Patent Publication Number: US-2007119802-A1

Title: Rack

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to collapsible and re-expandable modular racks. In particular, the invention relates to modular wine racks and methods to make such racks.  
      2. Description Of Related Art  
      Wine racks have been known for years. However, most wine stores, particularly smaller stores, do not sell wine racks. Wine racks take up too much retail space to be worth the shelf space in a wine store. What is needed is a collapsible and re-expandable wine rack that can be collapsed for shipment and storage in compact form and then expanded for display in the wine store. Then, the wine store would only need to display one or two expanded wine racks since additional racks could be easily expanded as the display models are sold.  
      Life Style Products of Vermont sells a 12 bottle wine rack that has wooden rails and dowels inserted in bores in the wooden rails. The dowels are inserted in the rails to assemble a rack to various sizes. However, this rack must be disassembled, piece by piece, for compact storage.  
      Stackable modular wine racks are known.  FIG. 16  illustrates a known wine rack assembled from individual bottle holder modules. These individual modules have been assembled into a 12 bottle rack. However, known modular wine racks are not collapsible and re-expandable. There remains a need for expandable and modular wine racks. In particular, there remains a need for an expandable and modular wine rack so that a wine store could display only the smaller formats, for example a 4, 6, 9 or 12 bottle expandable wine rack, but still assemble the a larger format, for example 16, 24, 36 and 48 bottle expandable wine racks, from the modular expandable smaller formats. For example, there is a need for an expandable modular wine rack such that the wine store, or the customer, could expand several, for example four, smaller expandable racks, for example four 6 bottle wine racks, such as might be displayed in the wine store, and then modularly combine the smaller format wine racks into a larger format wine rack, for example a 24 bottle wine rack.  
     SUMMARY OF THE INVENTION  
      The invention improves the state of the art by providing an expandable modular rack  
      A first section of the rack, according to an embodiment of the invention, includes a first lower wire bend, a second lower wire bend, a first upper wire bend, and a second upper wire bend. The first section also includes a first pivot coupling into which is received a first end of each of the first and second lower wire bends and into which is received a first end of each of the first and second upper wire bends. The first section also includes a second pivot coupling into which is received a second end of each of the first and second lower wire bends and into which is received a second end of each of the first and second upper wire bends.  
      In another embodiment of the invention, a method of making a rack includes bending wire, forming a first frame, forming a complementary frame locating the first frame inside of the complementary frame, and inserting first and second pivotal connectors. The bending of wire bends wire into a first lower wire bend, a second lower wire bend, a first upper wire bend and a second upper wire bend. The forming of the first frame includes inserting ends of the first lower wire bend and the second upper wire bend into first and second molds and insert molding the ends into first and second coupling parts. The forming of the complementary frame includes inserting ends of the second lower wire bend and the first upper wire bend into third and fourth molds and insert molding the ends into third and fourth coupling parts. The inserting of pivotal connectors includes inserting a first pivotal connector through apertures in the first and third coupling parts and inserting a second pivotal connector through apertures in the second and fourth coupling parts. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
      The invention will be described in detail in the following description of preferred embodiments with reference to the following figures wherein.  
       FIG. 1  is a perspective view of an exemplary section of a rack according to an embodiment of the invention.  
       FIG. 2  is a plan view of a wire bend according to an embodiment of the invention.  
       FIG. 3  is a side view of a pivot coupling according to an embodiment of the invention.  
       FIG. 4  is a sectional view of the pivot coupling of  FIG. 3 .  
       FIG. 5  is a front view of a frame that includes two wire bends and two coupling parts according to an embodiment of the invention.  
       FIG. 6  is a side view of the frame of  FIG. 5 .  
       FIG. 7  is an exploded view of an alternative pivot coupling according to another embodiment of the invention.  
       FIG. 8  is a perspective view of an exemplary rack with two modular sections arranged vertically according to an embodiment of the invention.  
       FIG. 9  is a perspective view of a resilient clip according to an embodiment of the invention.  
       FIG. 10  is a sectional view of the clip of  FIG. 9 .  
       FIG. 11  is a perspective view of an exemplary rack with two modular sections arranged side by side according to an embodiment of the invention.  
       FIG. 12  is a perspective view of a fully open exemplary rack with four modular sections arranged in a two by two array according to an embodiment of the invention.  
       FIG. 13  is a perspective view of the fully open exemplary rack of  FIG. 12  with four bottles stored thereon.  
