Patent Publication Number: US-6908000-B2

Title: Multi-tiered corner shelving unit

Description:
RELATED APPLICATION DATA 
   This patent is related to co-pending U.S. provisional application Ser. No. 60/355,515, which was filed on Feb. 7, 2002. 

   BACKGROUND OF THE DISCLOSURE 
   1. Field of the Disclosure 
   The present invention relates generally to shelving systems, and more particularly to a modular shelving unit for mounting in a corner. 
   2. Description of the Related Art 
   It is known in the art to provide modular shelving systems or units. One type of modular unit includes a plurality of rectangular panels or shelves, wherein each shelf has four sockets, one provided in each corner of the shelf. Successive shelves can be stacked and interconnected to vertically adjacent shelves by inserting posts or risers into each of the sockets. The modular construction provides flexibility for the consumer to assemble a shelf system or unit with a desired number of shelves and/or a desired height. Examples of such shelving systems are disclosed in, for example, U.S. Pat. Nos. 6,079,339 and 6,178,896, each incorporated herein by reference in their entirety. Each shelf of the units disclosed in these exemplary patents typically provides a planar storage surface for supporting stored objects. 
   One problem with these known modular shelving units is that if you stack a large amount of material on the units, it can be difficult to access stored objects hidden behind other stored objects on each shelf. It can be time consuming and quite a nuisance to have to move a number of objects in order to access a hidden object on a shelf. It can also be uncomfortable to do so on lower shelves, as the user will likely have to bend or kneel to access the shelf while looking for a particular object. 
   Another problem with these known shelving units is that they are typically of a rectangular shelf or panel construction wherein each shelf has a greater width than a depth. Such units can be mounted against a wall and can have one end placed in and abutting a corner of the room. A shelf unit can be mounted adjacent either wall at a corner. The shelf unit sticks out into the room environment at the end opposite the corner facing end and can impede foot traffic within the room space. If such a unit were mounted in a corner at an angle traversing the walls at the corner, the unit would extend quite a ways into the room, also impeding traffic around the unit. Further, since the shelves are typically rectangular, the space behind each shelf when the unit is placed in a corner is not suitable for storing objects because the shelves do not extend all the way to the corner, rending the corner space unusable. 
   Moreover, shelving units supported by socket and riser assemblies, such as those disclosed in the above-noted patents, often transmit a disproportionate amount of force to one particular socket and supporting riser of each shelf or panel. This is caused, in part, by the rigid connection between the socket and riser, and in part by the rigid structure of the socket. The entire force at each riser, and particularly at the heavily loaded riser, the riser of the shelf applied to the socket is directly distributed into the panel and the riser. Such force distribution to rigid components can cause either or both the panel around the socket and the riser to crack or fail. If this occurs even at one connection, the entire shelving structure is weakened. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Objects, features, and advantages of the present invention will become apparent upon reading the following description in conjunction with the drawing figures, in which: 
       FIG. 1  is a front view of one example of a multi-tiered shelving unit constructed in accordance with the teachings of the present invention. 
       FIG. 2  is a partially exploded view of the shelving unit shown in FIG.  1 . 
       FIG. 3  is a cross section of a turntable assembly as shown in FIG.  1 . 
       FIG. 4  depicts a front view of a multi-tiered shelving unit such as that shown in FIG.  1  and positioned in a corner. 
       FIG. 5  depicts a side view of the shelving unit shown in FIG.  4 . 
       FIG. 6  is a front view of another example of a multi-tiered shelving unit constructed in accordance with the teachings of the present invention. 
       FIG. 7  is a partially exploded view of the shelving unit shown in FIG.  6 . 
       FIG. 8  is a perspective view of one example of a panel for the shelving units shown in  FIGS. 1 and 6 , and including an example of a socket constructed in accordance with the teachings of the present invention. 
       FIG. 9  is a top plan view of the panel shown in FIG.  8 . 
       FIG. 10  is a side cross-section of the rear socket taken along line X—X of the panel in FIG.  9 . 
