Patent Document

FIELD 
       [0001]    The present invention relates to hinges and supports for mounting a shelf to a structure and more particularly to such apparatus for supporting light shelves. 
       BACKGROUND 
       [0002]    Light shelves are known for redirecting and controlling sunlight that enters a building. Variations on the apparatus and methods for mounting such shelves are desireable. 
       SUMMARY 
       [0003]    The disclosed subject matter relates to a cantilever mounting for connecting a member to a structure, which includes a receiver attachable to the structure, the receiver having a recess and an abutment surface spaced therefrom. An inserter is capable of being attached to the member. The inserter has an insertion leg and an abutment support spaced therefrom, the insertion leg is insertable into the recess of the receiver, the abutment support being capable of resting upon the abutment surface when the insertion leg is in the recess. The weight of the member attached to the inserter pulls the abutment support into engagement with the abutment surface and pushes the insertion leg into engagement with the recess, holding the member at a given orientation relative to the structure. 
         [0004]    In accordance with another aspect of the disclosure, the member is a light shelf. 
         [0005]    In accordance with another aspect of the disclosure, the light shelf has a base, a panel contacting the base and a frame extending from a first end of the base around the panel to a second end of the base, capturing the panel between the base and the frame. 
         [0006]    In accordance with another aspect of the disclosure, the inserter is a first inserter and further including a second inserter to yield a pair of inserters, wherein each inserter of the pair has an attachment leg which projects into the base, the attachment leg of the first inserter projecting into the base at a first end there of and the attachment leg of the second inserter projecting into the base at a second end there of, for attachment there to, each inserter having an extension portion that extends into a corresponding end of the frame for attachment thereto, the pair of inserters connecting the frame to the base, the frame and the base having a groove dimensioned to receive and hold the panel therein. 
         [0007]    In accordance with another aspect of the disclosure, the inserter has a bending strength limited to be less than an attachment strength of the receiver to the structure. 
         [0008]    In accordance with another aspect of the disclosure, the bending strength is limited by an aperture in the inserter, which reduces the cross-sectional area of the inserter. 
         [0009]    In accordance with another aspect of the disclosure, the aperture extends through the inserter proximate the conjunction of the extension and the abutment support in a direction perpendicular to a surface of the abutment support of the inserter that contacts the abutment surface of the receiver when the inserter and receiver are holding the member at a given orientation relative to the structure. 
         [0010]    In accordance with another aspect of the disclosure, the aperture extends through the inserter proximate the conjunction of the extension and the abutment support in a direction parallel to a surface of the abutment support of the inserter that contacts the abutment surface of the receiver when the inserter and receiver are holding the member at a given orientation relative to the structure. 
         [0011]    In accordance with another aspect of the disclosure, the bending strength is limited by a slot in the inserter, which reduces the cross-sectional area of the inserter proximate the conjunction of the extension and the abutment support. 
         [0012]    In accordance with another aspect of the disclosure, the receiver is bilaterally symmetric allowing the receiver to be used in conjunction with an inserter installed on either the left side or the right side of a member. 
         [0013]    In accordance with another aspect of the disclosure, the receiver has a mitered side face which extends from the structure at an angle other than 90 degrees. 
         [0014]    In accordance with another aspect of the disclosure, a pair of receivers with mitered side faces abut together in a corner to allow the installation of pair of adjacent members in a corner of the structure. 
         [0015]    In accordance with another aspect of the disclosure, the mounting includes a pair of receivers and a pair of inserters, the pair of receivers attachable to a structure with a spacing there between, a first of the pair of inserters attachable to one side of the member and a second of the pair of inserters attachable to another side of the member, the spacing of the pair of receivers matching the width of the member to allow the insertion leg of the first and second inserters to engage the recess of the first and second receivers, respectively, to hold the member at the given orientation relative to the structure. 
         [0016]    In accordance with another aspect of the disclosure, the abutment surface extends from the structure when attached thereto at an angle other than 90 degrees. 
         [0017]    In accordance with another aspect of the disclosure, the structure is not plumb and the angle of the abutment surface compensates for the out-of-plumb condition of the structure to hold the member perpendicular to plumb. 
         [0018]    In accordance with another aspect of the disclosure, the angle of the abutment surface is selected to provide a selected orientation of the member relative to plumb. 
