Repositionable Wire Deck Assemblies for a Storage Rack

Abstract

Storage systems are described comprising wire shelves and brackets, which are configured to increase the storage capacity of a storage rack by utilizing or converting the space between adjacent shelves into additional storage space is provided. In one embodiment, a storage system utilizes a full-width wire rack and a partial-width wire rack to convert a space between a first shelf panel and a second shelf panel on a storage rack into usable storage space. The full-width wire rack comprises a plurality of longitudinal rods, at least one transverse rod interconnected with at least some of the plurality of longitudinal rods, and a plurality of downwardly turned prongs configured to detachably engage a plurality of keyhole-shaped openings in at least one of the first and second vertical support members to detachably connect the full-width wire rack to the storage rack. The partial-width wire rack is suspended from the full-width wire rack by at least one S-shaped bracket.

Description

This application claims priority to a U.S. Patent Provisional Application Nos. 61/804,612 and 61/804,599, both filed on Mar. 22, 2013, the entire contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to wire shelves and brackets configured to be detachably connected to a storage rack.

BACKGROUND

Storage racks and shelving units are commonly used to store a variety of different articles, such as tools and equipment in a garage (e.g., drills, brooms, shovels, extension cords, etc.), in an organized and readily accessible manner. Typical storage racks include left and right end support units and front and rear cross beams extending between the end support units. Together, corresponding front and rear crossbeams extending between the end support units define a frame configured to support a shelf for storing various articles. Typically, each end support unit includes front and rear vertical support members and cross braces, both horizontal and diagonal, interconnecting the front and rear vertical support members.

One common type of storage rack known in the art is a “boltless” rack, in which at least some of the members of the rack are configured to be assembled without the use of permanent mechanical fasteners. In some conventional boltless racks, the members of the end support units are permanently coupled together, such as by welding or riveting, and the crossbeams are detachably connected to the vertical support members of the end support units. Typically, the vertical support posts include a series of apertures, such as wedge-shaped slots or keyhole-shaped openings, configured to detachably receive interconnecting members, such as rivets or lances, on opposite ends of the cross beams. Accordingly, boltless racks are configured to permit easy assembly and disassembly of the storage rack or shelving unit without the use of tools, and to permit compact and economical shipment of the unit. An example of a boltless shelving unit is shown and described in U.S. patent application Ser. No. 13/360,543, entitled “Modular Rack Assembly,” the entire contents of which are hereby incorporated by reference.

The storage capacity of conventional storage racks is limited by the number of shelves. However, adding additional full length shelves may not accommodate taller articles stored on the shelves (i.e., taller articles may not permit additional full length shelves to be installed between two existing adjacent shelves).

One attempt to address this problem is to add a rod attachment to the wire shelves. For example, U.S. Pat. No. 5,405,026 to Lee discloses a clothes hanger rod attachment to be used in combination with wire shelves. In Lee, the hanger rod is connected to the wire shelves via hooks without using a bracket. Yet, Lee's disclosure is limited to use with clothes hanger rod which is unlikely provide enough storage space between the rod and the wire shelves.

Another approach is to use a suspended shelving system. For example, U.S. Pat. No. 7,798,341 to Richardson discloses a suspended shelving system including a shelving panel supported by a plurality of hanger members, which are secured to overhead members. However, Richardson's suspended shelving system requires that it is secured to an overhead structure or ceilings. Furthermore, the crossmembers connecting the shelving system to a hanger is rotatable, yet fixed to a distal end of the shelving member, which renders less flexibility in locating the suspended shelving system.

Thus, there is still a need for a storage system, which enables a user to utilize or convert a space between two storage shelves in a storage rack to increase the storage capacity of a storage rack with a minimum use of tools.

SUMMARY OF THE INVENTION

The present invention is directed to wire shelves and brackets which are configured to increase the storage capacity of a storage rack by utilizing or converting the space between adjacent shelves into additional storage space, for example, by adding shelves between the adjacent shelves. Additionally, the present invention may utilize one or more wire shelves which do not span the full width of the storage rack, thereby accommodating taller articles stored on the shelves.

In one embodiment, a storage system is configured to convert a space between a first shelf panel and a second shelf panel on a storage rack into usable storage space, such as by adding one or more shelves between the first and second shelf panels. The storage rack comprises a first vertical support member and a second vertical support member. The storage rack has a width defined by the distance between the first vertical member and the second vertical member. The system comprises a full-width wire rack comprising a plurality of longitudinal rods, at least one transverse rod interconnected with at least some of the plurality of longitudinal rods, and a plurality of downwardly turned prongs configured to detachably engage a plurality of keyhole-shaped openings in at least one of the first and second vertical support members to detachably connect the full-width wire rack to the storage rack. The system further comprises a partial-width wire rack suspended from the full-width wire rack by at least one bracket that is preferably S-shaped although other types of brackets could be used.

