Patent ID: 12256837

DETAILED DESCRIPTION OF THE INVENTION

Reference to terms such as “left”, “right”, “top”, “bottom”, “front” and “back” are intended for use in respect to the orientation of the particular feature, structure, or element within the figures depicting embodiments of the invention. It would be evident that such directional terminology with respect to the actual use of a device has no specific meaning as the device can be employed in a multiplicity of orientations by the user or users.

The description of elements in each figure may refer to elements of proceeding figures. Like numbers refer to like elements in all figures, including alternate embodiments of like elements.

FIG.1shows a portion of a rack assembly2, that beneficially is collapsible into a compact package for shipping purposes. Rack assembly2is useful for storing items in a home, office, garage, warehouse, or other facility. In certain examples, a wire decking rack assembly such as is depicted is frequently referred to as “a baker's rack.” As shown, rack assembly2includes a plurality of vertical supports4,5,6,7(shown in phantom line drawing), a plurality of press fit members (two members10,11are indicated), and a plurality of elongated shelves or racks20,40,60,80(seeFIGS.6and7for shelf80). Vertical supports4,5,6,7, in certain examples, are elongated tubular members (or rods, columns, etc.) that may be formed with a plurality of annular notches spaced evenly along a length of each vertical support104. Press fit members, e.g., wedge shaped plastic sleeves10,11, are configured to engage one of the annular notches and position and secure the elongated shelves20,40,60,80to vertical supports4,5,6,7. Additionally, in one example embodiment, vertical supports4,5,6,7and elongated shelves20,40,60,80are metallic.

Vertical supports4,5,6,7may each comprise a plurality of vertical members, or may be one unitary member made from a single piece of material (e.g., metal). They are structured to extend between and support elongated shelves20,40,60,80when rack assembly2is in an ASSEMBLED position. Moreover, for purposes that will be apparent below, each of elongated shelves20,40,60,80are preferably structured the same.

Referring toFIGS.2-5, elongated shelf20includes a corner region22, a sleeve member23, and a rail24extending from sleeve member23(or similar mount) of corner region22. Additionally, it will be appreciated that press fit members10,11are configured to be coupled to one another, be disposed within sleeve member23, and receive vertical support6in order to secure vertical support6within sleeve member23in a press fit manner.

As shown inFIG.4, corner region22further has a notch apparatus in the form of a bent rail26. Bent rail26is advantageously structured to receive a rail of one of elongated shelves40,60,80, such as by forming or creating a notch or inset (such as where a rail or other portion of another shelf is located in the inset or notch created by the bent rail26, extending generally transverse or perpendicular thereto) in order to allow elongated shelf20to nest within the other elongated shelf40,60,80when the collapsible rack assembly2is in a COLLAPSED position. This aspect of rack assembly2advantageously allows for improved space savings, as compared to known rack assemblies. In this manner, manufacturers will be able to ship more rack assemblies in transit and store owners will be able to stack more collapsed rack assemblies on shelves, to name a few of the advantages. This improvement in the flow of commerce translates into a cost savings for the parties involved.

Referring toFIG.5, bent rail26preferably includes a first segment30, a second segment31parallel to the first segment30, and a third segment32connecting the first and second segments30,31. As shown, the third segment32extends at an angle33greater than ninety degrees from the first segment30. This construction allows for the aforementioned nesting capability, as will be appreciated below.

Additionally, as shown inFIG.4, elongated shelf20further has another corner region27located opposite corner region22and having a notch apparatus in the form of a bent rail28which is symmetric to the bent rail26of corner region22. It will be appreciated that the other end of elongated shelf20has symmetric bent rails as well, which simplifies orienting rack assembly2in the COLLAPSED position.

As shown inFIGS.6-10, elongated shelves40,60may be sandwiched between elongated shelves20,80when rack assembly2is in a COLLAPSED state. This is shown most clearly inFIG.9, although since all elongated shelves20,40,60,80are preferably structured the same, it will be appreciated that the numbering of shelves are interchangeable. As shown inFIG.9, rail44of elongated shelf40is nested within notch apparatus (e.g., bent rail26) of elongated shelf20. This translates into a significant space savings. More specifically, and referring toFIG.10, elongated shelves40,60are structured to nest within elongated shelves20,80in the COLLAPSED position such that a combined height H1of elongated shelves20,40,60,80, when nested, is less than a combined height 4*H2of elongated shelves20,40,60,80, individually, where H2is the height of each of elongated shelves20,40,60,80individually.

FIG.11Ashows another collapsible rack assembly102, in accordance with another non-limiting embodiment of the disclosed concept, wherein like numbers represent like features.FIG.11Bshows a front view of elongated shelf120. It will be appreciated with reference toFIG.11Bthat corner region122has a cutout and the notch apparatus is in the form of an insert126coupled to the rack, such as the wire frame that forms a cutout. Insert126may be made of a different material than the rest of elongated shelf120. As shown, insert126has a groove (or inset or notch)130for receiving a rail of elongated shelf140in a similar manner in which bent rail26(FIG.9) of elongated shelf20(FIG.9) received rail44(FIG.9) of elongated shelf40(FIG.9). Accordingly, stacking advantages discussed above with reference to rack assembly2also apply to rack assembly102.