         [0019]    In accordance with another aspect of the disclosure, an adjustment screw is threaded into an aperture extending through at least one of the abutment support and the receiver, an end of the adjustment screw extending to a selected degree from at least one of the surface of the abutment support and the abutment surface and pressing against at least one of the abutment surface and the abutment support to adjust the orientation of the member. 
         [0020]    In accordance with another aspect of the disclosure, the receiver has an upper bracket and a lower bracket extending from an upright portion, the upper and lower brackets being spaced from each other to define a slot there between, the upper bracket having a depending block spaced from the upright portion by the recess, the lower bracket having a floor extending from the upright portion to a lip proximate the abutment surface, the space between the lip and the upper bracket defining a threshold opening through which the insertion leg may enter the slot. 
         [0021]    In accordance with another aspect of the disclosure, the mounting includes a pair of receivers and a pair of inserters, a first of the pair of receivers attachable to a structure at a spacing relative to a second of the pair of receivers, a first of the pair of inserters attachable to one side of the member and a second of the pair of inserters attachable to another side of the member, the spacing of the first and second receivers approximating the width of the member to allow the insertion leg of the first and second inserters to engage the recess of the first and second receivers, respectively, to hold the member at the given orientation relative to the structure, wherein the member is a light shelf with a base, a panel contacting the base and a frame extending from a first end of the base around the panel to a second end of the base, capturing the panel between the base and the frame, wherein each inserter of the pair has an attachment leg which projects into the base on the first end and the second end, respectively, for attachment there to and an extension that extends into a corresponding end of the frame for attachment thereto, the inserters intermediating between the frame and the base, the frame and the base having a groove dimensioned to receive and hold the panel therein when the base and the frame are connected to the pair of inserters. 
         [0022]    In accordance with another aspect of the disclosure, a method for removably mounting a member to a structure using a cantilever mounting having a pair of spaced receivers attached to the structure, each of the receivers having a recess and an abutment surface spaced there from, and a pair of inserters attached to opposite sides of the member, each of the inserters having an insertion leg and an abutment support spaced there from, wherein each receiver has an upper bracket and a lower bracket extending from an upright portion, the upper and lower brackets being spaced from each other to define a slot there between, the upper bracket having a recess proximate the conjunction of the upright portion and the upper bracket, includes the steps of: 
         [0023]    (A) positioning the member and the pair of inserters relative to the pair of receivers; 
         [0024]    (B) inserting the insertion leg of each of the pair of inserters into the slot of a corresponding one of the pair of receivers; 
         [0025]    (C) raising the member such that the abutment support of the inserter is above the abutment surface of the receiver; 
         [0026]    (D) sliding the insertion leg toward the upright portion; 
         [0027]    (E) lowering the member to allow the abutment support to contact the abutment surface and pivot the insertion leg up into the recess to hold the member at a given orientation relative to the structure. 
         [0028]    In accordance with another aspect of the disclosure, the member is removed from the mounting by 
         [0029]    (F) lifting the member to pivot the insertion leg down out of the recess and lifting the abutment support of the inserter out of contact with the abutment surface of the receiver; 
         [0030]    (G) sliding the insertion leg away from the upright portion; and 
         [0031]    (H) removing the insertion leg of each of the pair of inserters from the slot of a corresponding one of the pair of receivers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]    For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings. 
           [0033]      FIG. 1  is a perspective view of a light shelf in accordance with an embodiment of the present disclosure. 
           [0034]      FIG. 2  is an enlarged, partially phantom view of a segment of the light shelf of  FIG. 1 , showing the mounting apparatus thereof. 
           [0035]      FIG. 3  is an exploded view of the apparatus of  FIGS. 1 and 2   
           [0036]      FIGS. 4   a - f  are sequential, diagrammatic views of the cooperation of elements of the apparatus of  FIGS. 1-3 . 
           [0037]      FIG. 5  is a plan view of a pair of light shelves installed in a corner of a structure in accordance with another embodiment of the disclosure. 
           [0038]      FIG. 6  is an enlarged, partially phantom view, like  FIG. 2 , of an alternative embodiment of the present disclosure. 
           [0039]      FIG. 7  is an exploded view of the apparatus of  FIG. 6 . 
           [0040]      FIG. 8   a  is a perspective, partially phantom view of a inserter in accordance with an alternative embodiment of the present disclosure. 
           [0041]      FIG. 8   b  is a top view of the inserter of  FIG. 8   a.    
           [0042]      FIG. 9   a  is a perspective, partially phantom view of a inserter in accordance with an alternative embodiment of the present disclosure. 
