Patent Description:
Retail shelving is a staple in the retail merchandise environment. While such shelving comes in many forms, it generally includes a vertical support structure which supports one or more shelves extending outwardly from the vertical structure. The vertical structure is typically a wall-like structure and contains integrated mounting rails, referred to in in the industry as gondola uprights, to which the shelves.

The shelves of such shelving systems present several drawbacks. These shelves are typically steel structures which can corrode over time and which are heavy making them difficult to remove for cleaning. One alternative has been to utilize aluminum shelving instead, but this material results in a more costly system. Also, such steel or aluminum shelves do not meet the requirements for NSF Certification by NSF International, which is a highly desired certification in certain retail display applications in which the shelving surface comes into direct contact with the product being merchandised.

<CIT> discloses an assembling shelf capable of displaying articles of different heights.

Examples of the present application provide improvements over the current state of the art as it relates to retail shelving systems.

In one example, a deck panel for a retail shelving system is provided. The deck panel is used to support merchandise. The deck panel includes a panel and a region of strengthening ribbing. The panel has a top surface configured for supporting retail merchandise and a bottom surface. The region of strengthening ribbing includes a plurality of ribs extending outward from the bottom surface of the panel. The bottom surface of the panel has a border region that extends around the region of strengthening ribbing on at least three sides.

In a particular example, the border region is substantially flat (e.g. projections that are greater than <NUM>% of the thickness of the panel are not present extending from the border region.

In an example, the panel has a front edge, a rear edge and a pair of side edges extending between the front edge and the rear edge. The border region extends along the pair of side edges and the rear edge.

In an example, the border region has a thickness measured perpendicular to the bottom surface. The plurality of ribs extending outward from the bottom surface have an average height that is measured perpendicular to the bottom surface. The average height is at least five times the thickness.

In an example, the border region is free of projections.

In an example, the border region includes apertures extending entirely through a thickness of the border region (e.g. through the top and bottom surfaces).

In an example, the front edge is provided by a vertical wall that extends outward beyond the top surface and outward beyond the bottom surface.

In an example, a plurality of the plurality of ribs are all interconnected with one another and interconnected with the vertical wall.

In an example, a first portion of the border region extends between the vertical wall and the rear edge along one of the pair of side edges. A second portion of the border region extends between the pair of side edges along the rear edge. A third portion of the border region extends between the vertical wall and the rear edge along the other one of the pair of side edges.

In an example, the panel has a generally rectangular periphery. The region of strengthening ribbing may optionally have a rectangular periphery as well.

In an example, the region of strengthening ribbing has an outer periphery that includes pair of opposed sides and a rear side. These sides may be provided by outer most ribs extending outward from the bottom surface (e.g. generally perpendicular - plus/minus <NUM> degrees). The opposed sides are generally parallel. The rear side is generally perpendicular to the sides of the pair of opposed sides. The pair of opposed sides is parallel to and spaced inward from the pair side edges and the rear side is parallel to and spaced inward from the rear edge.

In an example, the border region is free of projections or apertures in the portion thereof extending along the rear edge.

In an example, the panel includes a plurality of apertures extending through the top and bottom surfaces. The ribs do not extend across any of the apertures such that the ribs do not have a portion of an aperture on one side of the rib and apportion of the same aperture on the other side of the rib. The ribs may be immediately adjacent apertures.

In another example, a shelf is provided. The shelf includes first and second support arms, front and rear support bars and a deck panel as outlined above. The first and second support arms are arranged in opposed lateral spaced relation to one another. The front and rear support bars extend laterally between the first and second support arms. The deck panel is supported by the front and rear support bars. The border region extends over the first and second support arms. The region of strengthening ribbing is positioned laterally between the first and second support arms.

According to the invention, a shelf is provided. The shelf includes first and second support arms, front and rear support bars and a deck panel. The first and second support arms are arranged in opposed lateral spaced relation to one another. The front and rear support bars extend laterally between the first and second support arms. The deck panel is supported by the front and rear support bars. The deck panel includes a panel having a top surface configured for supporting retail merchandise and a bottom surface. The deck panel includes a region of strengthening ribbing including a plurality of ribs extending outward from the bottom surface of the panel. The bottom surface has a border region that extends around the region of strengthening ribbing on at least three sides. The border region extends over the first and second support arms. The region of strengthening ribbing being positioned laterally between the first and second support arms.

In an example, the portion of the border region that extends over the first support arm is unitarily formed as a single piece with the portion of the border region that extends over the second support arm.

According to the invention, the border region extends laterally outward beyond the first and second support arms.

In an example, the region of strengthening ribbing includes a front channel and a rear channel. The front support bar is received in the front channel and the rear support bar is received in the rear channel.