       FIG. 11  illustrates a cross section of another example of a socket and riser connection constructed in accordance with the teachings of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The disclosed shelving units are each directed to a modular shelving unit  10  that either solves or improves upon one or more of the problems in the prior art described above. Particularly, multi-tiered modular shelving units are disclosed herein. One of the disclosed modular shelving units is configured to mount in a corner of a room and incorporates one or more turntable assemblies  12  or “lazy-suzan” structures that are modular and simple in construction. A turntable assembly can be selectively installed or not installed on each given shelf of the unit as desired without otherwise affecting the unit structure. Another exemplary shelving unit described herein includes no turntable assemblies but is configured to mount in a corner of a room and is adapted to provide storage space on each shelf completely into the corner of the room. Yet another exemplary shelving unit has a weakened socket and riser assembly for deflecting force away from the risers. Each of the entire shelving units disclosed herein, both with or without one or more turntables, can be easily broken down and assembled without the use of tools and in a very simple manner. 
   Referring now to the drawings, one of the modular shelving units disclosed herein is illustrated in  FIGS. 1-5  and is identified as the modular shelf unit  10 . The unit  10  has a plurality of panels  14  that define support surfaces or regions for storing objects, as do prior known modular units. These panels  14  are interconnected, stacked, and vertically spaced by a plurality of elongate risers  16 . Each pair of adjacent panels  14  is separated and interconnected by inserting each riser  16  into a corresponding socket  18  formed in the facing sides of the panels. The connection between the socket and riser forms a socket junction. Each socket  18  of each panel  14  of the modular unit  10  can be adapted to receive a riser  16  inserted from either or both the underside of the panel and the top side of the panel. Thus, this construction permits modular assembly and stacking of multiple panels as desired, and yet also permits manufacture and assembly of multiple identical panels and risers to comprise a modular unit. Alternatively, a given unit can be provided with two or more different panel structures if desired for a particular application. 
   As used herein, the term “panel” describes any of a plurality of possible structures suitable for supporting and storing objects thereby constituting one shelf, a plurality of which define a shelving system. Various alternatives or modifications for the panels can be substituted and yet fall within the scope and spirit of the present invention. 
   Generally, the risers  16  and panels  14  can be fabricated from relatively light weight, durable, and sturdy plastic or thermoplastic materials such as polyethylene, polypropylene, polystyrene, or other suitable plastic materials. The process or processes used to form the various components of the disclosed shelf unit  10  can also vary considerably as necessary to form each given component. For example, the risers  16  can be elongate hollow plastic tubes. The risers can be injection molded, blow molded, extruded, vacuum formed, rotation molded, or the like. The manufacturing process or processes can be selected based on feasibility, cost, tooling concerns, as well as other factors for a given application. 
   Either one or both end section  20  (top end as installed) and  22  (bottom end as installed) of the risers  16  can be designed and adapted with specific structural features and characteristics such as a taper  24  (shown only on bottom end sections  22  herein) that mate with corresponding features and characteristics of the sockets  11 . Similarly, either the top side, the bottom side, or both sides of the sockets  18  can be constructed as desired. Alternatively, one or both ends  20 ,  22  of each riser  16  can simply be a circular cylinder of the same or a reduced diameter relative to the diameter of the riser exterior surface. The sockets  18  can be further adapted or constructed in a corresponding manner to accept this simple cylindrical riser. 
   The panel construction can also vary considerably. For example, the panels  14  can be fabricated from plastic materials such as polypropylene, polyethylene, polystyrene, or other suitable plastic materials. The panels can have solid, non-perforated storage surfaces, structural ribs added for panel rigidity, open mesh or grid storage surfaces, or other such features, depending on the needs of a given application. One or more of the panels can have a generally planar top or storage surface, can include surface variations and features for storing particular objects, can be in the form of a shallow depth basket, or the like. The panels can also be molded or otherwise formed utilizing a suitable molding or other process. 
   The modular construction of the storage unit  10  disclosed herein renders the unit easy to assemble and break down. When broken down, the unit  10  can be easily and compactly packaged in a carton for shipping and transport. No tools are required to assemble or break down the unit. 