FIG.12shows another rack assembly202in accordance with another embodiment of the disclosed concept, wherein like reference numbers represent like features.FIG.13shows an exploded view of a portion of the rack assembly202ofFIG.12. As shown, elongated shelf220has an end222with opposing corner regions224,226that each have a corresponding opening225,227. Additionally, rack assembly further has a pair of end caps235,245coupled to elongated shelf220(see also end caps255,256,265,266,275,276,285,286inFIG.12for elongated shelves250,260,270,280). In one example embodiment, elongated shelves220,250,260,270,280, vertical supports204,205,206,207, and end caps235,245,255,256,265,266,275,276,285,286are all metallic.

Each of elongated shelves220,250,260,270,280is configured to couple with end caps235,245,255,256,265,266,275,276,285,286in order to reduce an overall footprint. In particular, the removable end caps allow for the vertical supports to be stacked on the elongated shelves when packaged, and reduce the overall height of the packaging, and allowing for more packaged rack assemblies202to be shipped in a shipping container.

As shown inFIG.12, end cap235has first and second thru holes236,237that are each aligned with a corresponding opening225,227of elongated shelf220and configured to receive vertical supports206,207. It will be appreciated that end cap245likewise receives vertical supports204,205in a similar manner. Also shown inFIG.12, end cap235has a thru hole238(and another thru hole disposed proximate thru hole236) located proximate thru hole237. Rack assembly202further has a pair of fasteners (e.g., without limitation, one set screw244is indicated) configured to extend through a corresponding one of the thru holes238(and the other opposing thru hole, not shown) of end cap235and be located proximate the vertical supports206,207in order to more securely maintain rack assembly202in an ASSEMBLED position.

Referring toFIGS.14and15, rack assembly202further includes a number of inserts240,246each coupled to the vertical supports206,207. In one example embodiment, the inserts240,246are each coupled to an interior of the vertical supports206,207. Insert240may be a cap that is located at a top of the rack assembly202when rack assembly202is in an ASSEMBLED position and disposed on a horizontal ground. See, for example,FIG.12. Three other inserts are also shown in this FIG., but only insert240is indicated. Insert240, and the other three inserts, may function to provide surfaces for a table to advantageously be formed on rack assembly202. Additionally, as shown inFIG.14, insert240has a number of ridges241-1,241-2,241-3that may be configured to be located in corresponding grooves of vertical support206in order to maintain insert240in a fixed position within vertical support206. As insert240functions to provide a top of rack assembly202, insert246shown inFIG.15functions to provide a foot for rack assembly202, so that it can more stably be positioned in an upright manner when in an ASSEMBLED position and located on a horizontal ground. As shown inFIG.12A, three other feet (not labeled) are also provided with rack assembly202. Continuing to refer toFIG.15, an externally threaded sleeve247may be provided in order to more securely couple insert246to vertical support207.

An insert342,442may also be threadably coupled to an interior of a vertical support306,406-1,406-2, as shown inFIGS.16and17. In the case of the embodiment ofFIG.16, insert342, which functions as a top, is relatively securely coupled by virtue of the threads. Regarding the embodiment of the rack assembly ofFIG.17, insert442advantageously allows for segment406-1of the vertical support to be more stably connected to segment406-2, where before they might only have been maintained at such a joint via a press fit connection.

FIGS.18and19show assembled and exploded views, respectively, of rack assemblies502and an elongated shelf520configured to be coupled in order for more versatile applications to be provided, such as further storage capabilities.FIGS.20and21show assembled and exploded views, respectively, of rack assemblies502and an elongated shelf520configured to be coupled in order for more versatile applications to be provided, such as further storage capabilities. In some configurations, connectors, such as fasteners, may be used to join the shelves520and/or racks502. For example, one or more apertures may be provided in the end caps245(seeFIG.13), whereby aligned end caps (such as placed side by side or end to end) may be joined, such as with one or more fasteners (such as a nut/bolt, etc.)

FIG.22shows an isometric view of another elongated shelf620. As shown, the elongated shelf620includes a first half portion621, a second half portion623, and an elongated sleeve625for connecting the first and second half portions621,623. Accordingly, it will be appreciated that yet an even greater space savings can be afforded for rack assemblies including elongated shelves structured the same as elongated shelf620, in that different portions621,623can be overlaid on top of one another in order to further reduce the footprint of a corresponding rack assembly.

