Patent Publication Number: US-11040367-B2

Title: Spray rack system

Description:
FIELD OF INVENTIVE CONCEPT 
     The present general inventive concept relates to systems and methods of retaining and maneuvering cabinetry, wood products or other items for purposes of applying or spraying coating materials to surfaces of such items. 
     BACKGROUND 
     Known systems and apparatuses for spraying, painting, or coating cabinetry, wood products or other items to be surface finished, have been less than satisfactory in facilitating quick and easy handling, processing, and maneuvering of such items. Improvement is desired in the handling, maneuvering, and support of such items to increase efficiency, throughput, and quality of the spraying, painting, and/or coating process. 
     BRIEF SUMMARY 
     Example embodiments of the present general inventive concept provide a system for retaining and maneuvering wood products, cabinetry items, or other items to be spray-coated, including a rack having a horizontal rail to hang one or more of the items, one or more car members coupled to the horizontal rail such that the one or more car members move along a length of the horizontal rail, and one or more attachment devices removably attachable to the one or more car members and to the one or more items. 
     Example embodiments of the present general inventive concept also provide a system for retaining and maneuvering items to be spray-coated, including one or more movable racks each having a first horizontal rail to support a plurality of items to be spray-coated and a first channel disposed along a length of the first horizontal rail, one or more car members coupled to the at least one rail such that the one or more car members are configured to move along the first channel of the first horizontal rail and to rotate in multiple distinct positions about an axis perpendicular to the length of the first horizontal rail, one or more attachment devices removably attachable to the one or more car members and the one or more items to be spray coated, respectively, such that the one or more items to be spray-coated hang from the first horizontal rail when the one or more car members are coupled to the first horizontal rail and the attachment devices are respectively attached to the one or more car members and items to be spray coated, a movable base configured to support the first horizontal rail, and one or more fixed racks each having a second horizontal rail and a second channel disposed along a length of the second horizontal rail, the second channel being configured to mate with the first channel to facilitate movement of one or more of the car members between the first channel and the second channel. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The following example embodiments are representative of exemplary techniques and structures designed to carry out the objectives of the present general inventive concept, but the present general inventive concept is not limited to these example embodiments. Moreover, in the accompanying drawings and illustrations, the sizes and relative sizes, shapes, and qualities of lines, entities, and regions may be exaggerated for clarity. A wide variety of additional embodiments will be more readily understood and appreciated through the following detailed description of the exemplary embodiments, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a spray rack system according to an example embodiment of the present general inventive concept; 
         FIG. 2  is a close-up view of a horizontal rail of a spray rack system, according to an example embodiment of the present general inventive concept; 
         FIG. 3A  is a perspective view of a car member, according to an example embodiment of the present general inventive concept; 
         FIG. 3B  is a front, internal view of a car member, according to an example embodiment of the present general inventive concept; 
         FIG. 3C  is a perspective view of a car member, according to an example embodiment of the present general inventive concept; 
         FIG. 4  is a perspective view of a shelf holder, according to an example embodiment of the present general inventive concept; 
         FIG. 5  is a perspective view of a drawer front holder, according to an example embodiment of the present general inventive concept; 
         FIG. 6  is a perspective view of a door holder along with an attached door, according to an example embodiment of the present general inventive concept; 
         FIG. 7A  is a front view of an expandable hole mount, according to an example embodiment of the present general inventive concept; 
         FIG. 7B  is a front view of an expandable hole mount, according to an example embodiment of the present general inventive concept; 
         FIG. 8  is a front view of a hanger, according to an example embodiment of the present general inventive concept; 
         FIG. 9  is a perspective view of a finishing clip, being used in conjunction with a hanger, according to an example embodiment of the present general inventive concept; 
         FIG. 10A  is a top view of a rail coupling, according to an example embodiment of the present general inventive concept; 
         FIG. 10B  is a front view of a rail coupling, according to an example embodiment of the present general inventive concept; 
         FIG. 10C  is an interior view of a rail coupling, according to an example embodiment of the present general inventive concept; 
         FIG. 10D  is an interior view of a rail coupling, according to an example embodiment of the present general inventive concept; 
         FIG. 10E  is a perspective view of a rail coupling, according to an example embodiment of the present general inventive concept; 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to the example embodiments of the present general inventive concept, examples of which are illustrated in the accompanying drawings and illustrations. The example embodiments are described herein in order to explain the present general inventive concept by referring to the figures. 
