Patent Publication Number: US-7895955-B2

Title: Shelf system

Description:
This application claims the benefit of U.S. Provisional Application Ser. No. 60/782,553 filed on Mar. 15, 2006. 
    
    
     TECHNICAL FIELD 
     The invention relates generally to an improved shelf system for attachment to the bottom of a single floor or ceiling beam for storing items and the like. More specifically, the invention relates to an improved shelf system that comprises one or more reinforced sections that are attached to the bottom of a single floor or ceiling beam and that are capable of being attached or connected at their ends so as to form a continuous shelf system that spans the entire length of the beam and maximizes the amount of available storage space for the user. 
     BACKGROUND OF THE INVENTION 
     In the past, others have developed overhead storage devices in an effort to utilize wasted or unused overhead space in a basement, garage, or the like. The prior art overhead storage devices commonly require that the device be secured to at least two overhead beams. Many of the prior art devices rely heavily upon equal or accurate spacing for their installation because they are affixed to more than one beam and may require additional installation hardware, which is both costly and time consuming and therefore undesirable. The overhead storage devices of the prior art tend to be cumbersome to install and/or operate and may require more than one installer or even a skilled installer. 
     Moreover, these prior art devices make searching, storing and retrieving an item difficult inasmuch as the individual may not be able to view the article from where they are standing beneath the device and may require multiple trips up and down a step ladder or similar device just to locate the stored item. 
     Similarly, other prior art devices that require the user to store an item inside a box or container also make it difficult for the party storing the item to locate the stored item without moving the box or container, or items contained therein, to access the item the user is looking for. Further, items stored in closed boxes or containers without any ventilation are susceptible to stale odors and/or mildew over time. 
     Other prior art devices are relatively weak and tend to warp or deflect, and even fail, over time due to the weight of the stored items, which can result in injury to a user or passerby or damage to the stored items. 
     There is a need within the art for a shelf system that allows for overhead storage and requires the device be secured to only one overhead beam, while allowing the user to easily access items stored using the shelving system. 
     SUMMARY OF THE INVENTION 
     The present invention provides for an improved shelf system that allows for overhead storage. The improved shelf system provides for inwardly sloping shelf sections that may be secured to a single beam. While a single shelf section attached to a single beam can be utilized, the invention also provides embodiments wherein numerous single shelf sections of the improved shelf system may be installed to individual beams, and connected together to form one continuous shelf system. 
     The installation of the shelf system of this invention is such that a single installer can easily install the system with common household tools. No specialty tools or training is necessary in order to install the system. Items can be stored on the shelf system and easily viewed from a location below the shelf system. 
     Accordingly, it is an objective of the present invention to provide the art with a new storage system that eliminates the disadvantages associated with prior art overhead storage devices. A further objective of the present invention is to provide a shelf system that can be easily installed and modified by the user to increase or decrease the amount of available storage space available depending upon the user&#39;s storage needs. 
     Yet another objective of the present invention is to provide a durable and reinforced shelf system capable of withstanding heavy loads for prolonged periods of time with minimal or no deflection. 
     A further objective of the present invention is to allow the user to locate the stored item from the floor by simply walking parallel to the beam until the desired item is located, then using a short ladder or step stool, if necessary, to retrieve the stored item from the shelf. An additional objective of the present invention is to provide a shelf system capable of preventing stored items from rolling or slipping off the shelf and causing injury or damage. 
     The present invention solves the above described problems and achieves new results by providing an improved shelf system that comprises one or more reinforced and inwardly sloping sections that are attached to the bottom of a single floor or ceiling beam and that are capable of being attached or connected at the ends so as to form a continuous shelf system that can span the entire length of the beam and maximize the amount of available storage space. 
     These and other objects of the present invention will become more readily apparent from a reading of the following detailed description taken in conjunction with the accompanying drawings wherein like reference numerals indicate similar parts, and with further reference to the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may take physical form in certain parts and arrangements of parts, numerous embodiments of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein: 
         FIG. 1  is a perspective view of one section of the shelf system of an embodiment of the invention; 
         FIG. 2  is a top elevational view of one section of the shelf system of an embodiment of the invention; 
         FIG. 3  is a side elevational view of one end of one section of the shelf system of an embodiment of the invention; 
         FIG. 4  is a side elevational view of the opposing end of one section of the shelf system of an embodiment of the invention as that shown in  FIG. 3 ; 
         FIG. 5  is a side elevational view of one section of the shelf system of an embodiment of the invention; 
         FIG. 6  is a top elevational view of a portion of one section of the shelf system of an embodiment of the invention, cut along plane A-A, with a side elevational view of the same portion of one section of the shelf system along plane A-A; 
         FIG. 7  is a diagram showing the shelf system of an embodiment of the invention as installed on beams; 
         FIG. 8  is a side elevational view of two sections of the shelf system of an embodiment of the invention in connected and unconnected configurations; 
         FIG. 9  is a graph indicating the deflection of the shelf system of an embodiment of the invention under varying loads for varying periods of time; 
         FIG. 10A  is a side elevational close-up view of the fastening of a section of the shelf system of an embodiment of this invention with use of a washer; and 
         FIG. 10B  is a side elevational close-up view of the fastening of a section of the shelf system of an embodiment of this invention without use of a washer. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring now to the drawings wherein the showings are for purposes of illustrating numerous embodiments of the invention only and not for purposes of limiting the same, the figures illustrate the novel idea of an improved shelf system for overhead storage. 