   Each example of a modular shelf or storage unit  10  shown or described herein can be assembled utilizing one or more of the so-called panels  14  and any number of the risers  16  as necessary to support each panel. Particular features and characteristics of the modular unit  10  are now described with reference to accompanying drawing figures. 
     FIGS. 1-5  illustrate one example of the multi-tiered shelving or storage unit  10  constructed in accordance with the teachings of the present invention. The plurality of object supporting panels  14  are provided in the form of generally planar shelves in this example. Each shelf  14  has an upper storage surface  26  for storing objects (not shown) thereon. Because the unit  10  is modular, one or more of the shelves  14  could be replaced, if desired, with an alternate panel or object supporting structure. However, the alternate structure or structures must cooperatively adapt to the configuration of the remaining components of the unit  10 . In this disclosed example, the shelves  14  are essentially identical and interchangeable with one another. 
   Each disclosed shelf  14  is generally crescent shaped in plan view and adapted for placement in a corner of a room. However, as will be evident to those having ordinary skill in the art, the shelves  14  in the example illustrated in  FIGS. 1-5  can have virtually any polygonal, rounded, or other shape, such as circular, triangular, rectangular, or the like. The shape of the shelves  14  or other such panels can vary considerably according to the needs of a particular application. 
   Each shelf  14  disclosed herein has a pair of back edges  30  arranged generally perpendicular to one another. Respective ends of the back edges  30  meet at and define a rear shelf corner  32  which can be positioned in a corner of a room. Alternatively, a corner apex may join the back edges such that there is a space between the rear shelf corner and the corner of the room. This corner apex may be circular or have one or more edges. An opposite end of each back edge  30  terminates and connects with a corresponding rear end of a respective side edge  34 . The side edges  34  in this example are oriented perpendicular relative to the back edges  30  and to one another, though their orientation can vary considerably. The back and side edges in this example are also linear, though the shape of the respective edges can vary without departing from the spirit and scope of the present invention. 
   Each forward end of the side edges  34  joins with a respective opposed end of a front face  36  of the shelf. Again, the front face  36  of each shelf  14  can be linear or can be some other shape, though the disclosed front face is a segmented, angled configuration. 
   A socket  18  is positioned at each shelf corner where adjacent edges or faces of the shelf meet. Each socket  18  is open at both a top side of the panel and a bottom side of the panel, thus defining a top receptacle and a bottom receptacle for receiving therein an end section  20  or  22  of a riser  16 . 
   Each shelf also has a “land locked” or interior socket  38  that is located generally centrally within the shelf in this example. The interior socket  38  can be essentially identical to the sockets  18 , and is preferably so in this example. The interior socket  38  also is adapted to receive an interior riser  40  from both a top side and a bottom side of each shelf. The interior riser  40  can be essentially identical to the other riser  16 , and is preferably so in this example. A turntable assembly  12  can be installed, if desired, on the interior riser  40 , as described below in greater detail. 
   The plurality of risers  16  for the disclosed unit  10  interconnect the plurality of shelves  14  in a spaced apart and stacked configuration as shown in the drawings. The plurality of shelves  14  are identified hereinafter as shelves  14   a ,  14   b ,  14   c , and  14   d , moving from the bottom to the top in FIG.  1 . The turntable assemblies, sockets, and risers associated with each shelf are similarly identified hereinafter for convenience of description. In the disclosed example, the bottom shelf  14   a  rests on a ground or floor surface. In this example, the bottom end sections  22   a  of the risers  16   a  are installed into the top side of each socket  18   a  and  38   a  of the shelf  14   a . If desired, a turntable assembly  12   a  can be installed on the interior riser  40   a.    