     Note that spatially relative terms, such as “up,” “down,” “right,” “left,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over or rotated, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Although example embodiments the present general inventive concept will be particularly described as being applied to a system for applying coatings to cabinets or wood products, it will be appreciated that the present general inventive concept can be applied to a variety of other objects, for example furniture, windows, models, and can be made of materials other than wood. 
     Referring to  FIG. 1 , example embodiments of the present general inventive concept can be implemented in connection with a rack system for holding multiple movable car members for suspending cabinetry items, which for the purposes of the invention may also include, but is not limited to, other items such as doors or windows. As illustrated in the example embodiment of  FIG. 1 , a cantilevered rack  100  is shown with multiple slideable, car members  110  attached to its horizontal rail  120 . Although  FIG. 1  shows 13 car members  110 , any number of car members  110  may be utilized subject to the size constraints of the horizontal rail  120 . The horizontal rail  120 , as shown, may have a rail coupling (described below) so that it can be configured to join securely with other racks  100 . A vertical arm  140  is shown which may support the weight of the horizontal rail  120  along with any items being held. The vertical arm  140  is shown attached to a cart  150  with rotatable cart wheels  160 . The horizontal rail  120 , vertical arm  140 , and cart  150  may be constructed of a material strong enough to be able to support the weight of the cabinets, fairly rigid to avoid against undue flex, light weight for easy transportation, and not overly expensive. Two examples of such material are aluminum and steel, although other materials are also possible. Although the cart  150  is shown in  FIG. 1  as 2 joists spanned by a cross beam, it is also possible to carry out embodiments of the present general inventive concept using other systems which are configured for supporting and moving the rack. All such configurations and modifications are intended to be included within the scope and spirit of the present general inventive concept. 
       FIG. 2  is a close-up view of the horizontal rail  120  with multiple car members  110  shown attached to the horizontal rail  120 . Multiple attachment devices (shown in subsequent figures) can be specialized for cabinet components, and are used to suspend cabinet components and other objects from the rack  100 . Included amongst these attachment devices may be a drawer front holder  400 , a shelf holder  300  and a hanger  700 . Further description of these devices will be provided in the description below. Also shown in the close up view of  FIG. 2  is a cut out view of the horizontal rail  120 , showing the channel  200  within which the car members  110  may be suspended, and within which they may move in a lateral direction. Although not shown in  FIG. 2 , in an example embodiment, a stop may be placed at the end of the horizontal rail  120  in order restrain the car members  110  in a lateral direction. Such embodiment will be described in a subsequent paragraph below. 
       FIGS. 3A and 3B  show different views of the car members  110 .  FIG. 3A  shows a perspective view of a car member  110 . The car member wheels  210  are configured to hang and roll within the channel  200  of the horizontal rail  120 . It may be useful for the car member wheels  210  encounter enough resistance within the channel  200  such that the cabinet components do not move under the force of the spray finishing. Additionally, wheel brakes (not shown) may be utilized to resist the movement of the car members  110  and the cabinet components in a lateral direction once a desired position is reached. The car member wheels  210  may be attached to each other with axles  220 , and the car member wheels  210  and axles  220  attached to a spindle  230 . The car member wheels  210 , axles  220  and spindle  230  (or “upper assembly”) may be configured to rotate on a platform  240  in relation to the lower assembly  250 . In one embodiment of the invention, the lower assembly  250  may rotate in 4 distinct positions relative to the upper assembly, in 90 degree increments, to provide easy access to the cabinet components for finishing and also to resist movement in a circumferential direction. However, it also possible in other embodiments to have more or less than 4 distinct positions subject to physical size constraints. In addition to the rotation as described herein, the car members  110  may also pivot in relation to the horizontal plane, in order to limit the amount of running paint or other finish and to allow proper drying, for example. Additionally, the car members  110  may include a spring system to enable staggered height of adjacent cabinet components or doors. Also shown in  FIG. 3  are the lower grooves  260 , which may be configured to accept the multiple attachment devices, and which may include the drawer front holder  400 , the shelf holder  300 , and the hanger  700 . A foam pad may also be provided for use with the rack system  100  to pad between cabinet components after they have dried, and the foam pad may be attached to the car members  110  as by a magnet, hook or other attachment structure. 