     Described within this application is an improved shelf system that allows for overhead storage. The improved shelf system provides for inwardly sloping shelf sections that may be secured to a single beam. Non-limiting examples of the beam to which the shelf section attaches include a joist or rafter. While a single shelf section attached to a single beam can be utilized, the invention also provides embodiments wherein numerous single shelf sections of the improved shelf system may be installed to individual beams, and connected together to form one continuous shelf system. 
     A typical shelf segment of the improved shelf system of the present invention is indicated generally at  10  in  FIGS. 1 through 5 . In the preferred embodiment, shelf segment  10  further includes a pair of side panels  11 ,  12 , and a mounting strip  13 . In certain embodiments the shelf may also include a front plate  14  and a rear plate  15 . Unless otherwise stated, all components of shelf segment  10  are preferably constructed of a heavy duty plastic with flame retardant additives though it is contemplated that other types of materials could also be used, such as wood, steel, polymers, aluminum or other metals, without affecting the overall concept of the present invention. In the preferred embodiment, the shelf segment is manufactured through a blow molding process commonly know in the art though it is contemplated that other manufacturing and/or production techniques could also be used, depending on the type of materials being utilized, without affecting the overall concept of the present invention. 
     Side panels  11 ,  12  are substantially identical so only one will be described below. Side panel  11  further comprises a base  21 , an outer rib or lip  22  and a plurality of reinforcement gussets or ribs  24  formed in, and longitudinally spaced apart along base  21  as best illustrated in  FIGS. 1 and 2 . Outer rib  22  is formed along the perimeter of base  21  and serves multiple functions. More specifically, outer rib  22  adds strength to shelf segment  10 , particularly if shelf segment is installed and interconnected with another shelf segment to form the improved shelf system of the present invention as described more fully below. Additionally, because outer rib  22  rises above the surface of base  21 , outer rib  22  tends to prevent the stored item from rolling or slipping off of shelf segment  10 . Further, the segment of outer rib  22  adjacent to mounting strip  13  serves the further purpose of enabling the installer of shelf segment  10  to easily align and properly install shelf segment  10  on a beam  30 , as best illustrated in  FIG. 7  and described more fully below. 
     As indicated above, reinforcement ribs  24  are spaced apart longitudinally along shelf base  21  and also add strength to shelf segment  10 , thereby reducing or eliminating the deflection and deformation problems associated with prior art overhead storage devices as illustrated in the table contained in  FIG. 9 . In the preferred embodiment, reinforcement ribs  24  also help keep the top and bottom surfaces of base  21  from collapsing against each other. A cross section of reinforcing rib  24  is shown generally in  FIG. 6 . 
     Each of side panels  11  and  12  are positioned generally longitudinally parallel to one another, such that the side panels run in the same direction and are spaced apart and separated by mounting strip  13 , as best shown in  FIGS. 1 ,  2  and  6 . The width of mounting strip  13  is preferably sized to accommodate the width of most beams though it is contemplated that the width can be greater or smaller, depending on the application and needs of the user, without affecting the overall concept of the present invention. In certain embodiments, mounting strip  13  further comprises a plurality of continuous openings  28  formed therein for receipt of a fastener (not shown) used to mount shelf segment  10  to beam  30  as best shown in  FIG. 7 . More specifically, an installer (not shown) desiring to mount shelf segment  10  on beam  30  can use those outer ribs  22  of side panels  11 ,  12  adjacent to mounting strip  13  to align shelf segment  10  on beam  30  such that beam  30  fits between said outer ribs  22  nearest mounting strip  13 . The installer can then removably attach shelf segment  10  to beam  30  by inserting fasteners  31 , such as screws or nails, through openings  28  and into beam  30 , thereby securely, but removably, attaching shelf segment  10  to beam  30 . Alternatively, it is also contemplated that shelf segment  10  could be affixed to a beam through a drywalled or plastered ceiling (not shown) with the use of a beam extension (not shown), without affecting the overall concept of the present invention. Moreover, in the preferred embodiment of the present invention, each of fasteners  31  further comprise a built-in washer  33 , as illustrated in  FIG. 10A  and  FIG. 10B , to add further strength to shelf segment  10  by more securely attaching shelf segment  10  to beam  30 . Providing a built-in washer  33  with fastener  31  also reduces the likelihood that a consumer or installer will misplace the washer, as is commonly the case with stand alone washers. Notwithstanding, it is contemplated that a stand alone washer (not shown) of a type common in the art, or a fastener  31  with an oversized head portion but no washer (not shown), could also be used without affecting the overall concept of the present invention. 
