Patent Publication Number: US-2003233965-A1

Title: Shelving system

Description:
BACKGROUND OF THE INVENTION  
       [0001] 1. Field of the Invention  
       [0002] The present invention relates to shelving systems and in particular, but not exclusively, to modular shelving kits suitable for use for example in the home, in offices, in businesses and as product display shelving in shops.  
       [0003] 2. Description of Related Art  
       [0004] Modular shelving systems, which have greatly simplified the installation of either wall-hung or free-standing shelving, have been generally available for a number of years and are popular both for commercial installations and in the DIY market. FIG. 1 illustrates a conventional wall-hung metal shelving system comprising a pair of uprights  1 ,  2 , a pair of brackets  3 ,  4 , one bracket being mounted on each of the two uprights  1 ,  2 , and a shelf  5  secured to the brackets  3 ,  4 . Whilst the uprights  1 ,  2  and the brackets  3 ,  4  are generally made of a metal such as steel the shelf  5  is most commonly of wood or a similar artificial composite material. Normally a shelving system would consist of two or more pairs of brackets and an equivalent number of shelves which are mounted on the uprights one above the other with space in between each shelf.  
       [0005] The two uprights  1 ,  2  are intended for mounting generally vertically and parallel with one another on a wall. Each upright  1 ,  2  has a substantially U-shaped cross-section such that when it is secured to the wall it defines with the surface of the wall an enclosed channel extending substantially vertically. Each upright  1 ,  2  includes at least two through holes  6  for receiving wall screws for attaching the uprights to the wall. Each upright  1 , 2  additionally includes two parallel lines of repeating lozenge-shaped apertures  7  extending the length of the upright and opening to the enclosed channel defined by the upright and the wall.  
       [0006] The brackets  3 ,  4  are also of generally U-shaped cross-section with each side of the bracket generally describing a right-angled triangle. The two sides of the bracket are joined along the hypotenuse edge of each side of the bracket and the two other edges of each side of the bracket respectively contact the front surface of an upright and the lower surface of the shelf. Thus, the U-shape of the bracket is deepest adjacent the upright and gradually reduces in size to a point furthest from the upright. Two through holes  8  are provided in the downwardly facing surface of each bracket intermediate its two ends. The through holes  8  are adapted to receive screws  9  for securing the shelf  5  to the bracket, as is described in greater detail below. At the edge of the bracket which contacts the upright, a pair of parallel flat hooks are provided which project outwardly from the edge of the bracket. The hooks are L-shaped and are adapted to be inserted through one pair of lozenge-shaped apertures  7  in the upright and to engage with the upright in this manner.  
       [0007] The shelf  5  is a generally rectangular slab which rests over and is supported by the upwardly facing parallel edges of the two brackets  3 ,  4 . Screws  9  inserted through the apertures  8  in the brackets have to be sufficiently long to extent across the depth of the bracket to the underside of the shelf. The screws are then screwed into the underneath of the shelf to secure the shelf to the brackets and to prevent the shelf  5  from tipping if a force were to be applied to the edge of the shelf furthest from the wall.  
       [0008] Construction of a shelving system of the type described above is relatively easy. As long as the two uprights are secured to the wall vertically, aligned and parallel with one another and the brackets present horizontal upper edges when mounted into the slots of the upright, the individual shelves should be horizontal. Such a shelving system also permits the person constructing the shelving to decide the spacing between adjacent shelves and the shelving system allows for different spacing between adjacent shelves in a series of shelves mounted on the same pair of uprights.  
       [0009] Shelving systems of the type described above have often been promoted on the basis that they are re-useable and that individual shelves can be re-positioned as required. However, re-use of a shelving system such as the one illustrated in FIG. 1 is not as straightforward as the modular nature of the system would suggest. As mentioned above, to prevent individual shelves from slipping the shelves are secured to the brackets by means of screws which must pass from the underside of the bracket through the depth of the bracket into the underside of the shelf. This requires a comparatively long screw, the length of which is not accessible within the bracket. As a result, the screw often penetrates the underside of the shelf at an acute angle which can undermine the holding strength of the screw in the shelf. Additionally, penetration of the screw into the underside of the shelf leaves a screw hole. When a shelving system is disassembled or the shelves are removed so as to be re-positioned, the same screw holes cannot be reused as a screw will not adequately hold the shelf if screwed into the same hole. Therefore, the shelf is usually turned over so that a new screw hole can be cut into the other side of the shelf. However, this leaves the former screw holes clearly in the visible upper surface of the shelf.  
