Space-saving rack

Abstract

A rack for transporting and storing carriers includes a base, rolling members connected to the base, a frame, and a bumper portion. The base may include projecting portions extending outward relative to the corner regions of the frame. The frame extends upwardly from the base and includes supports for supporting carriers. The supports have metal surfaces for contacting the carriers. The bumper portion is disposed on at least a peripheral portion of the rack and is formed of plastic. A first elongated restraining member may be provided to inhibit carriers from being removed from the frame.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 60/355,835, filed Feb. 13, 2002, and U.S. Provisional Application No. 60/418,178, filed Oct. 15, 2002.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to a rack and, more particularly, to a rack for carrying food products.

[0004] 2. Description of Related Art

[0005] Racks are often used in commercial kitchens to hold and transport food products. For example, racks are used to hold hot sheet pans after they have been removed from an oven. Racks also can be used to carry items such as food boxes, insert pans, and food trays.

[0006] Conventional racks typically have frames and supports that are formed entirely of metal. Such racks have disadvantages due to their all-metal construction. For example, a user's hands may stick to the metal when the rack is used in cold applications. Also, sharp edges on the metal parts may injure users or those around them or can damage items contacted by the racks. In addition, the racks are not aesthetically pleasing.

[0007] Conventional racks also can be unstable due to their design. The racks are typically relatively tall and slender. This configuration can cause them to tip during transport or if they are subjected to a significant lateral force.

[0008] Carriers, such as sheet pans, that are supported by conventional racks can slide out of position when being loaded or transported. Conventional racks often have vertically displaced supports, which are open at two opposing ends. Consequently, the sheet pans are not fixed in place on the supports.

[0009] These racks also can occupy much valuable space. Often many different racks are required because racks of different sizes are needed to hold items of different sizes. Also multiple racks of the same size are often required in a kitchen producing a high volume of food products. When the racks are not being used, the floor space they occupy can be significant. This is not only undesirable in a commercial kitchen where space can be at a premium, but it can be hazardous.

[0010] In addition, in a commercial kitchen producing a high volume of food products, it can be difficult to move those products. Conventional racks can be difficult to maneuver. Additionally, a person typically can only move one rack at a time.

SUMMARY OF THE INVENTION

[0011] An aspect of the present invention relates to a rack for transporting and storing carriers. The rack includes a base and rolling members connected to the base. The rack also includes a frame extending upwardly from the base. The frame includes a plurality of supports for supporting carriers. The supports have metal surfaces for contacting the carriers. The rack also includes a bumper portion on at least a peripheral portion of the rack, wherein the bumper portion is formed of plastic.

[0012] Another aspect of the present invention relates to a rack for transporting and storing carriers. The rack has a frame including a plurality of supports for supporting carriers. The frame has corner regions within which the carriers can be positioned. The rack also includes a base supporting the frame, the base including projecting portions extending outward relative to the corner regions of the frame. The rack further includes rolling members connected to the projecting portions.

[0013] Yet another aspect of the present invention relates to a rack for transporting and storing carriers. The rack includes a base, rolling members connected to the base, and a frame extending upwardly from the base. The frame includes a plurality of supports for supporting carriers, and a first elongated restraining member extending substantially vertically. The first elongated restraining member is moveable substantially horizontally between a hold position in which the first elongated restraining member inhibits carriers from being removed from the frame and an unload position in which the first elongated restraining member permits carriers to be removed from the frame.

[0014] Yet another aspect of the present invention relates to a rack for transporting and storing sheet pans. The rack includes a first side panel including wire runners for supporting sheet pans, a second side panel including wire runners for supporting sheet pans, and a connector that connects the first side panel and the second side panel. The connector is configured to be moveable from an open position in which the first wire side panel is located a maximum distance from the second wire side panel to a folded position in which the first wire side panel is located a minimum distance from the second wire side panel.

[0015] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the description, serve to explain principles of the invention.

[0017] FIG. 1 is a perspective view of a first preferred embodiment of a rack according to the present invention.

