid into narrow slots, which requires precision and can damage the wet finish. 
         [0029]    It is desirable to have a portable and modular stacking system that is stable and easily transportable to replace sawhorses. 
         [0030]    It is further desirable to have a portable and modular stacking system that is lightweight while being able to support heavy materials. 
         [0031]    It is further desirable to have a portable and modular stacking system that allows the user to add stacking layers as needed. 
         [0032]    It is further desirable to have a portable and modular system that can accommodate a wide range of sizes of materials. 
         [0033]    It is further desirable to have a portable and modular system which can be adapted to fit the needs of a specific job. 
         [0034]    It is further desirable to have a portable and modular system that minimizes the amount of dust/debris free space needed for drying finished woodwork. 
       SUMMARY OF THE INVENTION 
       [0035]    The present invention is a modular stacking system for continuous stack drying of millwork that is easily transported and takes up a minimal amount of floor space when assembled. The modular stacking system is comprised of modular stabilizing stackable blocks and lightweight cross members which allow the user to create multiple stacking layers. The stackable blocks are comprised of a housing having a flattened outer surface, an inner surface, and contoured sides having a flange. The housing further includes apertures for inserting a cross member and a horizontal stabilizing member. A plurality of stacking ribs and structural ribs are located in the interior of the housing. 
         [0036]    The first stacking layer is created by inserting two or more cross members between stackable blocks and placing the stackable blocks so that the cross members are parallel to each other with the desired amount of spacing in between the cross members. One or more pieces of millwork may then be arranged over the cross members. 
         [0037]    To create additional stacking layers, the process is repeated with the second set of stackable blocks being stacked directly on top of those of the first layer. The user determines the number of stacking layers needed. The design of the stackable blocks ensures that the stacking system remains stable even with a large number of stacking layers. 
         [0038]    For additional support, horizontal stabilizing members may be inserted through apertures in the stackable blocks of the first stacking layer. The horizontal stabilizing members rest on the ground, extending parallel to the floor. Stabilizing struts may be used to provide additional support when 7 or more stacking layers are assembled. 
       DETAILED DESCRIPTION OF INVENTION 
       [0039]    For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of a modular stacking system for drying millwork, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent components, materials, and dimensions may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention. 
         [0040]    It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements. 
         [0041]    Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. 
         [0042]      FIG. 1  illustrates a perspective view of an exemplary embodiment of modular stacking system  100  with five stacking layers in use. In the embodiment shown, modular stacking system  100  is comprised of four stacking block columns  25   a ,  25   b ,  25   c ,  25   d , each of which contains five stackable blocks  20 . Between each set of stackable blocks  20  in stacking block columns  25   a ,  25   b  and each set of stackable blocks  20  in stacking block columns  25   c ,  25   d  is cross member  60 . When stacked, stackable blocks  20  are self-stabilizing and do not require additional vertical support components. 
         [0043]    Each stacking block column further includes horizontal stabilizing members  65 . In the embodiment shown, one horizontal stabilizing member  65  is placed through an aperture in the first stackable block  20  of each stacking block column  25   a ,  25   b ,  25   c ,  25   d . Horizontal stabilizing members  65  rest on the ground and extend parallel to the floor providing additional support to modular stacking system  100 . 
         [0044]    In the embodiment shown, cross members  60  and horizontal stabilizing members  65  are comprised of the same material and have the same dimensions. In other embodiments, horizontal stabilizing members are not used or may be comprised of a different material and/or have different dimensions than the cross members. 
         [0045]    In the embodiment shown, two cross members  60  are used resulting in four columns  25   a ,  25   b ,  25   c ,  25   d . In other embodiments, more cross members and columns may be used to provide additional support (e.g., for longer materials). 
         [0046]    Also visible is millwork  200  which rests on cross members  60 . In the embodiment shown, millwork  200  is a plurality of doors. 
         [0047]    Modular stacking system  100  allows for continuous stack drying. The user assembles stacking layers as needed, permitting the user to simply set pieces of millwork on top of cross members  60 , rather than having to slide the pieces between preassembled stacking layers or already placed pieces. Placing the millwork directly on top of cross members  60  saves time and protects the upper surface of the piece from damage. 