           [0043]      FIG. 9   b  is a top view of the inserter of  FIG. 9   a.    
           [0044]      FIG. 10   a  is a perspective, partially phantom view of a inserter in accordance with an alternative embodiment of the present disclosure. 
           [0045]      FIG. 10   b  is a top view of the inserter of  FIG. 10   a.    
           [0046]      FIG. 10   c  is a side view of the inserter of  FIG. 10   a.    
           [0047]      FIG. 11  is a diagrammatic side view of an alternative embodiment of a portion of a light shelf mounting assembly in accordance with the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0048]      FIG. 1  shows a light shelf assembly  10  mounted to structural members  12   a,    12   b,  e.g., metal studs of a wall of a building or a mounting framework for a plurality or array of light shelves, e.g., stacked one above another with a spacing there between. The assembly  10  may include a shelf  14  with a panel  16  formed from sheet metal, such as aluminum or an aluminized plastic to confer reflectivity to the surface(s) of the panel  16 . The panel  16  may be painted with reflective paint, such as aluminum or white paint. In addition, the panel  16  could be made from a polymeric material, which could be translucent or opaque. Alternatively, the panel  16  may be composed of a variety of rigid or flexible materials with a variety of visual characteristics. In the embodiment shown, the panel  16  is supported in a frame  18 , e.g., made from extruded aluminum alloy, like that used to make aluminum windows and doors. Alternatively, the frame may be made from other materials, such as plastic, wood, stainless steel or other types of metals. The frame  18  and/or panel  16  is attached to a base member  20  that spans the width of the panel  16  and frame  18 . As shall be described further below, the base member  20  is connectable to a structure via mounting assemblies  22 ,  24 . 
         [0049]      FIGS. 2 and 3  show that the mounting assemblies,  22 ,  24  feature a receiver portion  26  (receiver) and an inserter portion  28  (inserter). The receiver  26  may be fastened to a support member, such as structural member  12   a  or  12   b,  via fasteners  30 , such as bolts, screws, rivets, nails, etc. Alternatively, the receiver  26  may have other coupling features, such as integral hooks that insert into apertures in a structural member  12   a  or  12   b,  similar to peg board hooks or other conventional removable shelf hooks. In the embodiment shown, the receiver  26  may be used in both mounting assemblies  22  and  24  to support both sides of the shelf  14 , such that specialized right and left receivers are not required. The receiver  26  has a lower bracket  32  and an upper bracket  34  which extend laterally from an upright portion  36 , which extends longitudinally and which receives the fasteners  30  to hold the receiver  26  to a structural member  12   a  or  12   b.  As described below in reference to  FIG. 11 , in another embodiment, the lower bracket  32  and the upper bracket  34  may extend at different angles relative to the upright portion  36  to accommodate different installation requirements. The lower bracket  32  and the upper bracket  34  are separated by a slot  38 . The inserter  28  has an insertion leg  40 , a pair of base attachment legs  42 ,  44 , and an abutment leg  46  with an extension  48  to which the frame  18  may be attached. As described below in reference to  FIGS. 8   a - 10   c,  the inserter  26  may utilize features that promote bending of an overloaded mounting assembly too avoid disengagement from a structural member  12   a,    12   b.  The inserter  28  may be fastened to a base member  20  by sliding the base attachments legs  42 ,  44  into a hollow  50  of the base member  20 , and retained therein by fasteners  52  that are received in apertures  54 . Similarly, the frame  18  is held to the extension  48  by fasteners  56  and apertures  58 . A groove  60  may be provided in the base member  20  to receive a panel  16 , which is not shown in  FIGS. 2 and 3 . The depth and width of the groove  60  may be varied to accommodate panels  16  having different sizes and thicknesses. A set screw  61  is received in threaded aperture  61   a  in abutment leg  46  and may be used to adjust the position of the shelf  14 , i.e., by encountering abutment support surface  70  and pushing the abutment leg  46  away from the abutment surface  70  to a selected degree. 