[0018] FIG. 2 is a side view of the rack of FIG. 1.

[0019] FIG. 3 is a front view of the rack of FIG. 1.

[0020] FIG. 4 is a top view of the rack of FIG. 1.

[0021] FIG. 5 is a partial cross-sectional view of a restraining member and a top connector of the rack of FIG. 1.

[0022] FIG. 6 is a partial cross-sectional view of a restraining member and a base of the rack of FIG. 1.

[0023] FIG. 7 is a perspective view of a second preferred embodiment of a rack according to the present invention.

[0024] FIG. 8 is a side view of the rack of FIG. 7.

[0025] FIG. 9 is a front view of the rack of FIG. 7.

[0026] FIG. 10 is a top view of the rack of FIG. 7.

[0027] FIG. 11 is a perspective view of a third preferred embodiment of a rack according to the present invention in an open position.

[0028] FIG. 12 is a partial bottom view of a top connector of the rack of FIG. 11.

[0029] FIG. 13 is a bottom view of a base of the rack of FIG. 11.

[0030] FIG. 14 is a perspective view of the rack of FIG. 11 in a folded position.

[0031] FIG. 15 is a perspective view of a fourth preferred embodiment of a rack according to the present invention in an open position.

[0032] FIG. 16 is a perspective view of a hinge of the rack of FIG. 15.

[0033] FIG. 17 is a perspective view of the rack of FIG. 15 in a folded position.

[0034] FIG. 18 is a perspective view of multiple racks of the type shown in FIG. 15, which have been nested.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. An effort has been made to use the same reference numbers throughout the drawings to refer to the same or like parts.

[0036] FIGS. 1-6 show a first preferred embodiment of a rack 10 for transporting and storing carriers 90 according to the present invention. The carriers 90 can be, for example, sheet pans, trays, or boxes. The rack 10 includes a base 20, a top connector 30, a frame 40, rolling members 50, and bumper portions 70.

[0037] The base 20 can provide support for the frame 40. The base 20 preferably is an integral member formed of plastic by, for example, injection molding. A particularly preferred plastic is polypropylene, although other plastics can be used, such as high-density polyethylene. The base 20 can be configured to receive a lower portion 41 of the frame 40. For example, the lower portion 41 of the frame 40 can be connected to the base 20 by conventional techniques. For example, threads (not shown) can be provided on the lower portion 41 and nuts (not shown) can be attached to the threads after the lower portion 41 is inserted through the base 20. The base 20 preferably includes an outer portion 22, which extends around the periphery of the base 20 and forms a substantially rectangular outer shape, and an inner portion 24, which is located within the outer portion 22 and has a substantially X-shape that provides structural stability while maintaining light weight.

[0038] The top connector 30 can assist in maintaining the frame 40 in an appropriate position. The top connector 30 is preferably an integral member formed of plastic by, for example, injection molding. A particularly preferred plastic is polypropylene, although other plastics can be used, such as high-density polyethylene. The top connector 30 can be configured to receive an upper portion 42 of the frame 40. For example, the upper portion 42 of the frame 40 can be connected to the top connector 30 by conventional techniques. For example, threads (not shown) can be provided on the upper portion 42 and nuts (not shown) can be attached to the threads after the upper portion 42 is inserted through the top connector 30. As shown in FIG. 4, the top connector 30 preferably includes an outer portion 32, which extends around the periphery of the top connector 30 and forms-a substantially rectangular outer shape, and an inner portion 34, which is located within the outer portion 32 and has a substantially X-shape that provides structural stability while maintaining light weight.

[0039] The frame 40 is configured to support carriers 90, such as sheet pan racks that are used in commercial kitchens. The frame 40 preferably includes a first side panel 43 and a second side panel 44. The first and second side panels 43, 44 extend between the base 20 and the top connector 30.