         [0048]      FIG. 2  illustrates a perspective view of an exemplary embodiment of modular stacking system  100  with fifteen stacking layers in use. In the embodiment shown, modular stacking system  100  is comprised of four stackable block columns  25   a ,  25   b ,  25   c ,  25   d , each of which contains 15 stackable blocks  20 . Between each set of stackable blocks  20  in stackable block columns  25   a ,  25   b  and each set of stackable blocks  20  in stackable block columns  25   c ,  25   d  is cross member  60  (shown in phantom). 
         [0049]    Each stackable block column further includes horizontal stabilizing members  65 . In the embodiment shown, one horizontal stabilizing member  65  is placed through an aperture in the first stackable block  20  of each stackable block column  25   a ,  25   b ,  25   c ,  25   d.    
         [0050]    In the embodiment shown, each stackable block column  25   a ,  25   b ,  25   c ,  25   d  of modular stacking system  100  further includes stabilizing struts  68   a ,  68   b  which are placed on each side of each stackable block column  25   a ,  25   b ,  25   c ,  25   d . The top of stabilizing struts  68   a ,  68   b  is U-shaped and hooks onto the top of cross member  60 . The bottom of stabilizing struts  68   a ,  68   b  is forked and has two prongs which rest on each side of horizontal stabilizing member  65 . In the embodiment shown, the top of stabilizing struts  68   a ,  68   b  are hooked on the cross member that runs between the seventh stackable blocks  20  in each stackable block columns  25   a ,  25   b  and stackable block columns  25   c ,  25   d.    
         [0051]    Stabilizing struts  68   a ,  68   b  provide addition support to modular stacking system  100 . In an exemplary embodiment, stabilizing struts  68   a ,  68   b  are used when modular stacking system  100  contains 7 or more stacking layers. 
         [0052]    In the embodiment shown, millwork  200  is a plurality of trim pieces. 
         [0053]    In an exemplary embodiment, the components of modular stacking system  100  are sold in 5 or 10 stacking layer kits. For example, the 5 stacking layer kit would include 20 stackable blocks and 14 cross members and horizontal stabilizing members (e.g., 40 inches long), while a 10 stacking layer kit would include 40 stackable blocks, 24 cross members and horizontal stabilizing members, and 4 stabilizing struts. In other embodiments, modular stacking system  100  is sold in a kit containing components needed to assemble fewer or more layers. In addition, the components needed to create additional layers may be sold separately. 
         [0054]    In an exemplary embodiment, modular stacking system  100 , when dissembled, may be and stored and transported in a single carry bag (e.g., having a length of 42 inches, a width of 10 inches, and a height of 8 inches). 
         [0055]      FIG. 3  illustrates an exploded view of an exemplary embodiment of modular stacking device  100  with millwork  200 . To assemble the first stacking layer of modular stacking system  100 , stackable blocks  20   a ,  20   b  are assembled into the ends of cross member  60   a  and stackable blocks  20   c ,  20   d  are assembled into the ends of cross member  60   b  creating stacking block columns  25   a ,  25   b ,  25   c ,  25   d  (see  FIGS. 1 and 2 ). 
         [0056]    Cross members  60   a ,  60   b  with attached stackable blocks are placed on a flat surface so that cross members  60   a ,  60   b  are parallel to each other creating the first stacking level of modular stacking system  100 . The distance between cross members  60   a ,  60   b  may vary depending on the length of the material to be supported. 
         [0057]    In the embodiment shown, one horizontal stabilizing members  65   a ,  65   b ,  65   c ,  65   d  is placed through an aperture in each stackable block which makes up the first stacking layer, i.e., stackable blocks  20   a ,  20   b ,  20   c ,  20   d.    
         [0058]    When the first stacking layer is assembled, millwork  200  is laid across the top of horizontal cross members  60   a ,  60   b  as shown. After millwork  200  is placed, a second stacking layer may be added by placing a second set of cross members and attached stackable blocks on top of cross members  60   a ,  60   b  and stackable blocks  20   a ,  20   b ,  20   c ,  20   d . Millwork is then placed on the second stacking layer, followed by the addition of additional sets of cross members and stackable blocks as needed. 