         [0050]      FIG. 4   a  shows a receiver  26  fastened to a structural member  12   b  juxtaposed next to an inserter  28 . The inserter  28  has an insertion leg  40  and an abutment leg  46 . A frame  18  is attached to the inserter  28  and depends downwardly therefrom for supporting a panel  16  (not depicted) of a shelf  14 . The shelf  14  would typically be held by a person (installer) in their hands and lifted and moved through the sequence of movements shown in  FIGS. 4   a - 4   f  in order to assemble and position the inserter  28  into the receiver  26  to hold the shelf  14  at a desired position. The lower bracket  32  of the receiver  26  has a floor  62  extending between a back wall  64  and a front wall  66 , which extends upwardly to form a lip  68 . The lip  68  is adjacent an abutment support surface  70 . The upper bracket  34  has a downwardly depending block  72  which defines a recess  74  proximate back wall  64  and a relief  76  opposite to the lip  68  of the lower bracket  32 , which defining a threshold gap  78  through which the insertion leg  40  may be passed into the slot  38 . 
         [0051]      FIG. 4   b  shows the insertion leg  40  as it is inserted into the threshold gap  78 . In the embodiment shown, the insertion leg  40  has a rectangular cross-section, such that the insertion leg will only clear the threshold gap  78  if held in the orientation depicted, i.e., with the smaller dimension of the rectangular cross-section of the insertion leg  40  parallel to the threshold gap  78 , i.e. extending across the gap  78 . This dimensional relationship may be used to control the angle at which the insertion leg  40  may be passed into and out of the slot  38 , e.g., to prevent inadvertent removal during assembly, adjustment and disassembly of the light shelf assembly  10  (and consequently the orientations of the shelf  14  that enable/disable these functions). In the embodiment shown in  FIG. 4   b , the shelf  14  is perpendicular to the horizon/ground for insertion. The threshold gap  78  may be modified to permit/require different angles of insertion of the insertion leg  40  and may be enlarged so as to allow insertion at any angle. 
         [0052]    As shown in  FIG. 4   c , once past the threshold gap  78 , the insertion leg  40  may drop down and rest on the floor  62  proximate the lip  68 . Since a pair of mounting assemblies  22 ,  24  may be used to support a shelf  14 , the engagement between the inserter portion  28  and the receiver portion  26  may take place on the mounting assemblies  22 ,  24  on opposite sides of the base member  20 , such that the shelf  14  may be hung in the position shown in  FIG. 4   c  without the support of a person. The installer can therefore release the light shelf  10  and it will hang from the assemblies  22 ,  24 . 
         [0053]      FIGS. 4   d  and  4   e  show that the shelf  14  can be pivoted up on the insertion leg  40  within the slot  38  and slid back until the insertion leg  40  encounters back wall  64 . As shown in  FIG. 4   d , the pivoting of the insertion leg  40  is conducted while the insertion leg  40  is positioned proximate the lip  68 , allowing the abutment leg  46  to clear the lower bracket  32  as it swings upward.  FIG. 4   e  shows that once the abutment leg  46  is clear of the lower bracket  32  and held at an angle B relative to the horizontal H, the insertion leg  40  can be slid back to the rear wall  64 , bringing the abutment block  46  over the abutment support surface  70 . 
         [0054]      FIG. 4   f  shows that when the shelf  14  is then swung down to the horizontal position, the abutment leg  46  or the adjustment set screw  61  (see  FIG. 3 ) comes to rest upon the abutment support surface  70  and the insertion leg  40  pivots up into engagement with the recess  74  and is held in that position by the force of gravity G. The insertion leg  40  engaging the recess  74  resists forces directed perpendicular to the support member  12   b,  and in cooperation with the abutment leg  46  and abutment support surface  70 , provides a cantilevered mounting for the shelf  14 , which is held in a horizontal orientation. If removal of the shelf  14  is desired, it can readily be accomplished by reversing the foregoing procedure. As can be appreciated, the shelf  14  can be adjusted between a depending orientation to a horizontal orientation and installed and removed from a mounted receiver  26  without tools. Referring to  FIGS. 2 and 3 , one or more set screws  79  may be used to adjust the angle of the shelf  14 . More particularly, the degree to which the set screw  79  protrudes through the abutment leg  46  and pushes the abutment leg away from the abutment surface  70  can be adjusted by turning the screw  79  in or out, varying the angle of the shelf  14  relative to the horizontal orientation. 