   The next upwardly adjacent shelf  14   b  is then installed on the previously installed risers  16   a  and  40   a . The upper ends  20   a  of the installed risers  16   a  and  40   a  are received in the bottom side of sockets  18   a  and  38   a . A next set of risers  16   b  and  40   b  can then be installed in the sockets  18   b  and  38   b  of the shelf  14   b . Again, a turntable assembly  12   b  can be installed on the interior riser  40   b , if desired. The next adjacent shelf  14   c  is similarly installed on the risers  16   b  and  40   b . Risers  16   c  and  40   c  are then installed in the sockets  18   c  and  38   c . A turntable  12   c  can optionally be installed as before. The last or upper most shelf  14   d  is installed on the risers  16   c  and  40   c . If another shelf were to be installed, another set of risers (not shown) would the be installed as before into the top side of the sockets  18   d  and  38   d . Here, the unit only utilizes four shelves and, therefore, a maximum of three sets of risers and turntable assemblies need be used. One or more additional shelves can be added or removed to increase or decrease the storage space and height of the unit. 
   Referring particularly to  FIGS. 2 and 3 , each turntable assembly  12  can include, in this example, a turntable  50  having a top storage surface  52 , a center opening  54 , and a bottom surface  56 . The center opening  54  of the turntable  50  is mounted or installed over a selected one of the interior risers  40 . The turntable  50  can be molded or otherwise formed from a suitable material such as polypropylene, polyethylene, polystyrene, or the like. 
   A raised bushing or bearing surface  58  of the turntable  50  surrounds the center opening  54  and extends downward from the bottom surface  56  of the turntable and radially outward from the center opening. A washer  60  is installed between the bearing surface  58  and the top surface  26  of the shelf  14 . The washer  60  can be made from any suitable material for reducing static and sliding friction, such as, for example, TEFLON. However, the material should at least be compatible with the shelf and turntable materials and be wear resistant. The washer material also preferably results in reduced sliding friction for the rotating turntable  50 . The raised bearing surface  58  is preferably of a height such that the bottom surface  56  of the turntable  50  is elevated slightly above the top surface  26  of the shelf  14 . 
   A plurality of roller-type or ball-type bearings  62  can be provided between the bottom surface  56  and the top surface  26  of the shelf  14 . The bearings  62  further support the turntable  14  and enhance the rotational capability of the turntable. Thus, the turntable can support unevenly distributed object loads on its storage surface  52  and can rotate easily even when heavily loaded with objects. The bearings  62  can again be made from any suitable material such as wear resistant thermoplastic, and in one example are TEFLON bearings. In this disclosed example, the shelves  14  and turntables  50  are preferably made from a highly durable material such as a heavy polyethylene or a polystyrene. The shelf and turntable materials can be selected to prevent premature wear caused by rolling and/or sliding movement between the bearings  62  and both the shelf and the turntable materials during use. 
   In this example, the bearings  62  are mounted in bearing depressions  64  formed in the top surface  26  of each shelf  14 . The depressions  64  can alternatively be provided in the bottom surface of the turntable. Alternatively, a recessed track (not shown) can be provided in either the shelf top surface or the turntable bottom surface. The bearings can then be retained in the track and roll freely therein. In any alternative, the bearings  62  are preferably arranged in a circumferential path concentric with the turntable so that they support the turntable at a consistent location as the turntable rotates. In one example, the bearings  62  are positioned about two thirds the radial distance outward from the axis of the turntable center opening  54 . The bearings  62  are preferably spaced apart circumferentially relative to the circumference of the track turntable  50 . In one example, the depressions  64  and bearings  62  can be spaced apart circumferentially at desired intervals, depending upon the size of the turntable  50 . The structure used to retain the bearings  62  can be virtually any construction suitable to retain the bearings at the desired spacing. 
   An installed turntable assembly  12  can be rotated about its respective interior riser  40  to access any part of the storage surface  52 . The bearings  62  and washer  60  assist in making rotation of the turntable relatively easy, even when loaded with stored objects. Preferably, the front surface  36  of each shelf  14  is design to permit a result in a slight overhang of a turntable  50  beyond a front surface edge of the shelf. In this manner, a consumer can easily grasp the exposed front part of the turntable to impart rotation to the turntable assembly  12 . 