       [0010] The present invention seeks to address the problems encountered with conventional modular shelving systems and to provide an improved shelving system.  
       BRIEF SUMMARY OF THE INVENTION  
       [0011] In accordance with the present invention there is provided a shelving system comprising at least one upright, at least one bracket for attachment to the upright and at least one shelf for mounting on the bracket, the bracket including at least one bracket screw hole for receiving a screw to be screwed into the underside of a shelf, shelving system further comprising at least one screw guide having a screw channel for guiding the passage of a screw and a bracket coupling member adapted for holding the screw guide in position within the bracket adjacent the bracket screw hole.  
       [0012] Thus with the present invention individual shelves may be attached to the brackets of the shelving system confident in the knowledge that the shelves are securely screwed to the brackets as the screws through the brackets will be accurately guided to the underside of the shelf via the screw guide in the bracket.  
       [0013] Ideally, the screw guide includes a biasing member associated with the bracket coupling member and movable between a holding position in which the screw guide is held in position within the bracket and a releasing position in which the screw guide is able to move into and out of the bracket.  
       [0014] The bracket coupling member may be in the form of opposed lugs adapted for engagement in apertures provided in the sides of the brackets, the lugs being mounted on respective resilient arms or flanges.  
       [0015] With this preferred embodiment the screw guide is removable from the bracket and once attached to a shelf the screw guide remains with the shelf even if the shelf is subsequently re-positioned. This means that unsightly screw holes in the shelf may be avoided and the re-positioning of the shelf is simple and reliable.  
       [0016] Moreover, with the shelving system of the present invention individual brackets may be capable of withstanding a 110 Kg force when attached to an upright.  
       [0017] In an alternative aspect the present invention provides a shelving screw guide for use with a shelving system consisting essentially of an upright, at least one bracket and at least one shelf, the shelving screw guide comprising a screw channel for guiding the passage of a screw, a bracket coupling member adapted for holding the screw guide in position within the bracket and a biasing member associated with the bracket coupling member movable between a holding position and a releasing position.  
       [0018] Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which: 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0019]FIG. 1 illustrates a conventional modular shelving system, not in accordance with the present invention;  
     [0020]FIG. 2 illustrates in an exploded perspective view a wall mounted shelving system in accordance with the present invention;  
     [0021]FIG. 3 illustrates an alternative suspended shelving system in accordance with the present invention;  
     [0022]FIG. 4 illustrates the screw guide of the shelving system of FIG. 2;  
     [0023]FIG. 5 is a cross-sectional drawing of the screw guide of FIG. 4;  
     [0024]FIGS. 6 a - 6   c  illustrate the movement of the flanges of the screw guide of FIG. 4 as the screw guide is inserted into a shelving bracket;  
     [0025]FIGS. 7 a  and  7   b  are perspective views from above and below respectively of a first alternative screw guide in accordance with the present invention;  
     [0026]FIGS. 8 a  and  8   b  are perspective views from above and below respectively of a second alternative screw guide in accordance with the present invention;  
     [0027]FIGS. 9 a  and  9   b  are perspective views from above and below respectively of a third alternative screw guide in accordance with the present invention; and  
     [0028]FIGS. 10 a  and  10   b  are perspective views from above and below respectively of a fourth alternative screw guide in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0029] The shelving system illustrated in FIG. 2 has similar components to those of the conventional shelving system illustrated in FIG. 1 and is intended to be capable of being retro-fitted to conventional shelving uprights. Hence, like reference numerals shall be used where appropriate.  