         [0055]      FIG. 5  shows a corner  80 , e.g., of a room in which a pair of light shelf assemblies  82   a,    82   b  have been installed. The light shelf assemblies  82   a,    82   b  have similar features as the light shelf assembly  10  described above in reference to  FIGS. 1-4 , except for mitered edges  84   a,    84   b,  which allow close relative juxtaposition in corner  80 . As before, the light shelf assemblies  82   a,    82   b  are mounted to structural members  86 , e.g., studs of a wall of a building or a mounting framework for a plurality or array of light shelves. The light shelf assemblies  82   a,    82   b  may include a shelf  88   a,    88   b,  with a panel  90   a,    90   b,  respectively, formed from the same type of materials described above in reference to the embodiment shown in  FIG. 1 . The panels  90   a,    90   b  may be supported in a corresponding frame  92   a,    92   b,  respectively, e.g., made from extruded aluminum alloy, like that used to make aluminum windows and doors. Alternatively, the frame  92   a,    92   b  may be made from other materials, such as plastic, wood, stainless steel or other types of metals. The frames  92   a,    92   b  and/or panels  90   a,    90   b  are attached to base members  94   a,    94   b.  As before, the base members  94  and  94   b  are connectable to a structure via mounting assemblies  96   a,    96   b  that are like the mounting assemblies  22 ,  24  described above, but also by mitered corner mounting assemblies  98   a,    98   b  that have features providing a relative mitered fit one to another. 
         [0056]      FIGS. 6 and 7  show that the mitered mounting assemblies,  98   a,    98   b  feature a receiver portion  100  having a mitered face  102  which is disposed at angle C, e.g., 45 degrees relative to opposing face  104 . The inserter portion  106  features an extension  108  with a distal portion  110  that extends from a root portion  112  at an angle D, e.g., 135 degrees. The angled extension  108  holds frame  92   a  at acute angle E, e.g., 45 degrees, relative to base member  94   a  when coupled to the inserter portion  106 . End  114  of frame  92   a  is cut at an angle F, e.g., 45 degrees, to cover distal portion  110  up to the root portion  112 . As shown in  FIG. 5 , the mitered mounting assemblies  98   a,    98   b  are mirror images of one another, such that they conjoin in a complementary, mitered relationship to fit in corner  80 . Beyond the foregoing differences, the mitered mounting assemblies  98   a,    98   b  are constructed and function in a similar manner to the mounting assemblies  22 ,  24  described above in relation to  FIGS. 1-4 . 
         [0057]    Each of  FIGS. 8   a - 10   c  show inserters  120 .  130 .  140 , respectively, which have the same basic form and function as the inserters  28  and  106  described above with respect to  FIGS. 1-7 , but illustrating different approaches to limiting the bending strength thereof. More particularly,  FIGS. 8   a  and  8   b  show an inserter  120  having an aperture  122  extending through the inserter  120  proximate the junction of the extension  126  and the abutment leg  128  and having an orientation approximately perpendicular to the threaded aperture  124  (which would receive an adjustment set screw (not shown) like screw  61  of  FIG. 3 ). The aperture  122  is dimensioned to reduce the bending strength of the inserter  120 , such that the extension  126  is likely to bend relative to the abutment leg  128  prior to the failure of mounting screws  30  (See  FIG. 3 ) holding a cooperating receiver  26 , e.g., as shown in  FIG. 3 . In the instance of an unexpected loading of a light shelf, e.g.,  14  or  88   a,  e.g., due to an installer pulling on the shelf  14  or  88   a,  bending is preferred in that it occurs more gradually, allowing perception of the bending movement and corrective action to be taken (encouraging the installer to stop pulling on the shelf. In addition, early bending limits the amount of force that can build up in the system. 
         [0058]      FIG. 11  shows a receiver  150  affixed to a structural member  152  that is disposed at an angle K relative to plumb P. The receiver  150  has a lower bracket  154  and an upper bracket  156  that extend from the base attachment leg  158  at an angle that, in cooperation with an inserter  160  supports the light shelf  162  in a horizontal orientation. A receiver  26  like that shown in  FIGS. 2 and 3  would have an orientation like that illustrated by the lower bracket  164  shown in dotted lines, if installed on an angled structural member  152  and would require a re-orientation through angle Q, in order to hold the shelf horizontal. A receiver  26 ,  152  may be selected with a lower bracket  32 ,  154  and upper bracket  34 ,  156  orientation that provides a desired incidence angle I and reflection angle R for light L, such that the reflected light RL is directed to a desired location within a given building for any given structural member  12   a,    152  orientation. 
         [0059]    It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the claimed subject matter. For example, while the disclosure has been expressed in terms of apparatus for supporting light shelves, the apparatus disclosed herein could be utilized to support other types of horizontal members, shelves and support surfaces, e.g., storage shelves. All such variations and modifications are intended to be included within the scope of the appended claims.

Technology Category: 1