In another embodiment, a storage rack comprises first and second vertical support members each having a plurality of key-hole shaped openings. In this embodiment, a first wire rack has a plurality of longitudinal rods, at least one transverse rod interconnected with at least some of the plurality of longitudinal rods, and at least one downwardly turned prong configured to detachably engage at least one of the plurality of keyhole-shaped openings in the vertical support member to detachably connect the wire rack to the storage rack. The distance between the first and second vertical support members defines a width of the rack. The system comprises a second wire rack having a plurality of interconnected longitudinal rods and transverse rods and at least one downwardly turned prong. The system further comprises at least one bracket, preferably S-shaped, having a first hook end and a second hook disposed at either end, sized and dimensioned to hook at least one of the longitudinal rods and transverse rods.

Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of support bracket according to the present invention are described with reference to the following figures. The same reference numerals are used throughout the figures to reference like features and components. The figures are not necessarily drawn to scale.

FIG. 1 is a front perspective view of an existing boltless storage rack having wire shelves and brackets of the present invention installed thereon;

FIG. 2A is a perspective view of full-width wire shelf according to one embodiment of the present invention;

FIG. 2B is a perspective view of a partial width wire shelf according to one embodiment of the present invention;

FIG. 2C is a perspective view of a partial width wire shelf according to one embodiment of the present invention; and

FIG. 3 is a perspective view of a hook according to one embodiment of the present invention.

DETAILED DESCRIPTION

The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

The present invention relates generally to wire shelves and brackets configured to be detachably connected to a storage rack. The wire shelves and brackets are configured to increase the storage capacity of an existing storage rack by utilizing or converting the space between two adjacent shelves on the existing storage rack into additional organized storage space. The wire shelves are repositionable along the vertical support posts such that the height of the wire shelves and the spacing between the wire shelves and the existing shelf panels on the storage rack can be selected to accommodate variously shaped and sized articles, such as tools and other equipment commonly stored in a garage. Additionally, the brackets are configured to suspend additional wire shelves from the wire shelf which is coupled to the vertical support posts of the storage rack.

Referring now to the embodiment illustrated in FIG. 1, a storage rack 100 is illustrated having two full-width wire shelves 101 detachably coupled to the storage rack 100. The storage rack is also illustrated having two partial-width wire shelves 102 detachably coupled on one end to the storage rack 100 and suspended on an opposite end from one of the full-width wire shelves 101 by a plurality of S-shaped brackets 104, although other shaped brackets could be used. Additionally, the storage rack 100 is illustrated having two partial-width wire shelves 103 completely suspended from one of the full-width wire shelves 101 by a plurality of S-shaped brackets 104. As used herein, the term “plurality” shall mean two or more.

With continued reference to FIG. 1, the storage rack 100 includes left and right end support units 105, 106, respectively, interconnected by front and rear crossbeams 107, 108, respectively. Each end support unit 105, 106 includes front and rear vertical support posts 109, 110, respectively, and horizontal braces 111 extending between the front and rear vertical support posts 109, 110 (i.e., front ends 112 of the horizontal braces 111 are connected to the front vertical support posts 109 and rear ends 113 of the horizontal braces 111 are connected to the rear vertical support posts 110). In the illustrated embodiment, each end support unit 105, 106 includes five horizontal braces 111, although it will be appreciated that the end support units 105, 106 may have any other suitable number of horizontal support braces 111, such as between two and ten or more, depending upon the desired storage capacity of the storage rack 100 and the shape and size of the various articles the storage rack 100 is configured to support. In another embodiment, the end support units 105, 106 may also include diagonal braces extending between the front and rear vertical support posts 109, 110, respectively. In the illustrated embodiment, the horizontal braces 111 are boltlessly and detachably connected to the vertical support posts 109, 110, although it will be appreciated that the horizontal braces 111 may be connected to the vertical support posts 109, 110 by any other suitable means, such as mechanical fastening or welding.

With continued reference to FIG. 1, a width can be defined by a distance between two front vertical support posts 109. It is also contemplated that a width can be defined by a distance between the front vertical post 109 and the rear vertical support 110. The full-width wire shelf 101 has a first width that is substantially similar to the width as defined. The partial-width wire shelves 102, 103 have a second width that is shorter than the first width of the full-width wire shelf 101.