       FIG. 14  is a perspective view of the exemplary rack of  FIG. 12  in a half-way open configuration.  
       FIG. 15  is a perspective view of the exemplary rack of  FIG. 12  folded flat.  
       FIG. 16  is a view of a known wine rack. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
      In  FIG. 1 , an example of a rack, according to the invention, includes a first section. The first section includes a first lower wire bend  10 , a second lower wire bend  20 , a first upper wire bend  30 , and a second upper wire bend  40 . The first section further includes a first pivot coupling  50  and a second pivot coupling  60 . A first end  12  of each of the first and second lower wire bends and each of the first and second upper wire bends is received in the first pivot coupling  50 . A second end  14  of each of the first and second lower wire bends and each of the first and second upper wire bends is received in the second pivot coupling  60 .  
       FIG. 2  depicts a typical wire bend  10  with first end  12  and second end  14  in a plane defined in by X, Y axes. The wire bend is generally in the shape of a letter “C” and is formed of metal wire, for example steel. The metal wire may be, but need not be, chrome plated, power coated or painted. As used herein, the term “wire bend” may also include an element of similar form, fit and function (as described herein) made of any suitable material. For example, a resilient plastic that is formed into the described shape may be designed to have a similar form, fit and function.  
       FIG. 3  depicts an example of a pivot coupling, e.g., pivot coupling  50  viewed from a direction orthogonal to a plane defined by the Y, Z axes. Pivot coupling  50  is formed from first coupling part  51 , second coupling part  52 , and pivotal connector  58 . Pivotal connector  58  may be a rivet made of metal or plastic, a nut and bolt or any equivalent.  FIG. 4  depicts a sectional view of pivot coupling  50  taken through sectional line  4 - 4  of  FIG. 3 . Each of the first and second coupling parts  51 ,  52  preferably include a thinned portion  54 , as depicted in  FIG. 4 , to form a half-lapped pivotal connection between coupling parts  51 ,  52 .  
       FIG. 5  depicts a frame comprised of two wire bends  10 ,  40  and two coupling parts  51 ,  52 .  FIG. 5  illustrates how the first end  12 , of each of wire bends  10  and  40 , is anchored in second coupling part  52  of pivot coupling  50  as viewed from a direction orthogonal to a plane defined by the X, Y axes. Second coupling part  52 , in this example, is formed out of an injection molded plastic, preferably nylon, but not necessarily nylon. The first ends  12  are placed in a mold and plastic is injected into the mold to surround the wire ends to form coupling part  52  with the wire ends permanently anchored in coupling part  52  in a process often called “insert-molded.” The second end  14 , of each of wire bends  10  and  40 , is similarly anchored in a coupling part  51  of pivot coupling  60 . This completes the frame, depicted in  FIG. 5 , that constitutes a partial section of the rack that is depicted in  FIG. 1 .  
      In another example, the wire ends  12  and  14  may be bent or upset by stamping (if metal) or upset thermally (if made of a thermally formed plastic) before the insert-molding process to better anchor the wire ends in the molded coupling parts.  
      In yet another example, the coupling parts, e.g.,  51  and  52 , are formed of metal. In  FIG. 7 , pivot coupling  50  is formed of first coupling part  51 , second coupling part  52  and pivotal connector  58 . First coupling part  51  includes a thin portion  66  through which aperture  68  has been formed and two metal ends  62  and  64  able to be crimped. Similarly, second coupling part  52  includes a thin portion  76  through which aperture  78  has been formed and two metal ends  72  and  74  able to be crimped. During assembly, wire ends  12  and  14  are inserted in metal ends  62 ,  64 ,  72  and  74  and the metal ends of the coupling parts are crimped.  
      In the example of the wire bend depicted in  FIG. 2 , the wire bend is formed with offset bends  16  and  18 . However, other embodiments of the rack may use wire bends without such offset bends. However, an advantage of the offset bends is that a maximum area inside the wire bend is achieved without the pivot couplings  50  and  60  being forced to extend beyond the width W of the wire bends that constitute the frame as depicted in  FIG. 5 .  
      In another example, as depicted in  FIG. 6  and as viewed from a direction orthogonal to a plane defined by the Y, Z axes, wire bends  10  and  40  are bent at their ends  12 ,  14  in a direction out of the X, Y plane so that coupling part  52  lies transverse to the X, Y plane. This will help facilitate folding the rack for storage or shipment as described more fully below.  