         [0059]    In the embodiment shown, stackable blocks  20  weigh less than ½ lb, with a length of 4 inches, a width of 2¼ inches and a height of 4½ inches and are molded so that they interlock when stacked. In other embodiments, stackable blocks  20  have a length and width of 2 to 6 inches and a height of 3 to 6 inches high. 
         [0060]    In the embodiment shown, cross members  60  and horizontal stabilizing members  65  are round and hollow with a diameter of ⅝ inch and are made of steel. In other embodiments, cross members  60  and horizontal stabilizing members  65  may be solid, tubular, square, rectangular, flattened, telescoping or any other shape and configuration and may be made of another material, such as aluminum or plastic. In the embodiment shown, cross members  60  and horizontal stabilizing members  65  have a diameter of ⅝ inch, is hollow and is comprised of steel. In other embodiments, cross members  60  and horizontal stabilizing members  65  have a smaller or larger diameter and is comprised of another material, such as aluminum or plastic. 
         [0061]    In the embodiment shown, cross members  60   a ,  60   b  and horizontal stabilizing members  65   a ,  65   b ,  65   c ,  65   d  are comprised of the same material and have the same dimensions. In other embodiments, horizontal stabilizing members are not used or may be comprised of a different material and/or have different dimensions than the cross members. 
         [0062]      FIG. 4   a  illustrates a perspective view of one exemplary embodiment of modular stacking system  100  with one stacking layer. In the embodiment shown, four horizontal stabilizing members  65   a ,  65   b ,  65   c ,  65   d  are used and each is inserted through a single stackable block  20   a ,  20   b ,  20   c ,  20   d . Stackable blocks  20   a ,  20   b ,  20   c ,  20   d  and horizontal stabilizing members  65   a ,  65   b ,  65   c ,  65   d  are positioned so that horizontal cross members  60   a ,  60   b  are located a substantial distance apart (i.e., for drying doors or longer pieces of trim). 
         [0063]      FIG. 4   b  illustrates a perspective view of a second exemplary embodiment of modular stacking system  100  with one stacking layer. In the embodiment shown, only two horizontal stabilizing members  65   a ,  65   b  are used. Horizontal stabilizing member  65   a  is inserted through stackable blocks  20   a ,  20   b  and horizontal stabilizing member  65   b  is inserted through stackable blocks  20   c ,  20   d  allowing cross members  60   a ,  60   b  to be located closer to one another (i.e., for drying smaller millwork, such as cabinet doors). 
         [0064]      FIG. 5  illustrates a perspective view of an exemplary embodiment of modular stacking system  100  in use. 
         [0065]      FIG. 6   a  illustrates a perspective view of the back of an exemplary embodiment of stackable block  20  for modular stacking system  100 . The side of stackable block  20  illustrated in  FIG. 6   a  faces inward when modular stacking system  100  is assembled. 
         [0066]    Stackable block  20  is comprised of outer surface  30 , contoured sides  22   a ,  22   b ,  22   c ,  22   d  ( 22   a ,  22   b  not visible) and flange  40 . Contoured sides  22   a ,  22   c  further include cross member apertures  50   a ,  50   c  ( 50   a  not visible) and bottom cross member apertures  62   a ,  62   c  ( 62   a  not visible). Contoured sides  22   b ,  22   d  further include horizontal stabilizing member apertures  75   b ,  75   d  ( 75   b  not visible) for inserting horizontal stabilizing member  65  (not shown) and base protuberances  80   b ,  80   d  ( 80   b  not visible) for supporting optional horizontal stabilizing member  65 . 
         [0067]    In the embodiment shown, stackable block  20  is semi-rectangular with contoured sides  22   a ,  22   b ,  22   c ,  22   d  that are tapered to facilitate removal from the mold during injection molding. In the embodiment shown, contoured sides  22   a ,  22   c  are flat and contoured sides  22   b ,  22   d  are concave. 
         [0068]    Horizontal stabilizing member  65  is placed through horizontal stabilizing member apertures  75   b ,  75   d  of stackable block  20  of first stacking layer so that approximately equal length of horizontal stabilizing member  65  sticks out on each side of stackable block  20 . Base protuberances  80   b ,  80   d  provide additional reinforcement to stackable block  20  and help avoid fracturing of stackable block  20  at the knit line as well as provide additional structural support to modular stacking system  100 . 