In an example, for each of the front and rear channels, a bottom thereof is defined by short rib regions. The top of the front and rear support bars abut the short rib regions. In an example, each of the first and second support arms has a top surface. The border region is vertically spaced from the top surface of the first and second support arms. A gap may be formed therebetween.

In an example, the shelf includes a single deck panel extending laterally beyond both of the first and second support arms and being supported by the front and rear support bars.

In an example, the deck panel includes resilient finger tabs that snap engage the deck panel to at least one of the front and rear support bars.

In another example, a shelving system including a deck panel or shelf as outlined above is provided. The shelving system includes a pair of upright supports. Each upright support has an upper end and a lower end. Each upright support has a plurality of apertures mounting the first and second support arms thereto.

With specific reference now to <FIG>, the same illustrates an exemplary embodiment of a shelving system <NUM> according to the teachings herein. Shelving system <NUM> includes a grid assembly with one or more shelves <NUM> mounted thereto. While one shelf <NUM> is shown, it is contemplated that any number of shelves may be mounted to this grid assembly. Further, while shelf <NUM> illustrated the full length of the grid assembly, shorter shelf lengths are entirely possible.

The grid assembly includes an upper rail <NUM> and a separate lower rail <NUM>. Upper and lower rails <NUM>, <NUM> are configured to mount to a support structure such as a vertical wall, the interior of a refrigerated or freezer case, etc. Indeed, upper and lower rails <NUM>, <NUM> may be adapted to mount to any structure capable of supporting the same. As such, upper and lower rails <NUM>, <NUM> may incorporate any mounting expedient, including screws, bolts, pins, hooks, ledges, etc..

In the illustrated embodiment, the upper and lower rails <NUM>, <NUM> are separate components. As a result, they may be separately installed to the aforementioned support structure. This makes installation simpler than in prior designs which require lifting a large welded grid structure as a single unit and installing it in place on a support structure.

A plurality of upright supports 106a, 106b, 106c are slidably received in upper and lower rails <NUM>, <NUM>. Upright supports 106a-c are used for mounting shelf <NUM> thereto. It should be noted that three upright supports 106a-c are illustrated for purposes of description. However, only the outer most upright supports 106a, 106c are needed for mounting the illustrated shelf <NUM>. Multiple additional shelves <NUM> may mount to the same two upright supports 106a, 106c below shelf <NUM> as illustrated. Further, shelves <NUM> having a shorter length may be mounted between upright supports 106a and 106b, or between upright supports 106b and 106c. Unless otherwise specifically noted herein, any description of the structure, function, or use of one upright support 106a-c applies equally to the others. Additionally, when multipole shelves are mounted to the upright supports 106a-c, the shelves may be identical or different such as, for example only, different lengths, different angles, different depths, etc..

Having separate upright supports 106a-c provides the ability to add or remove a desired number of upright supports as discussed below to allow for a specific shelving configuration. Welded designs, such as ones having a fixed number of upright supports are also permissible in some implementations. The number of upright supports will be entirely dependent upon the shelving configuration desired. Therefore, the three upright supports 106a-c should be taken as only one of many possible examples. While two rails <NUM>, <NUM> are shown and described, it is contemplated that only a single upper rail <NUM> could be utilized for receiving and supporting upright supports 106a-c.

While the modular system is illustrated, embodiments according to the present invention can use, cooperate with or be mounted to welded designs where the grid is a single welded assembly. Further in some embodiments, the upper and lower rails may not be required at all and only upright supports 106a-c may be used.

Turning now to <FIG>, once upper and lower rails <NUM>, <NUM> are installed, each upright support 106a-c is installed by generally situating the upright supports 106a-c into upper and lower rails <NUM>, <NUM> by moving them generally in direction <NUM>, and then sliding them in direction <NUM> to their final destinations. Upper and lower rails <NUM>, <NUM> are designed such that they each include a channel within which the end portions of the upright supports 106a-c are situated and slidable in.

Indeed, referring specifically to upright support 106a shown in <FIG>, the same includes an upper end <NUM> and a lower end <NUM>. A plurality of apertures <NUM> are formed therein for shelf mounting. These apertures <NUM> may take on any shape. An identical description to that of upright support 106a applies to 106c. Upright support 106c differs only in that it include two parallel rows of apertures <NUM> as illustrated. In many situations, and as illustrated, apertures <NUM> may be vertically elongated.

Turning now to <FIG>, the same illustrate shelf <NUM> in greater detail. With particular reference to <FIG>, shelf <NUM> includes a deck panel <NUM>. In one embodiment, the shelves <NUM> have a width that is four feet measured from side edge <NUM> to side edge <NUM>. However, other widths are contemplated. Although illustrated as mounting the grid assembly discussed above relative to <FIG>, it is contemplated that shelf <NUM> may be configured to mount to any existing structure by minor modification of the structure it utilizes for mounting. More generally, it is contemplated by the teachings herein, that the invention may be embodied as a combined system as reflected in <FIG> for example, or as a standalone shelf <NUM> that may be retrofit into an existing system.