[0040] The first and second side panels 43, 44 preferably each include outer vertically extending members 45 and inner vertically extending members 46. The outer vertically extending members 45 can form corner regions 47 of the frame 40. The inner vertically extending members 46 provide a lateral boundary and thus assist in retaining the carriers 90 on the frame 40. Preferably the carriers 90 can be fit within the corner regions 47 and are held laterally in place in at least one direction by the inner vertically extending members 46. Each of the inner and outer vertically extending members 45, 46 preferably are formed of heavy metal rods, which can have an outside diameter of ¼ inch.

[0041] The first and second side panels 43, 44 also preferably each include supports 48 that extend between the outer vertically extending members 45. The supports 48 can be connected to the outer vertically extending members 45 by conventional means, such as welding. The supports 48 preferably are configured to support carriers 90. The supports 48 each have a contact surface 49 that contacts the carriers 90. See FIG. 2. The contact surface 49 of the supports 48 is preferably formed of metal, to provide resistance to deformation or damage caused by the high heat of the carrier 90. Also, metal is resistant to abrasion caused by sliding carriers 90 over the supports 48. As shown in the preferred embodiment, the entire support 48 is formed of metal. The supports 48 can be, for example, formed of heavy metal rods, which can have an outside diameter of ¼ inch.

[0042] The rolling members 50 can be provided on the rack 10 to provide mobility. The rolling members 50 may be, for example, casters that are connected to the base 20 in a conventional manner. Other conventional rolling members could be used. Preferably the rolling members 50 are free to pivot such that they can move in any direction.

[0043] One or more handles 60 can also be provided on the rack. This first preferred embodiment includes two handles 60. Each handle 60 has a grip or cross member 61 extending between first and second connecting portions 62. The grip member 61 can be fit into recesses in the connecting portions 61, 62 and held in place by bolts (not shown). The connecting portions 62 are preferably connected to the frame 40 by conventional screws that extend into a member (not shown) on an opposite side of the frame. The grip member 61 is preferably formed of metal and the first and second connecting portions 62 are preferably formed of plastic. A particularly preferred plastic is polypropylene, although other plastics can be used, such as high-density polyethylene.

[0044] The bumper portion 70 is provided on the rack 10 to reduce negative effects that may result from the bumping the rack 10 into something or someone. The bumper portion 70 is preferably made of plastic, due to its ability to absorb impact. A particularly preferred plastic is polypropylene, although other plastics can be used, such as high-density polyethylene. The bumper portion 70 can be provided in one location or in a variety of locations on the rack. In this first preferred embodiment, bumper portions 70 are provided on the base 20, on the top connector 30, and on the frame 40. The bumper portion 70a is formed as part of the base 20 and extends around the periphery of the base 20. The bumper portion 70b is formed as part of the top connector 30 and extends around the periphery of the top connector 30. The bumper portions 70c are formed as part of the handles 60 and are provided on the four corners of the frame 40. Instead of being integral parts of the base 20, top connector 30, and handles 60, the bumper portions 70 can be members attached to those structures.

[0045] A first elongated restraining member 80 can also be provided on the rack to provide a lateral boundary and assist in retaining the carriers 90 on the frame 40. The first elongated restraining member 80 extends substantially vertically. It is moveable substantially horizontally in the direction of arrow A between a hold position in which the first elongated restraining member 80 inhibits carriers 90 from being removed from the frame 40 and an unload position in which the first elongated restraining member 80 permits carriers 90 to be removed from the frame 40. The elongated restraining member 80 can be, for example, a heavy metal rod, which can have an outside diameter of ⅜ inch. The restraining member 80 is preferably pivotally connected to the base 20 and the top connector 30, although it could be connected directly to the frame 40.