         [0069]    Cross member apertures  50   a ,  50   c  are adapted to receive cross member  60 . Cross member  60  is inserted through cross member aperture  50   c  in contoured side  22   c  and passed through the interior of stackable block  20  and cross member aperture  50   a  in contoured side  22   a . Stop lip  70  (see  FIG. 6   b ) stops cross member  60  preventing cross member  60  from passing completely through stackable block  20 . 
         [0070]    Bottom cross member apertures  62   a ,  62   c  facilitate stacking and are shaped to accommodate the top edge of the cross member of the previous layer allowing a stackable block to be placed on top of another without contacting the cross member of the previous layer. 
         [0071]    In the embodiment shown, stackable block  20  is comprised of a rigid thermoplastic polymer (e.g., polypropylene) and is capable of supporting the weight of multiple stacking layers and millwork. In the embodiment shown, stackable block  20  is injection molded, but in other embodiments may be formed by using another molding or manufacturing process. In various embodiments, stackable block  20  may contain marks which result from the manufacturing process. For example, outer surface  30  of stackable block  20  may have a vestige. 
         [0072]      FIG. 6   b  illustrates a perspective view of the front of an exemplary embodiment of stackable block  20  for modular stacking system  100 . The side of stackable block  20  illustrated in  FIG. 6   b  faces outward when modular stacking system  100  is assembled. 
         [0073]    Visible are outer surface  30 , contoured sides  22   a ,  22   b , flange  40 , cross member aperture  50   a , stop lip  70 , bottom cross member aperture  62   a , horizontal stabilizing member aperture  75   b , and base protuberance  80 . 
         [0074]      FIG. 7   a  illustrates a bottom view of an exemplary embodiment of stackable block  20 . The inside of stackable block  20  contains friction ribs  35   a ,  35   b , stacking ribs  85  which extend from inner surface  32  (underside of outer surface  30 ) to top of flange  40  (not shown) and structural ribs  90  which provide additional structure support, strengthening stackable block  20 . 
         [0075]    When second stackable block  20   b  is stacked onto first stackable block  20   a  (see  FIG. 9 ), stacking ribs  85  of second stackable block  20   b  rest on the outer surface  30  of first stackable block  20   a  so that flange  40  of second stackable block  20   b  overlaps the upper portion of first stackable block  20   a.    
         [0076]    In the embodiment shown, friction ribs  35   a ,  35   b  are curved so that only a portion of friction ribs  35   a ,  35   b  contacts cross member  60  (see  FIG. 7   b ). In other embodiments, there may be more or fewer friction ribs  35   a ,  35   b  and/or friction ribs of varied shapes to provide the desired amount of contact with cross member  60 . 
         [0077]    In the embodiment shown, stackable block  20  has fourteen stacking ribs  85  which extend out ¼ inch from contoured sides  22   a ,  22   b ,  22   c ,  22   d  and are spaced 0.3 to 0.75 inches apart. In other embodiments, stackable block  20  may have more or fewer stacking ribs  85  which are shorter or longer (e.g., could extend from one side to the other) and/or with varied placement and spacing. In the embodiment shown, structural ribs  90  have various connecting points (e.g., inner surface) and are of various heights and shapes. In other embodiments, there may be more or fewer structural ribs in varied locations. 
         [0078]    The design of stackable block  20  allows stackable blocks  20  to support the weight of cross members  60  and millwork  200  so that up to 15 stacking layers may be assembled. In an exemplary embodiment, stackable blocks  20  can support up to approximately 200 lbs on 15 stacking layers and up to approximately 500 lbs on 10 stacking layers. 
         [0079]      FIG. 7   b  illustrates a bottom view of an exemplary embodiment of stackable block  20  with cross member  60 . When cross member  60  is inserted into stackable block  20 , friction ribs  35   a ,  35   b  brush against cross member  60 . 
         [0080]      FIG. 8  illustrates a cross-sectional view of an exemplary embodiment of stackable block  20  showing outer surface  30 , inner surface  32 , friction ribs  35   a ,  35   b , stacking ribs  85 , structural ribs  90 , flange  40 , horizontal stabilizing member apertures  75   b ,  75   d , and cross member  60 . 
         [0081]      FIG. 9  illustrates a perspective view of stackable block  20   a  and stackable block  20   b  stacked.