       FIG. 3B  shows an internal view of a car member  110  including one embodiment of a mechanism for providing the distinct positions of rotation between the lower assembly  250  and the upper assembly. The upper assembly including the spindle  230  are shown attached to a hat  270  with multiple detents  275  cut into the brim of the hat  270 . The detents  275  may be spaced in a circumferential direction around the brim of the hat  270  and correspond with the distinct rotation positions of the lower assembly  250  relative to the upper assembly. A pin  280  may rest matingly within the detents  275  of the hat  270 . A spring  290  may be in physical contact with the pin  280 , and the spring force may bias the pin  280  in an upward direction. Rotation of upper assembly including the spindle  230  in either a clockwise or counterclockwise direction rotates the hat  270 , applies a downward force on the spring and moves the pin  280  out of the detent  275  of the hat  270  within which it was resting, until the pin  280  finds an adjacent detent within which it can rest. Although there may be any number of detents  275  cut into the brim of the hat  270  subject to the physical size constraints of the hat  270 , pin  280 , and detent  275 , in one embodiment the detents  275  are spaced in equal increments apart such that they provide equal access to surface features of the cabinet components. 
       FIG. 3C  shows an alternative embodiment of the car member  110  including one embodiment of a mechanism for providing the distinct positions of rotation between the lower assembly  250  and the upper assembly. In this embodiment, internal spring plates  285  rest matingly within the detents  275  of the hat  270 , while intermediate positions between the detents  275  deflect the internal spring plates  285  in a downward direction. 
       FIG. 4  shows a perspective view of a shelf holder  300  configured for holding a shelf securely within the rack  100 . Two side tabs  310  are configured to fit matingly within the lower grooves  260  of the car members  110 . Additionally, a rear tab  330  with a corresponding hole may be used to attach to a hanger  700  when used with at least one other shelf holder  300 , as described in a subsequent paragraph. At the lower end of the shelf holder  300  is a bottom hole  320  of sufficient size to accept a wood screw. In one embodiment of the invention, the bottom hole  320  may be used to screw into a hidden edge of a cabinet shelf in order to support the shelf for spray finishing. Also shown in  FIG. 4  are additional side holes  325  which may be used for attachment to the cabinet shelf, for other cabinet components, or any other object for spray finishing. The multiple side holes  325  may provide a more secure attachment, as opposed to a single bottom hole  320 . 
       FIG. 5  shows a perspective view of a drawer front holder  400  configured for holding a drawer securely within the rack  100 . Two side tabs  410  are configured to fit matingly within the lower grooves  260  of the car members  110 . Additionally, a rear tab  430  with a corresponding hole may be used to attach to a hanger when used with at least one other drawer front holder  400 , as described in a subsequent paragraph. At the lower end of the drawer front holder  400  is a bottom hole  420  of sufficient size to accept a wood screw. In one embodiment of the invention, the bottom hole  420  may be used to screw into a hidden area, for example on the back of the drawer front, in order to support the drawer for spray finishing. 
       FIG. 6  shows a perspective view of a door holder  500  with attached door  520 . The door holder  500 , may consist of 2 distinct components, the door hanger  502  and one or more blocks  504 , and a pipe  516  which can be inserted through holes in blocks  504 . The door hanger  502  may include a center brace  510  which serves as the connection between the car member  110  and the door holder  500 . The center brace  510  has two tabs (not shown) which fit matingly within the lower grooves  260  of the car members  110 . The door hanger  502  may also include a support plank  512  and two or more hooks  514 . The hooks  514  are attached to the support plank  512 . In the embodiment shown in  FIG. 6 , slats are shown cut into the support plank  512 . By loosening the screws connecting the hooks  514  to the support plank  512 , an operator would then be able to move the hooks  514  in a lateral direction to provide for quick adjustment of the balance of the door  520  prior to spray refinishing. The blocks  504  may attach to the door  520  in the area of the hinge cutouts of the door  520 , which will be hidden from view once the hinges are installed or reattached. A pipe  516  is inserted through holes in the blocks  504 , and the door  520  may then be suspended onto the hooks  514  prior to refinishing of the door  520 . The pipe  516  may be made of steel, wood, or other solid material. In another embodiment, an expandable hole mount (shown as  600  in  FIG. 7 ) that fit into the knob hole of the door  520 , may be used to suspend the door  520  from the rack  100 . Although the door hanger  502  may be made of wood as shown in  FIG. 6 , other materials are also possible, for example aluminum or steel. 