[0046] As shown in FIGS. 5 and 6, the restraining member 80 includes an upper substantially U-shaped segment 81 and a lower substantially S-shaped segment 82. Portions of the segments 81 and 82 are pivotally disposed in corresponding holes 26 and 36 in the base 20 and top connector 30, respectively. The pivotal connections allow the restraining member 80 to move between the hold and unload positions. Two depressions 37 and 38 in the top connector 30 serve as holders that can maintain the elongated restraining member 80 in the hold and unload positions, respectively. The elongated restraining member 80 is automatically maintained in the hold and unload positions by the depressions 37 and 38. That is, once the elongated restraining member 80 is moved into on of the depressions 37 or 38, no further effort is required to maintain the elongated restraining member 80 in that position. However, the elongated restraining member 80 is maintained in that position in a manner that permits the first elongated restraining member to later be removed. The upper segment 81 fits into the depression 37 or 38 and is held in place by the force of a spring 83, which is fixed onto the end of segment 81 by washers 84 and 85 and nut 86. The force of the spring 83 can be overcome to move the restraining member 80 between the depressions 37, 38. A second elongated restraining member 80 can be positioned on a side of the frame 40 opposite to the first elongated restraining member.

[0047] FIGS. 7 to 10 show a second preferred embodiment of a rack 110 for transporting and storing carriers 90 according to the present invention. The rack 110 of this second embodiment is similar to the rack 10 of the first embodiment in many respects. In this embodiment, however, the rack 110 has a base 120 with four projecting portions 128 extending and projecting outward relative to the corner regions 47 of the frame 40. The projecting portions 128 are preferably outriggers that extend outward from a primary portion 129 of the base 120, as shown in the drawings. The base could be configured such that the projecting portions project outward relative to the corner regions 47 of the frame 40, but do not project outward from the primary portion of the base. That is, the primary portion of the base would fully envelope the projecting portions.

[0048] In this embodiment, the rolling members 50 are connected to the projecting portions. The rolling members 50 are preferably positioned on outermost areas of the projecting portions. The rolling members 50 can be positioned on the projecting portions at a distance that is at least about 1.3 times a width of the frame 40.

[0049] By providing the rolling members 50 on projecting portions 128 extending outward relative to the frame 40, the stability of the 110 rack is greatly enhanced. A test was conducted to determine the difference in stability between racks constructed according to the first and second embodiments. Both racks had frames of the same size, but had bases of different sizes. The rack according to the first embodiment had a caster footprint (swivel center to swivel center) of 20.286 inches wide by 25.506 inches long. The rack according to the second embodiment had a caster footprint (swivel center to swivel center) of 27.51 inches wide by 33.48 inches long. The test results are reproduced below: 1 Front Side Tip (lbf) Tip (lbf) Front Tip (lbf) Side Tip (lbf) No Load No Load 175 lbs. Load 175 lbs. Load Emb. 1 15.0 10.5 42.5 31.5 Emb. 2 19.5 14.5 66.5 52.0 Stability Incr. 30% 38% 56.5% 65%

[0050] As shown by this test, the rack according to the second embodiment has greatly improved stability. The stability increase is particularly noticeable when the rack contains carriers that add a load of 175 lbs.

[0051] FIGS. 11 to 14 show a third preferred embodiment of a rack 210 according to the present invention. The rack 210 of this third embodiment is similar in some respects to the rack of the first embodiment. This third embodiment, however, has different structures for the base 220, top connector 230, and frame 240.

[0052] The frame 240 has first and second side panels 243, 244 that preferably each include vertically extending members 245 and supports 248 extending between the vertically extending members 245. The supports 248 preferably are configured to support carriers 90. The side panels 243, 244 are preferably made from metal, such as aluminum or stainless steel, but they could be made from plastic. If the side panels 243, 244 are made from metal they preferably are formed by stamping or welding. If the side panels are made from plastic, they preferably are formed by injection molding.

[0053] The base 220 and the top connector 230 position the side panels 243, 244 relative to one another. The base 220 and the top connector are preferably made from plastic by injection molding. They could, however, be made from another material such as metal.

[0054] The base 220 includes a first fixed bottom member 221 connected to the first side panel 243 by a conventional connection and connected to a first movable bottom member 223 by a movable connection, such as a hinge 222. The base 220 also includes a second fixed bottom member 224 connected to the second side panel 244 by a conventional connection and connected to a second movable bottom member 226 by a movable connection, such as a hinge 225. As shown in FIG. 3, the first and second movable bottom members 223, 226 are preferably connected by a movable connection, such as a hinge 227.