     [0030] The uprights  1 ,  2  of FIG. 2 are of U-shaped cross-section and, when mounted on a wall, define in combination with the wall an enclosed channel. Two lines of apertures  7  extending the length of each of the uprights  1 ,  2  again provide access to the enclosed channel. In the shelving system of FIG. 2, however, the apertures  7  are mirrored D-shaped apertures rather than lozenge-shaped. The uprights  1 ,  2  are again attached to the wall by means of at least two apertures  6  in each upright that are adapted to receive conventional wall screws. Caps are additionally provided at each end of the uprights  1 ,  2  to close off the ends of the uprights and to provide a more pleasing appearance. The shelves  5  (only one is illustrated in FIG. 2) may be identical in all respects to conventional shelves and as before are preferably made of a wood or an equivalent material.  
     [0031] The brackets  10 ,  11  are similar to conventional shelving brackets in that they are of U-shaped cross-section with each side having a right-angled corner between two straight edges: the first edge  12 , abutting the upright  1 ,  2  and the second straight edge  13  abutting the underneath of a shelf  5 . The third downwardly facing edge  14  of the bracket, which would be the hypotenuse on a conventional shelving bracket, as illustrated in FIGS. 2 and 3 describes an arc rather than a straight line so that the bracket remains deeper for a greater proportion of its length before tailing off to a point furthest from the upright. Of course, this effect could be achieved with different shapes of brackets such as a stepped structure, for example. The brackets  10 ,  11  also include opposed pairs of L-shaped hooks  15  along the first edge  12  for attaching the brackets to the uprights  1 ,  2  by insertion of the hooks into the slots in an upright.  
     [0032] The brackets  10 ,  11  each includes a single screw hole  8  in the downwardly facing edge  14  of the bracket and because of the pronounced arc the screw hole  8  is positioned further from the upright in comparison to conventional shelving brackets. Additionally, a pair of opposed side apertures  16  are provided, one in each side of the bracket. The side apertures  16  are illustrated as generally rectangular in shape, however, alternative shapes of aperture may equally be employed and the side apertures  16  are positioned such that a line passing through the two side apertures intersects a vertical line passing through the screw hole  8 .  
     [0033]FIG. 3 illustrates an alternative suspended shelving system in which the two uprights are hung from a crossbar otherwise referred to as a suspension girder or rail. In all other respects the shelving system is identical to the one illustrated in FIG. 2. It is also envisaged that the shelving system described herein may be implemented as a free standing shelving system.  
     [0034] The shelving systems illustrated in FIGS. 2 and 3 include a further component not found in existing modular shelving systems. The further component consists of a screw guide  17  which may be more clearly seen in FIGS. 4 and 5. The screw guide  17  has a central wall  18  through which a screw hole  19  extends lengthways and has two outer flanges  20 ,  21  attached to the central wall  18  along one edge  22 . The screw guide is preferably fabricated from a hard plastics material such as nylon or polypropylene that has sufficient resilience to permit a small amount of flexure of the outer flanges  20 ,  21  along the edge  22  relative to the central wall  18 . On the outwardly facing surface of each of the two flanges  20 ,  21  respective lugs  23  are provided that are shaped to be inserted into and engage with the side apertures  16  of the brackets  10 ,  11 .  
     [0035] In use, a screw  9  is partially screwed into the screw hole  19  in the guide  17  so that the head of the screw  9  projects downwardly from the edge  22  of the guide  17  (FIG. 6 a ). The two flanges  20 ,  21  of the screw guide  17  are then urged towards the central wall  18  (FIG. 6 b ), against the natural outward bias of the flanges, so that the guide  17  can be inserted into the space between the two side walls of one of the brackets  10 ,  11  with the screw  9  and the edge  22  of the guide  17  leading the insertion of the guide  17  into the space between the two sides of the bracket. Once inside the bracket the screw guide  17  is moved to its final position in which the two lugs  23  are aligned with the side apertures  16 . With the screw guide  17  in its final position, the flanges  20 ,  21  automatically flex away from the central wall  18  and the lugs engage with the side apertures  16  (FIGS. 5 and 6 c ) thereby securely holding the screw guide  17  in position within the bracket  10 ,  11 . Location of the lugs  23  in the side apertures  16  also ensures that the screw  9  is aligned with the screw hole  8  in the bracket  10 ,  11 .  