FIG.23Ashows a portion of another rack assembly702, wherein like reference numbers represent like features. As shown, end cap735has an aperture738disposed proximate thru hole737, and a further aperture disposed on an opposing side (not shown). Referring toFIGS.23B and23C, elongated shelf720has a number of plates740,741,742coupled to corner region726. Plate742has a push pin743extending outwardly therefrom and being biased away from elongated shelf720. Push pin743is configured to extend through thru holes of plates740,741, which are securely maintained on corner region726by engaging and being disposed between opposing wires of corner region726. Furthermore, it will be appreciated that push pin743is configured to extend through aperture738of end cap735in order to securely maintain and connect end cap735with elongated shelf720. Opposing corner region724(FIG.23A) and end cap745(FIG.23A) are similarly structured and coupled in this pin to aperture manner, and so are other end caps and elongated shelves of rack assembly702(not shown). Accordingly, if end cap735is caused to slide with respect to elongated shelf720, the engagement between push pin743and plates740,741advantageously prevents decoupling.

FIG.24shows yet a further embodiment of the disclosed concept, wherein a portion of a rack assembly802is shown. As shown, rack assembly802has an elongated shelf820which is devoid of notches proximate end portions that couple to end caps—such as by not including an end rail at all, but wherein the end cap forms the end portion of the rack.

In one configuration, as illustrated inFIG.25, the elongated shelf920may define having cutout portions proximate corner regions922,924,926,928, which regions accept the end caps, including the associated sleeves. The resulting reduced thickness, as discussed above, advantageously allows elongated shelf920to be shipped with a reduced footprint, and may allow end caps to either be fixedly attached thereto, or otherwise be connected thereto during shipping and shelving.

One aspect of this version of the invention is that elongated shelf820and other elongated shelves of rack assembly802can be stacked with a minimal footprint. Additionally, because of the reduced thickness proximate end portions of elongated shelf820, end caps may be able to be fixedly attached to end portions, or otherwise connected while elongated shelf820is being shipped, thereby saving assembly time downstream. For example, in one packing configuration, the end caps are removed from a first rack, allowing it to be placed between second and third racks having the end caps attached thereto (wherein the reduced thickness of the first rack allows it to be placed between the second and third racks without an increase in stack dimension due to the space between the second and third racks created because of the increased dimension of the end cap/sleeves of the second and third racks).

In particular,FIG.26shows an exploded view of another rack assembly1002, which includes vertical supports1004-1,1005-1,1006-1,1007-1,1004-2,1005-2,1006-2,1007-2, elongated shelves1020,1040,1060,1080,1090, and end caps1025,1026,1085,1086,1095,1096.FIGS.27and28show different partially exploded views of the rack assembly1002. As will be appreciated below, rack assembly1002is configured to collapse in a relatively ergonomic manner.FIGS.29-31show different views of portions of the rack assembly ofFIG.26, andFIG.32shows an isometric view of rack assembly1002in a COLLAPSED position. As shown, the vertical supports (shown but not labeled) are enclosed by the elongated shelves1020,1080,1090without any being sacrificed, as can be appreciated by viewing the end caps. As shown, with two end caps1085,1095removed and coupled externally, all of the elongated shelves (e.g., including shelves1040,1060fromFIG.26, which fit between shelves1020,1080) can fit in the collapsed assembly. Additionally, as shown inFIGS.29-31, the collars of end caps1086have notches in order to allow the shelves that have the removed end caps (e.g., end caps1085,1095, seeFIG.32) to be slid into the notch a predetermined distance, so that the side rails fit into the slot in the collar of the end cap of the shelf above it. It will be appreciated that the two collars of end cap1086and the two collars of end cap1096have such notches, as shown inFIG.32. In one embodiment, utilizing this notched collar configuration, the shelves that have the removed end caps need to only be slid over or offset by 0.25″ to align the side rails into the notches, thus facilitating nearly aligned stacking of the shelves, but at the same time allowing the shelves without the end caps to be located in between the pairs of shelves with the end caps (this 0.25 inch offset is much smaller than other stacking configurations, such as the configuration where a notch is located in the wire of the decking or in an insert adjacent to the collar, in versions described above, and is much less in stacking height as compared to existing prior art where the shelves are directly placed on top of one another).

As illustrated inFIG.1, in one configuration the sleeves23may extend upwardly above and downwardly below a top and/or bottom of the shelf. However, in other embodiments, the top and/or bottom of the sleeve (such as integrated into the end cap) might be generally flush with the top (and/or bottom) thereof, such as illustrated inFIGS.24-25, and also inFIG.13(and whereby the cap or insert240(seeFIG.14) may merely be used to close the opening in the end cap or sleeve, with the top of the cap being generally flush with the top of the end cap.

FIG.24also illustrates how the rail portions of the shelf, such as the side rails (but also the end rails, as in the configuration illustrated inFIG.1) may be solid rails, rather than formed from wires (such as parallel wires with an intermedia Z-wire).

As indicated above, the end caps may be generally permanently mounted to one or more of the shelves, but in other embodiments, they may be removably attached, such as to for shipping and storage. In such a configuration the end caps might be connected to the shelf by one or more fasteners (nuts/bolts, push-pins, etc.)

This description uses examples to describe embodiments of the disclosure and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. For example, it will be appreciated that suitable alternative embodiments of the disclosed concept include elongated shelves have different aspects from any of the different aforementioned embodiments.