[0055] Similarly, the top connector 230 includes a first fixed top member 231 connected to the first side panel 243 by a conventional connection and connected to a first movable top member 233 by a movable connection, such as a hinge 232. The top connector 230 also includes a second fixed top member 234 connected to the second side panel 244 by a conventional connection and connected to a second movable top member 236 by a movable connection, such as a hinge 235. As shown in FIG. 2, the first and second movable top members 233, 236 are preferably connected by a movable connection, such as a hinge 237.

[0056] The base 220 and top connector 230 can be folded to conserve space when the rack 210 is not in use. As shown in FIG. 14, the base 220 and top connector 230 are folded at hinges 222, 227, 225, 232, 237, 235 to bring the side panels 243, 244 closer together and reduce the space occupied by the rack 210. The rack 210 can be held in the folded position by a pivoting latch 95 having an arm 96 pivotally mounted on the second movable top member 236 so as to engage a post 97 on the first movable top member 233.

[0057] FIGS. 15 to 18 show a fourth preferred embodiment of a rack 310 according to the present invention. The rack 310 of this fourth embodiment is similar in many respects to the rack of the third embodiment. This fourth embodiment, however, has different structures for the base 320 and top connector 330.

[0058] The base 320 and top connector 330 preferably can hold the side panels 243, 244 in many positions relative to one another. The base 320 and top connector 330 are preferably made from plastic by injection molding. They could, however, be made from another material, such as metal.

[0059] The base 320 includes a first fixed bottom member 321 connected to the first side panel 243 by a conventional connection and connected to a movable bottom member 323 by a movable connection, such as a hinge 322. The base 320 also includes a second fixed bottom member 324 connected to the second side panel 244 by a conventional connection and connected to the movable bottom member 323 by a movable connection, such as a hinge 325.

[0060] Similarly, the top connector 330 includes a first fixed top member 331 connected to the first side panel 243 by a conventional connection and connected to a movable top member 333 by a movable connection, such as a hinge 332. The top connector 330 also includes a second fixed top member 334 connected to the second side panel 244 by a conventional connection and connected to the movable top member 333 by a movable connection, such as a hinge 335.

[0061] The hinges 322, 325, 332, 335 preferably can be locked in a variety of positions. One hinge (i.e., 332) is shown in FIG. 16 for purposes of illustration. Preferably, the remaining hinges have the same structure as the illustrated hinge. Contacting sections of the fixed member 331 and movable member 333 preferably have holes 382 extending through them. A pin 380 can be inserted in the holes 382 of the fixed member 331 and movable member 333 to fix those members relative to one another. By providing a variety of holes 382, the angular relationship between the fixed member 331 and movable member 333 can be changed, thus changing the spacing between the first and second side panels 243, 244. Accordingly the width of the rack 310 can be adjusted to accommodate different width trays/containers, such as food boxes, sheet pans, insert pans, and meat trays. This adjustability creates a more flexible rack for multiple uses.

[0062] The base 320 and top connector 330 also can be folded to conserve space when the rack 310 is not in use. As shown in FIG. 17, the base 320 and top connector 330 are folded along hinges 322, 325, 332, 335 to bring the side panels 243, 244 closer together and reduce the space occupied by the rack 310. The rack 310 can be held in the folded position by inserting the pin 380 in an appropriate one of the holes 382 in hinge 332.

[0063] Additionally, multiple racks 310 can be nested. As shown in FIG. 18, one rack 310 can be inserted into another rack 310 to nest the racks 310. Nesting of the racks 310 reduces the space needed to store the racks 310 when they are not in use.

[0064] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

1. A rack for transporting and storing carriers, comprising:

a base;

rolling members connected to the base;

a frame extending upwardly from the base, the frame including a plurality of supports for supporting carriers, wherein the supports have metal surfaces for contacting the carriers; and

a bumper portion on at least a peripheral portion of the rack, wherein the bumper portion is formed of plastic.