       FIG. 7A  shows an illustration of the expandable hole mount  600 , which may be used to attach to a door knob opening, or other opening in a cabinet component or other object. The expandable hole mount  600  can act in the same fashion as the other attachment devices described above, which can be used to suspend cabinet components and other objects from the rack  100 . The expandable hole mount  600  consists of a prior art expandable plug  610 , with an actuation device  620 , shown as a wing nut in  FIG. 7A , but which could also be a lever, handle, knob, etc. Actuation of the expandable plug  610  creates a tight fit within a door knob opening, or other opening in a cabinet component or other object, and creates a secure attachment point. On the other end of the expandable hole mount  600  are two side tabs  630  which are configured to fit matingly within the lower grooves  260  of the car members  110 .  FIG. 7B  shows an alternate embodiment of the expandable hole mount  600 . In this embodiment, a screw knob  632  is rotated to actuate expanding core components  634  which may be used to attach to a door knob opening, or other opening in a cabinet component or other object. The expanding core components  634  consist of an inner block  635  and a sleeve  636  and rotation of the inner block  635  by rotating the screw knob  632  causes the sleeve  636  to move in an outward direction, which can cause it to provide a secure attachment within the knob hole of a door  520 . 
       FIG. 8  shows a hanger  700  which can be used to suspend cabinet components and other objects from the rack  100 . The hanger  700  can come in different sizes based on the size of the cabinet component or other object it is intended to support. At the top of the hanger  700  are two side tabs  710  which are configured to fit matingly within the lower grooves  260  of the car members  110 . Also located on the hanger  700  are multiple upward tabs  720 , which are generally equally spaced apart across the hanger rail  730 , and which can be used with finishing clips (shown as  810  in  FIG. 9 ). Additional embodiments may include a custom hangar  700  with multiple holes in different locations to support an operator created configuration. 
       FIG. 9  shows the hanger  700  being used in conjunction with the finishing clips  810  to support a cabinet door  820  from the rack  100 . The upper end of the finishing clips  810  may form a loop which can hang over the upward tabs  720 , and the upward tabs  720  resist movement of the finishing clips  810  and cabinet door  820  or other object in a lateral direction. The bottom end of the finishing clips  810  may form a hook which can fit within the hole  830  of the cabinet door  820  or other object in order to secure the cabinet door  820  or other object prior to and during spray finishing. Given their generally looser fit within a hole  830  of the cabinet door  820  or other object, in comparison with the expandable plugs  610  described above, the finishing clips  810  are intended to be used in pairs with the hanger  700 . 
       FIG. 10A  shows a rail coupling  910  which allows a rack  100  to be configured to join securely with other racks  100 . The horizontal rail  120  of each rack  100  is shown on the right and left of  FIG. 10 . The rail coupling  910  may be composed of two distinct parts, the spool coupler  912  and the fork coupler  914 . These two parts join together to provide for proper alignment and attachment of the two racks  100 . Also shown in  FIG. 10A  are the spools  920 , fork  930 , latch  940 , and latch release handle  946 . A latch limiting and adjustment screw  942  allows the user to adjust the latch for a secure fit. A side plate  944  is configured to overlap the horizontal rail  120  when the horizontal rails  120  are in a coupled state (as shown in  FIG. 10A ), in order to promote proper alignment of the horizontal rails  120 . 