Deck panel <NUM> generally includes a panel <NUM> that is generally planar. The panel <NUM> includes an upper surface <NUM> which is used to support merchandise. Deck panel <NUM> may include perforations that extend through panel <NUM> as shown, or any other features typical of retail shelving, e.g. features for mounting a front fence (not shown), features for mounting dividers (not shown), a price channel or price channel support <NUM>, channels or other features for receiving and retaining lighting elements, etc. Deck panel <NUM> may be formed of a plastic material, for example, an acrylonitrile butadiene styrene (ABS) plastic. Such a material selection allows for the use of NSF certified materials for contacting retail items such as produce or the like.

Further, because deck panel <NUM> is separable and removable from the remainder of shelf <NUM>, it may be easily cleaned in a dishwasher, sink, etc. Yet further, although not illustrated, pusher systems and other front facing devices may be readily mounted to deck panel <NUM>.

Still referring to <FIG>, in addition to deck panel <NUM>, shelf <NUM> includes a frame that supports the deck panel. The frame generally includes first and second support arms <NUM> that are laterally spaced apart arranged at opposed sides of shelf <NUM>. Support arms <NUM> are mirror images of one another, so a description of one applies equally well to the other. The frame of shelf <NUM> also generally includes front and rear support bars <NUM> which are also identical to one another. The front and rear support bars <NUM> are secured between and extend laterally between support arms <NUM>.

Turning now to <FIG>, shelf <NUM> is rapidly installable to the above described grid assembly by the following general process. First, each support arm <NUM> is mounted to a respective upright support 106a-c. In the illustrated embodiment, the left-most support arm <NUM> is mounted to upright support 106a, and the right-most support arm <NUM> is mounted to upright support 106c. Thereafter, each support bar is <NUM> is installed by moving the same generally in direction <NUM> until a support post <NUM> of each support arm <NUM> is situated within a channel of each support bar <NUM>. Once support bars <NUM> are in place, deck panel <NUM> is then affixed to support bars <NUM>.

Alternatively, where support bars <NUM> are closed profile tubular elements, it is also contemplated that each support bar <NUM> is installed by horizontally sliding it onto the mounting post <NUM> of each support arm <NUM>. Such an operation may be done prior to installing support arms <NUM> onto their associated upright support. Further, although a front and rear support bar <NUM> are shown, it is contemplated that for deeper shelves, additional support bars <NUM> intermediate of front and rear support bars <NUM> could be utilized as well. Likewise, it is also contemplated that shallower shelf depths may only require a single support bar <NUM>. As such, it is contemplated that at least one support bar <NUM> may be utilized for supporting the deck panel <NUM> of shelf <NUM>.

Still further, although shelf <NUM> is described as mounting to two separate upright supports 106a, 106c, it is contemplated that shelf <NUM> may mount to a single upright support. Such a single upright support may be wider than those shown to accommodate mounting multiple support arms <NUM>. For example, shelf <NUM> may mount to upright support 106b alone. Upright support 106b includes a double row of apertures <NUM> and can thus accommodate two support arms. The overall width of such a single upright support 106b may be varied to accommodate varying width shelves. As such, it is contemplated that at least one upright support is all that is required at a minimum for shelf mounting.

<FIG> is similar to <FIG>, but with the deck panel <NUM> flipped over to illustrate the bottom side of the deck panel <NUM> and the bottom surface <NUM> of the panel <NUM>. <FIG> shows the shelf <NUM> from a bottom side with the deck panel <NUM> attached to support arms <NUM> and support bars <NUM>.

Deck panel <NUM> includes a region of strengthening ribbing <NUM> extending outward from bottom surface <NUM>. A front and a rear channel <NUM> extends through/ are formed by the region of strengthening ribbing <NUM>. The channels <NUM> formed by the region of strengthening ribbing <NUM> receive support bars <NUM> therein (see e.g. <FIG>, <FIG>). The bottom of the channels <NUM> are formed by shorter ribs <NUM> of the plurality of ribs forming the region of strengthening ribbing <NUM> (see also <FIG>).

These channels <NUM> and shorter ribs <NUM> are further illustrated in <FIG>. The short ribs <NUM> have a height extending from bottom surface <NUM> of panel <NUM> that is less than the height of the surrounding ribbing, which forms a majority of the ribs forming the region of strengthening ribbing <NUM>. The height H1 of the short ribs <NUM> (e.g. distance extending perpendicularly from bottom surface <NUM>) may be less than half of the height H2 of the other ribs <NUM> (e.g. distance extending perpendicularly from bottom surface <NUM>), and preferably less than twenty five percent of the height of the other ribs <NUM>.