With continued reference to FIG. 1, each of the vertical support posts 109, 110 is a beam having two generally orthogonal legs 114, 115 (i.e., each of the vertical support posts 109, 110 includes a front leg 114 and a side leg 115 extending rearward from the front leg 114). Together, the legs 114, 115 define a beam having an L-shaped transverse cross-section. It will be appreciated, however, that the vertical support posts 114, 115 may have any other suitable shape, such as a U-shaped or Z-shaped transverse cross-section. Additionally, in the illustrated embodiment, each of the legs 114, 115 of the vertical support posts 109, 110 includes a plurality of keyhole-shaped openings 116 arranged in a column. Each of the keyhole-shaped openings 116 includes a relatively larger upper circular opening 117 and a relatively smaller elongated opening 118 extending downward from a lower end of the larger opening 117. As described in detail below, contemplated wire shelves 101, 102 can be boltlessly and detachably connected to the keyhole openings 116 in the vertical support posts 114, 115.

With continued reference to FIG. 1, opposite ends 119, 120 of the front and rear crossbeams 107, 108 are boltlessly coupled to the front and rear vertical support posts 109, 110, respectively. Together, the crossbeams 107, 108 and the horizontal braces 111 define a ledge or a frame configured to support at least one shelf panel 121 or other planar support member. It will be appreciated that the storage rack 100 may include any suitable number of crossbeams 107, 108, such as between two and ten or more. Additionally, the crossbeams 107, 108 may be positioned at any suitable elevation along the vertical support posts 109, 110, depending upon the locations of the keyhole-shaped openings 116 in the vertical support posts 109, 110, the desired storage capacity of the storage rack 100, and/or the shape and size of the various articles the storage rack 100 is configured to support. In the illustrated embodiment, the number and elevation of the front and rear crossbeams 107, 108 corresponds to the number and elevation of the horizontal braces 111, although it will be appreciated that the number and elevation of the front and rear crossbeams 107, 108 may differ from the horizontal braces 111. The crossbeams 107, 108 and the horizontal braces 111 may have any suitable shape, such as a generally omega-shaped, C-shaped, or Z-shaped transverse cross-section.

With continued reference to FIG. 1, two full-width wire shelves 101 and four partial width wire shelves 102, 103 are detachably coupled to the boltless storage rack 100. It will be appreciated, however, that any other suitable number of full-width and partial-width wire shelves 101, 102, 103 may be provided, depending upon the desired additional storage capacity of the storage rack 100 and the shape and size of the articles the user desires to store and arrange on the wire shelves 101, 102, 103 and the shelf panels 121.

With reference now to FIG. 2A, each of the full-width wire shelves 101 includes a plurality of interconnected longitudinal rods 125 and transverse rods 126. Together, the longitudinal and transverse rods 125, 126, respectively, define a mesh wire shelf 101 configured to support various articles, such as tools and other equipment commonly stored in a garage. Additionally, opposite ends of the outermost longitudinal rods 125 include downwardly turned prongs 127 (i.e., each of the four corners of the full-width wire shelf 101 includes a downwardly turned prong 127). The downwardly turned prongs 127 are configured to detachably engage the keyhole-shaped openings 116 in the side legs 115 of the vertical support posts 114, 115 to detachably couple the full-width wire shelf 101 to the storage rack 100, as illustrated in FIG. 1. The full-width shelves 101 are configured to extend completely between the vertical support posts 114, 115 of the storage rack 100 such that all four corners of the full-width wire shelf 101 are supported by the vertical support posts 114, 115.

With reference now to FIG. 2B, the partial-width wire shelf 102 includes a plurality of interconnected longitudinal rods 128 and transverse rods 129. Together, the longitudinal and transverse rods 128, 129, respectively, define a mesh wire shelf 102 configured to support various articles, such as tools and other equipment commonly stored in a garage. Unlike the full-width wire shelf 101 described above, only one end 130 of the partial-width wire shelf 102 is configured to be supported by the vertical support posts 109, 110 of the storage rack 100. The other end 131 of the partial-width wire shelf 102 is configured to be suspended from the full-width wire shelf 101 by at least one S-shaped bracket 104. In the illustrated embodiment of FIG. 1, each of the partial-width wire shelves 102 is suspended from the full-width wire shelf 101 by two S-shaped brackets 104, although it will be appreciated that the partial-width wire shelves 102 may be suspended by any other suitable number of S-shaped brackets 104, such as between one and four or more.