      In  FIG. 5 , the frame includes wire bends  10  and  40  and two coupling parts that have thinned portions disposed toward the center of the frame. A complementary frame (not illustrated) includes wire bends  20  and  30  and two coupling parts that have thinned portions disposed toward the outside of the frame. The two complementary frames are assembled together with the complementary thinned portions are disposed adjacent to each other before being fastened together with pivotal connections  58  to produce the section  100  of the rack illustrated in  FIG. 1 . Section  100  provides a basic building unit for making larger rack in a modular way.  
      In  FIG. 8 , another example of the rack  200 , according to the invention, includes first section  202  and second section  204 . Each section is constructed according to any of the above described embodiments and examples. The example of the rack depicted in  FIG. 8  further includes a first resilient clip  210  to hold the first lower wire bend of the second section to the first upper wire bend of the first section and a second resilient clip  220  to hold the second lower wire bend of the second section to the second upper wire bend of the first section.  
      In  FIG. 9 , resilient clip  210  includes two channels  212  and  214  sized hold a wire bend and a gap  216  sized to permit a wire bend to be urged through the gap into either one of the channels  212 ,  214 .  FIG. 10  depicts a cross section of the clip  210  with wire bends  10  and  30  seated in their respective channels. However, it is not necessary that clip  210  be formed with a cross section shape that allows the channels to conform to the cross section shapes of the wires. The clip  210  may provide a single oval shaped channel sufficient to hold two wire bends  10 ,  30 . The clip is formed of resilient material and the gap is sized so that when both wire bends are in the channel, neither wire bend is free to escape without sufficient force being applied to overcome a resilient resisting force. Thus, the clips hold the two wire bends. The resilient clips are made of a suitable resilient material. In an example, the clips are made of a resilient plastic co-molded with a rubber outside.  
      By using these resilient clips, any number of modular sections may be combined into a modular rack by snapping multiple wire bends together with such clips.  
      In  FIG. 11 , another example of a rack  201 , according to the invention, includes first section  202  and second section  204 . Each section is constructed according to any of the embodiments and examples discussed above with respect to  FIGS. 1-7 . The example of the rack depicted in  FIG. 11  further includes a first resilient clip  230  to hold the first lower wire bend of the first section to the first lower wire bend of the second section, a second resilient clip  240  to hold the second lower wire bend of the first section to the second lower wire bend of the second section, a third resilient clip  250  to hold the first upper wire bend of the first section to the first upper wire bend of the second section, and a fourth resilient clip  260  to hold the second upper wire bend of the first section to the second upper bend of the second section.  
      By combining the techniques for stacking sections vertically, e.g.,  FIG. 8 , and attaching sections horizontally, e.g.,  FIG. 11 , a rack with any number of sections may be produced. In  FIG. 12 , rack  400  with four sections in a 2 by 2 arrangement is illustrated. Beginning with the two-section horizontal rack  201  with the two sections attached with clips  230 ,  240 ,  250  and  260  and as depicted in  FIG. 11 , a second two-section horizontal rack is formed from sections  206  and  208  with the two sections being attached together with clips  270 ,  280 ,  290  and  300 . Then, the second two-section horizontal rack is attached to the rack  201  with clips  310 ,  320 ,  330  and  340 . Resilient clip  310  holds the first lower wire bend of the third section to the first upper wire bend of the first section. Resilient clip  320  holds the second lower wire bend of the third section to the second upper wire bend of the first section. Resilient clip  330  holds the first lower wire bend of the fourth section to the first upper wire bend of the second section. Resilient clip  340  to hold the second lower wire bend of the fourth section to the second upper wire bend of the second section.  FIG. 13  depicts one of the many uses of modular rack  400 , in this case, rack  400  is used to store wine bottles.  
      When not in use, rack  400  may be folded up and stored, with all clips in place, as depicted in  FIGS. 14 and 15 . The folded flat configuration is also useful for shipping. The advantage of bending wire bends  10  and  40  ( FIG. 6 ) at their ends  12 ,  14  in a direction out of the X, Y plane so that coupling part  52  lies transverse to the X, Y plane can be seen by comparing  FIG. 15  and  FIG. 6 . This facilitates folding the rack flat for storage or shipment.  
      Having described preferred embodiments of a novel rack (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments of the invention disclosed which are within the scope of the invention as defined by the appended claims.  
      Having thus described the invention with the details and particularity required by the patent laws, what is claimed and desired protected by Letters Patent is set forth in the appended claims.