   If a consumer prefers not to install a turntable assembly  12  on one or more of the shelves  14 , the appropriate interior riser  40  can be installed without installing the turntable  50 . If the bearings are mounted to the shelf  14 , they can be removed to provide a smooth object storage surface. If the bearings are mounted to the bottom surface of the turntable  50 , nothing else need be done. 
     FIGS. 6 and 7  illustrate another example of a multi-tiered shelving unit  100  constructed in accordance with the present invention. In this example, the unit  100  is essentially the same as the unit  10  described above and is shown utilizing the same reference characters for identifying the carious shelves  14 , riser  16 ,  40 , and sockets  18 ,  38 . However, the unit  100  does not have any turntable assemblies  12 . Instead, the unit  100  is simply a corner mounted shelving unit. 
   To achieve such a unit, a consumer can assemble the unit  10  and exclude all of turntables, thus resulting in a corner storage multi-tiered shelving unit nearly the same as the unit  100 . The user can also exclude the interior risers  40  if desired and if structurally feasible. Alternatively, a unit  100  can be designed and built for use without turntable assemblies  12 . Such a unit  100  could then eliminate the interior risers  40 , the interior sockets  38 , and the panel features such as the depressions  64 , bearings  62 , and washer  60 . However, the riser  40  and sockets  38  can be provided as additional support for the panels  14  even though turntables are to be utilized. 
     FIGS. 8 ,  9 , and  10  illustrate another example of a panel  200  a for multi-tiered shelving unit constructed in accordance with the present invention. In this example, the panel  200  has a different shape than that illustrated in the prior examples. The disclosed panel  200  has a five sided or heptagonal shaped perimeter. The panel  200  has five side edges including a pair of back edges  202  that meet and define a back corner  204 . The panel  200  also has a three segment forward edge including a front edge  206  and a pair of intermediate edges  208 . The panel  200  also has an upper surface  210 , an underside  212 , and a plurality of sockets  214  which include a rear socket  216  near the back corner  204 . As will be evident to those having ordinary skill in the art, and as mentioned above, the shape of the corner shelving unit panels can vary and yet fall within the scope and spirit of the present disclosure. 
   The panel  200  can include a means for reducing stress at the rear socket  216 , although any one or all of the sockets  214  and  216  can alternatively or also include this feature as desired. In this example, the rear socket  216  includes an opening  220  through the panel extending between the upper surface  210  and the underside  212 . The opening  220  is defined by a cylindrical continuous wall  222  formed as part of the panel. In this example, the opening  220  is generally vertically oriented relative to a horizontal panel orientation, and the wall  222  is also generally vertically oriented. However, the wall  222  and opening  220  can vary from the generally vertical orientations shown. For example, the wall  222  can be inclined or declined relative to a vertical opening axis “A”, or an upper part of the wall  222  can be inclined and a lower part of the wall can be declined relative to the opening axis. Also, the wall  222  in this example forms a circular cylindrical opening  220 , though other cylindrical shapes can also be utilized. 
   The socket  216  in this example also has a cylindrical tube  224  positioned within the opening  220  and spaced from the wall  222 , thus forming a space “S” therebetween. The tube is correspondingly shaped relative to the opening, and thus, in this example is a circular cylinder. A generally horizontally arranged support  226  extends around the opening  220  between the wall  222  and the tube  224 . The support  226  supports the tube suspended in the opening. The support in this example is integrally molded or formed as part of the panel and wall material. In this example, the support  226  is positioned about midway between the upper side  210  and the underside  212  of the panel  200 , but slightly nearer the underside. The support  226  can be positioned exactly midway along the tube if desired. The support  226  suspends the tube  224  within the opening  220  and yet will permit the tube to move based on flexure of the support and loads applied via a riser or risers inserted into the tube. 
   The tube  224  defines a top receptacle  228  and a bottom receptacle  230  of the socket  216 . In this example, the top receptacle  228  is slightly larger in diameter and is slightly longer or deeper that the bottom receptacle  230 . A divider ridge  232  is provided within the tube  224  to provide a positive stop surface for a riser inserted into either receptacle. In this example, the receptacles  228  and  230  are sized differently to accommodate a riser having two different ends, as mentioned above. However, the receptacles  228  and  230  can be substantially identical in all respects in order to accept either end of a symmetrical riser, if desired. 