     It is also foreseen that specialized shelf sections are envisioned to fit in specialized areas. By non-limiting example, certain embodiments of this invention include a shelf section wherein the two side panels are of different widths or configurations to allow a shelf section to be secured to a beam that abuts a wall or other vertical member, wherein a shelf section with two equal width side panels will not fit. A shelf section with only one side panel attached to the mounting strip is also foreseen, allowing the shelf to be mounted to a beam that abuts a wall. 
     As another important feature of the present invention, protruding member  32  such as a tongue is formed in front plate  14  and a corresponding groove  34  is formed in rear plate  15 , as best illustrated in  FIG. 8 . Protruding member  32  is designed such to be engageable with groove  34 , enabling a user or installer to interconnect multiple shelf segments  10  to form a continuous shelf system along beam  30 . More specifically, before or after installation of shelf segment  10  along beam  30  as described above, an installer can abut a second shelf segment  10  against the first shelf segment such that tongue  32  of first shelf segment  10  fits into groove  34  of second shelf segment, as shown in  FIG. 8 . Additional shelf segments can be similarly attached to one another and beam  30 , as appropriate, to accommodate the installer or user&#39;s storage needs. 
     As yet another important feature of the present invention, items stored on the improved shelf system of the present invention are easily viewed by the user. More specifically, shelf segment  10  extends from each side of supporting beam  30  enough distance, but short of spanning the entire distance between beams, to allow the stored items to be visible to the user and to allow the user to access base  21  for storage from any point along shelf segment  10 . Therefore, the user is not required to remember where he or she stored the item along shelf segment  10  and ladder access is not necessary until the user has visually located the item for retrieval. 
     It is also contemplated within certain embodiments of the invention, that base  21  of each of side panels  11 ,  12  can be inclined slightly in the general direction of mounting strip  13  to ensure that stored items do not slide or roll off of side panels  11 ,  12  and fall to the ground and injure a user or passerby or cause damage to the stored item. In further embodiments the entirety of side panels  11 ,  12  can be inclined slightly towards mounting strip  13  to achieve the same purpose. More specifically, stored items can be placed on the slightly inclined base  21  and leaned against the sides of floor beam  30  when mounting strip  13  is secured to beam  30 . The slight incline of base  21  towards beam  30 , along with outer rib  22 , helps prevent items from falling off shelf segment  10  and causing damage or injury. Moreover, shelf segment  10  permits items to be conveniently stored in the open air without the need for additional boxes and/or storage bins thereby reducing or eliminating the foul odors and condensation and mildew associated with items stored in boxes and bins for prolonged periods of time with little or no ventilation. 
     Additionally, minor variances in spacing between beams  30 , as is typical in older homes and buildings due to minor warping, does not affect the usefulness of the present invention because the shelf system is attached to only one beam. 
     Accordingly, the improved shelf system of the present invention is simplified, and provides an effective, safe, inexpensive, and efficient system which achieves all the enumerated objectives, eliminates costly and unnecessary features encountered with prior art overhead storage devices, and solves problems and obtains new results in the art. 
     Described herein is an overhead storage shelf which includes a pair of side panels, with each side panel including a base, an outer rib connected to the base, and at least one reinforcement rib connected to the base. The storage shelf further includes a mounting strip for connecting the pair of side panels, wherein the mounting strip facilitates the securing the shelf to a single beam. Certain embodiments of the invention include a front plate and a rear plate. In other embodiments of the invention either the front or rear plate includes a protruding member and the opposing or other plate contains a groove wherein the protruding member of the front or rear plate of one shelf section can be engaged in the groove of the front or rear plate of a second shelf section, allowing the shelf sections to removably interconnect. 
     In certain embodiments the shelf may have a plurality of reinforcement ribs longitudinally spaced along the base. In certain embodiments, the side panels may be inwardly inclined towards the mounting strip and in further embodiments only the base of the side panels may be inwardly inclined towards the mounting strip. The mounting strip may, but does not necessarily contain a plurality of openings formed to receive a fastener wherein the fastener secures the shelf to the beam. In certain embodiments the shelf may be constructed off a heavy duty plastic with flame retardant additives. 
     Also described herein is a shelf system that includes at least two shelf sections. Each shelf section includes a pair of side panels, with each side panel including a base, an outer rib connected to the base, at least one reinforcement rib connected to the base. Each shelf section further includes a mounting strip for connecting the pair of side panels, wherein the mounting strip facilitates the securing the shelf section to a single beam. A front plate and a rear plate are included, with either the front or rear plate including a protruding member and the opposite plate containing a groove wherein the protruding member of the front or rear plate of one shelf section can be engaged in the groove of the front or rear plate of a second shelf section, allowing the shelf sections to be removably interconnected. The sections can be attached to a single beam, positioned such that the shelf sections are interconnected along a single beam. 
     In the foregoing description, certain terms have been used for brevity, clearness, illustration and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, this invention has been described in detail with reference to specific embodiments thereof, including the respective best modes for carrying out each embodiment. It shall be understood that these illustrations are by way of example and not by way of limitation.