       FIG. 10B  shows a view of the spool coupler  912  and the fork coupler  914  in an uncoupled state. As the spool coupler  912  and the fork coupler  914  are advanced towards each other, the spools  920  are inserted between the arms of the fork  930 , providing for proper alignment of the two racks  100 . A latch tab  950  may be configured to mate with one of the spools  920 , so that once the spools  920  are fully inserted between the arms of the fork  930 , and the horizontal rail  120  ends meet up, the latch tab  950  engages with the spool  920  creating a locking fit. Moving the latch  940 , by means of the latch release handle  946  in a vertical direction releases the rail coupling  910 .  FIG. 10A  shows the engaged position of the two racks  100 . 
     Shown in  FIG. 10C  is an interior view of the distal end of the horizontal rail  120 . A stopper cam  955  is shown attached near the end of the horizontal rail  120 . The stopper cam  955  has a limited range of motion in the circumferential direction and serves to prevent the car members  110  from rolling off the ends of the rack  100  when uncoupled. As shown in  FIG. 10C , with the car member  110  resting against the stopper cam  955  near the end of the horizontal rail  120 , the stopper cam  955  has reached the limit of its range of motion in the counter-clockwise direction, and the car members  110  is prevented from rolling off the ends of the rack  100 . A torsion spring  960  is attached to the stopper cam  955  in order to bias the stopper cam  955  in a position so that it contacts the car member  110  as the car member  110  approaches the end of the of the horizontal rail  120 , when the rack  100  is in an uncoupled state. 
       FIG. 10D  shows an interior view of the distal end of the horizontal rails  120  in a coupled state. In this case, the stopper cams  955  rotate against the biasing force of the torsion spring  960  and are no longer in position to engage with a car member  110  as it approaches the end of the of the horizontal rail  120 . Thus, when the rack  100  is in a coupled state, the car members  110  can move freely between racks  100 . 
       FIG. 10E  shows a view of one end of a horizontal rail  120  when the rack  100  is in an uncoupled state, including a stopper cam finger relief  956 . By depressing the stopper cam finger relief  956 , the stopper cam  955  is no longer in position to engage with a car member  110  as it approaches the end of the of the horizontal rail  120 , and may be used to manually remove a car member  110 , for example to service it. 
     In one embodiment of the present general inventive concept, a rack  100  as shown in  FIG. 1  attached to a movable cart  150  may be coupled to a fixed rack  100  in order to provide a stable platform during the spray finishing process. The fixed rack  100  may be attached to a wall, ceiling, or other immovable surface. After suspending the cabinet component(s) from the car member  110  of the rack  100  attached to a movable cart  150 , the rack  100  may then be moved into position in line with the fixed rack  100 . The spool coupler  912  of one rack  100  may then be joined with the fork coupler  914  on the other rack  100  until they are locked in place, in order to provide a substantially pivot-free connection. At that point, the operator may proceed with spray finishing of the cabinet components. In one embodiment, one rack  100  may be used to spray a cabinet component, after which the sprayed and dried cabinet component may be loaded onto the other rack  100  for transport or storage or the like. 
     Example embodiments include providing systems for retaining and maneuvering cabinetry items from one or more rack systems while applying coatings to the cabinetry items, including providing one or more car members configured to support the cabinetry items, providing one or more attachment devices configured to be removably attachable to the one or more car members and to the cabinetry items, providing a horizontal rail configured to support the one or more car members and to provide a channel for the one or more car members to move in a generally parallel direction with respect to the rail, providing a base configured to support the weight of the rail, one or more car members, and cabinetry items such that the system supports the cabinetry item from the one or more of the attachment devices, and supports the attachment device and cabinetry item from one of the one or more car members such that the cars can be moved along the horizontal rail and rotated until the cabinetry item is in position for spray finishing. 
     The systems and methods can also include providing a rail coupling attached to the end of one or more horizontal rails to facilitate mating or coupling of one rack system with another to facilitate movement of items to be spray coated from one rack to another. 
     It is noted that the simplified diagrams and drawings do not illustrate all the various connections and assemblies of the various components, however, those skilled in the art will understand how to implement such connections and assemblies, based on the illustrated components, figures, and descriptions provided herein, using sound engineering judgment. 
     Numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the present general inventive concept. For example, regardless of the content of any portion of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. 
     While example embodiments have been illustrated and described, it will be understood that the present general inventive concept is not intended to limit the disclosure, but rather it is intended to cover all modifications and alternate devices and methods falling within the spirit and the scope of the invention as defined in the appended claims.