2. The rack of claim 1, wherein the base is an integral member formed of plastic.

3. The rack of claim 1, wherein the bumper portion is at least one of disposed on and formed as an integral part of a peripheral portion of the base.

4. The rack of claim 1, wherein the carriers are sheet pans and the supports are configured to support sheet pans.

5. The rack of claim 1, wherein the supports are configured such that only the metal surfaces contact the carriers.

6. The rack of claim 1, wherein the supports include wire runners.

7. The rack of claim 1, wherein the bumper portion is at least one of disposed on and formed as an integral part of a peripheral portion of the base.

8. The rack of claim 7, wherein the frame includes a handle, and the bumper portion is at least one of disposed on and formed as an integral part of the handle.

9. The rack of claim 1, further comprising a top connector, wherein the top connector is an integral member formed of plastic and the frame extends upwardly into and is fixed to the top connector.

10. The rack of claim 1, wherein the bumper portion is at least one of disposed on and formed as an integral part of a peripheral portion of the top connector.

11. A rack for transporting and storing carriers, comprising:

a frame including a plurality of supports for supporting carriers, the frame having corner regions within which the carriers can be positioned;

a base supporting the frame, the base including projecting portions extending outward relative to the corner regions of the frame; and

rolling members connected to the projecting portions.

12. The rack of claim 11, wherein the carriers are sheet pans and the supports are configured to support sheet pans.

13. The rack of claim 11, wherein the supports include wire runners.

14. The rack of claim 11, wherein the projecting portions include outriggers.

15. The rack of claim 11, wherein the rolling members are positioned on outermost areas of the projecting portions.

16. The rack of claim 11, wherein the rolling members are positioned on the projecting portions at a distance that is at least about 1.3 times a width of the frame.

17. The rack of claim 11, including four corner regions and four projecting portions.

18. A rack for transporting and storing carriers, comprising:

a base;

rolling members connected to the base;

a frame extending upwardly from the base, the frame including a plurality of supports for supporting carriers; and

a first elongated restraining member extending substantially vertically, wherein the first elongated restraining member is moveable substantially horizontally between a hold position in which the first elongated restraining member inhibits carriers from being removed from the frame and an unload position in which the first elongated restraining member permits carriers to be removed from the frame, and the first elongated restraining member is automatically maintained in the hold and unload positions in a manner that permits the first elongated restraining member to later be removed.

19. The rack of claim 18, wherein the carriers are sheet pans and the supports are configured to support sheet pans.

20. The rack of claim 18, wherein the supports include wire runners.

21. The rack of claim 18, wherein the first elongated restraining member includes a bar that extends substantially vertically along the frame.

22. The rack of claim 18, wherein the first elongated restraining member pivots between the hold position and the unload position.

23. The rack of claim 18, further comprising a top connector, wherein the frame extends upwardly into and is fixed to the top connector, and the first elongated restraining member is pivotally connected to the base and to the top connector.

24. The rack of claim 18, further comprising a maintaining member that maintains the first elongated restraining member in the hold position.

25. The rack of claim 18, further comprising a second elongated restraining member positioned on a side of the frame opposite to the first elongated restraining member.

26. A rack for transporting and storing sheet pans, comprising:

a first side panel including wire runners for supporting sheet pans;

a second side panel including wire runners for supporting sheet pans; and

a connector that connects the first side panel and the second side panel, wherein the connector is configured to be moveable from an open position in which the first wire side panel is located a maximum distance from the second wire side panel to a folded position in which the first wire side panel is located a minimum distance from the second wire side panel.

27. The rack of claim 26, wherein the connector includes a first fixed base member connected to the first wire side panel, a second fixed base member connected to the second wire side panel, and a moveable base member hingedly connected to the first and second fixed base members.

28. A rack of claim 27, wherein the connector includes a first fixed top member connected to a top of the first wire side panel, a second fixed top member connected to the top of the second wire side panel, and a moveable top member hingedly connected to the first and second fixed top members.