In an example, the height H1 is about equal to the thickness T of the panel <NUM>. In a preferred embodiment, the height H2 is at least five (<NUM>) times the thickness T of the panel <NUM>.

Each channel <NUM> includes finger tabs <NUM> which may snap engaged with the associated support bar <NUM> to secure deck panel <NUM> to support bars <NUM>. Although a front and rear channel <NUM>, <NUM> are shown, the number of channels utilized may be varied to accommodate fewer or greater support bars <NUM>.

<FIG> is a bottom view of the shelf <NUM> and <FIG> is a bottom view of the deck panel <NUM> removed from the support frame components (e.g. support arms <NUM> and support bars <NUM>).

The bottom surface <NUM> of the panel <NUM> forms a border region <NUM> that extends around at least three sides of the region of strengthening ribbing <NUM>.

In an embodiment, the border region <NUM> is substantially flat, e.g. does not include any projections or includes projections/surface ornamentation that does not have a height extending from bottom surface <NUM> that is more than twenty (<NUM>) percent and even more preferably no more than fifteen (<NUM>) percent the thickness of the panel <NUM> between the top surface <NUM> and bottom surface <NUM>. In one example, the thickness of the panel is approximately two (<NUM>) millimeters while any surface ornamentation is <NUM> millimeters. This shall still be considered flat.

In this example, the panel <NUM> is generally rectangular and has front and rear edges <NUM>, <NUM> and opposed laterally spaced apart side edges <NUM>, <NUM>. The region of strengthening ribbing <NUM> has a generally rectangular periphery and has opposed sides <NUM>, <NUM> that are laterally spaced apart and front side <NUM> and rear side <NUM>. The front side <NUM> generally corresponds to front edge <NUM>. The rear side <NUM> is generally parallel to and spaced inward from rear edge <NUM>. Opposed sides <NUM>, <NUM> are generally parallel to and spaced inward from side edges <NUM>, <NUM>.

In the illustrated example, a rear portion <NUM> of the border region <NUM> extend along and between the rear edge <NUM> of panel <NUM> and rear side <NUM> of the region of strengthening ribbing <NUM> is free of any projections at all and is free of any apertures therethrough.

However, side portions <NUM>, <NUM> of the border region <NUM> that extend along and between the side edges <NUM>, <NUM> of panel <NUM> and sides <NUM>, <NUM> of the region of strengthening ribbing <NUM> includes apertures spaced outward from the sides <NUM>, <NUM>.

According to the invention, the side portions <NUM>, <NUM> extend laterally outward beyond the corresponding support arms <NUM>. This illustrated in <FIG>, where the side edge <NUM> is spaced a distance D1 from the laterally outer most portion of support arm <NUM>. Further, in an example, the bottom surface <NUM> and particularly the border region <NUM> thereof is vertically spaced from the top surface <NUM> of the support arms <NUM>, forming a gap <NUM> therebetween.

In the illustrated example, the front edge <NUM> is provided by a vertical wall <NUM>. This vertical wall may be used to attach labels or label holders. The vertical wall <NUM> extends upward beyond the top surface <NUM> and downward beyond the bottom surface <NUM>. The ribs <NUM> of the region of strengthening ribbing <NUM> connect with the bottom portion of vertical wall <NUM>.

The upper portion of vertical wall <NUM>, e.g. the portion that extends upward of the top surface <NUM> may be used as a front stop to prevent merchandise from sliding off of the deck panel <NUM>.

Claim 1:
A shelf (<NUM>) comprising:
a first and a second support arm (<NUM>) arranged in opposed lateral spaced relation to one another;
a front support bar (<NUM>) extending laterally between the first and second support arms (<NUM>);
a rear support bar (<NUM>) extending laterally between the first and second support arms (<NUM>); and
a deck panel (<NUM>) supported by the front and rear support bars (<NUM>), the deck panel (<NUM>) comprising:
a panel (<NUM>) having a top surface (<NUM>) configured for supporting retail merchandise and a bottom surface (<NUM>);
a region of strengthening ribbing (<NUM>) including a plurality of ribs (<NUM>, <NUM>) extending outward from the bottom surface (<NUM>) of the panel (<NUM>);
the bottom surface (<NUM>) having a border region (<NUM>) that extends around the region of strengthening ribbing (<NUM>) on at least three sides, the border region (<NUM>) extending over the first and second support arms (<NUM>), the region of strengthening ribbing (<NUM>) being positioned laterally between the first and second support arms (<NUM>),
characterized in that the border region (<NUM>) extends laterally outward beyond the first and second support arms (<NUM>).