     [0036] With the screw guide  17  in place, a screw driver may be inserted through the screw hole  8  to engage with the head of the screw  9  and thereby enable the screw to be screwed into the underside of the shelf  5 . The screw hole  19  in the screw guide  17  ensures that even the very long screws required to bridge the space from the outside edge of the bracket to the underneath of the shelf are supported in the space between the sides of the bracket and are thus guided to the underside of the shelf  5 . This in turn ensures that the screw  9  is screwed into the shelf  5  substantially normal to the surface of the shelf rather than at an acute angle, as can often be the case with conventional modular shelving systems.  
     [0037] Furthermore, if at any stage in the future it is decided to disassemble the shelving system and re-position the height of individual shelves this can be done very easily without resorting to cutting extra screw holes into the shelves. To remove the shelves, the lugs  23  projecting through the side apertures in each of the two brackets  10 ,  11  are pressed and urged against their natural bias towards one another so as to be released from the side apertures  16  in the bracket. This enables the screw guide  17  to be removed from the bracket  10 ,  11  and enables the shelf  5 , still attached to the screw guide  17 , to be removed from the brackets  10 ,  11 . The brackets can then be re-positioned as desired on the uprights and the shelf re-attached to the brackets by re-inserting the two screw guides  17  between the side walls of respective brackets until the lugs  23  once again engage in the side apertures  16  of the brackets. Thus, once attached to the underneath of the shelf the screw guide  17  preferably remains attached to the shelf  5  at all times thereby avoiding the need to re-screw the shelf to the bracket when re-positioning the shelf.  
     [0038]FIGS. 7 a ,  7   b ,  8   a  and  8   b  illustrate two alternative designs of the removable screw guide  17  described above. In all cases however, the screw guide includes a through hole  19  which receives and guides the screw that will be used to secure the shelf to the screw guide  17 , at least one coupling member such as a lug  23  for coupling the screw guide  17  to the bracket  10 ,  11  inside the side walls of the bracket at a predetermined location and at least one biasing member such as the flanges  20 ,  21  to permit limited movement of the coupling member between an engaged and a releasing position. In the case of FIGS. 8 a  and  8   b  the flanges  20 ,  21  are arranged so as to be attached along an upper edge  24  of the screw guide  17 . In the case of FIGS. 7 a  and  7   b  the coupling members  23  are mounted on biasing members in the form of opposed pairs of bent arms  25  and  26  which permit compression of the coupling member towards to screw hole  19  but are naturally biased away from the central screw hole  19 . Other alternative coupling members and biasing members are envisaged without departing from the scope of the present invention as defined in the accompanying claims. For example, the screw guide may releaseably engage with a shoulder or ramp in the interior of the bracket rather than in apertures provided in the walls of the brackets, as illustrated.  
     [0039] Alternative permanent screw guides are illustrated in FIGS. 9 a ,  9   b ,  10   a  and  10   b . With these alternative screw guides a detent  27  is provided to establish a permanent attachment of the screw guide  17  to the bracket  10 ,  11 . In the case of FIGS. 9 a  and  9   b  the detent  27  is intended for engagement with a ridge or shoulder provided on the inner surfaces of the bracket sides. In the case of the screw guide illustrated in FIGS. 10 a  and  10   b  the detent  27  is intended to establish a force fit with the side walls of the bracket through rotation of the screw guide once in position between the bracket sides. Further alternative designs of the screw guide will, of course, be apparent which similarly provide the benefit of acting as a guide to a screw passing from the outer lower edge of a shelving bracket to the underside of a shelf. With the permanent screw guide  17 , the screw guide  17  still provides the benefit of guiding the screw  9  so that the screw cuts into the shelf  5  substantially normal to the surface of the shelf. However, as the screw guide  17  of FIGS. 9 and 10 are intended to be permanently held in the bracket  10 ,  11 , the shelf  5  must be unscrewed from the bracket  10 ,  11  in the conventional manner if it is decided to re-position the shelf.  
     [0040] Although reference has been made herein to metal modular shelving systems it will of course be immediately apparent that the features of the present invention may apply to a large range of different modular shelving systems and the present invention is not limited to shelving systems constructed using metal and encompasses systems of wood or composites for wood, for example.