   The socket  216  also has a plurality of rib buttresses  234  that are oriented generally vertically in this example. Again, the rib buttresses  234  can be oriented at an angle relative to vertical, if desired. In this example, each rib buttress has an upper section  234   a  positioned above the support  226  and a lower section  234   b  positioned below the support  226 . Each buttress  234  also has an inner portion  236  connected to the tube  224  and an outer portion  238  connected to the wall  222 . The buttresses, depending upon height, material selection, and thickness, assist in suspending and supporting the tube  224  within the opening  220 . The buttresses  234 , if formed having a height as tall as a wall height of the wall  222 , result in a substantially rigid socket structure. It has been learned that a rigid connection at the rear socket and riser will cause either the panel, socket, and/or the riser to break under stress. 
   Thus, as shown in  FIGS. 8 and 10 , each buttress rib  234  has a scalloped portion. In this example, a scalloped portion with a cut out  240   a  is provided on the upper section  234   a  and a scalloped portion with a cut out  240   b  is provided on the lower section  234   b . It is possible to provide a cut out only the top edges or the bottom edges, or to provide a top cutout and a bottom cut out on only some of the ribs  234  or on alternating ribs, as needed for a particular application. The scalloped buttress ribs  234  provide structural stability to the sockets  216 , and yet permit some flexibility between the tube  224  and the opening  220 . The flexibility permits some relative movement between the socket tube  224  and the panel  200 , which relieves significant stress at the socket and riser joint. The cut outs  240  in this example are smooth curves similar to an arc of a circle. However, the cut out shapes and sizes can vary considerably without departing from the spirit and scope of the disclosure, and can vary from rib to rib. 
   The buttress ribs  234  and support  226  may be molded or otherwise formed from a suitable material such as polypropylene, polyethylene, polystyrene, or the like. Alternatively, the support and the ribs may be formed from any other suitable material that permits slight bending or deflection while maintaining the overall strength and stability of the shelving unit. The socket  216  including the support  226 , opening  220 , tube  224 , and ribs  234  can thus be formed from the same material as the panel  200 , and can be formed integrally therewith. Alternatively, the socket  216  can be formed as a separate component from a suitable material, and then can be inserted into the panel or insert molded as part of the panel. 
   As a load is applied to the panel, stress is transmitted to the socket and dissipated into the support, ribs, and tube as it moves relative to the panel. Thus, stress is relieved from the panel itself and is dissipated prior to being transmitted into the riser. Additional relief openings  244  can be provided in the support  226  between the buttress ribs  234 , the tube  224  and the wall  220 . The relief openings can further assist in adding flexibility to the socket structure. 
     FIG. 11  illustrates an alternative stress reducing means for the sockets  214  and  216 , and particularly for the rear socket  216  as in this example. A semi-spherical shaped depression  250  is formed or provided in the underside  252  of a panel  254 . A similarly or identically shaped depression  256  is formed or provided in an upper side  258  of the panel  254 . Each rear riser  260  in this example has a ball  262  or dome shaped surface on both the upper end  264  and the lower end  266 . The ball of the appropriate end  264  or  266  of a riser is simply placed in each appropriate socket or depression  250  or  256 . If the many or all of the remaining risers and sockets of the system, other than the rear sockets and risers, provide a substantially fixed connection, this ball and socket type joint will relieve a substantial amount of stress from the panel, socket and riser. The ends of the riser can move freely relative to the depression, and thus the panel. 
   The depressions or sockets  250  and  256  can be formed integral with the panel surfaces, or can be formed separately and added to the panel using any suitable process. Additionally, the domed surfaces or balls  262  can also be formed integrally with the risers  260 , or can be formed separately and added thereto in any suitable manner. 
   Although certain modular shelving units have been disclosed and described herein in accordance with the teachings of the present invention, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the invention fairly falling within the scope of the invention, either literally or under the doctrine of equivalents.