With continued reference to FIG. 2B, end 130 of each of the outermost longitudinal rods 128 includes a downwardly turned prong 140. The downwardly turned prongs 127 are configured to detachably engage the keyhole-shaped openings 116 in the side legs 115 of the vertical support posts 114, 115 to detachably couple the one end 130 of the partial-width wire shelf 101 to the storage rack 100, as illustrated in FIG. 1. In the illustrated embodiment, the opposite end 131 of each of the outermost longitudinal rods 128 is not provided with a downwardly turned prong 140 because end 131 of the partial-width wire shelf 102 is suspended from the full-width wire shelf 101 by at least one S-shaped bracket 104, as illustrated in FIG. 1. Although in the illustrated embodiments, the S-shaped brackets 104 suspending the partial-width wire shelves 102 are detachably coupled to the full-width wire shelf 101, in an alternate embodiment, the S-shaped brackets 104 may be detachably coupled to one of the crossbeams 107, 108 of the storage rack 100.

With reference now to FIG. 2C, the partial-width wire shelf 103 includes a plurality of interconnected longitudinal rods 132 and transverse rods 133. Together, the longitudinal and transverse rods 132, 133, respectively, define a mesh wire shelf 103 configured to support various articles, such as tools and other equipment commonly stored in a garage. Unlike the full-width wire shelf 101 and the partial-width wire shelf 102 described above, both ends 134, 135 of the partial-width wire shelf 103 are configured to be suspended from the full-width wire shelf 101 by at least one S-shaped bracket 104. In the illustrated embodiment of FIG. 1, each partial-width wire shelf 103 is suspended from the full-width wire shelf 101 by four S-shaped brackets 104 (i.e., each corner of the partial-width wire shelf 103 is suspended from the full-width wire shelf 101 by one S-shaped bracket 104). It will be appreciated, however, that the partial-width wire shelves 103 may be suspended by another other suitable number of S-shaped brackets 104, such as between two and eight or more. Additionally, although in the illustrated embodiments, the S-shaped brackets 104 suspending the partial-width wire shelves 103 are detachably coupled to the full-width wire shelf 101, in an alternate embodiment, the S-shaped brackets 104 may be detachably coupled to the crossbeams 107, 108 of the storage rack 100.

With reference now to the embodiment illustrated in FIG. 3, the S-shaped brackets 104 each include a vertical segment 136, a downwardly turned hook portion 137 on an upper end of the vertical segment 136 and an upwardly turned hook portion 138 on a lower end of the vertical segment 136. The downwardly turned hook portion 137 of the S-shaped brackets 104 is configured to be detachably coupled to either the longitudinal rods 125 on the full-width wire shelf 101 or the crossbeams 107, 108. The upwardly turned hook portion 138 of the S-shaped brackets 104 is configured to be detachably coupled to the longitudinal rods 128, 132 of the partial-width wire shelves 102, 103. It will be appreciated that the length of the vertical segment 136 of the S-shaped bracket 104 may be selected to achieve the desired spacing between the full-width wire shelf 101 and the partial-width wire shelves 102, 103 suspended from the full-width wire shelf 101.

While this invention has been described in detail with particular references to exemplary embodiments thereof, the exemplary embodiments described herein are not intended to be exhaustive or to limit the scope of the invention to the exact forms disclosed. Persons skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structures and methods of assembly and operation can be practiced without meaningfully departing from the principles, spirit, and scope of this invention, as set forth in the following claims. Although relative terms such as “outer,” “inner,” “upper,” “lower,” “below,” “above,” “vertical, “horizontal” and similar terms have been used herein to describe a spatial relationship of one element to another, it is understood that these terms are intended to encompass different orientations of the various elements and components of the device in addition to the orientation depicted in the figures.

As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.

As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

1. A system configured to convert a space between a first shelf panel and a second shelf panel on a storage rack into usable storage space, the storage rack comprising a first vertical support member and a second vertical support member, and wherein the storage rack has a width defined by the distance between the first vertical member and the second vertical member, the system comprising:

a full-width wire rack comprising (i) a plurality of longitudinal rods, (ii) at least one transverse rod interconnected with at least one of the plurality of longitudinal rod, and (iii) a downwardly turned prong configured to detachably engage a of keyhole-shaped opening in at least one of the first and second vertical support members to detachably connect the full-width wire rack to the storage rack; and

a partial-width wire rack suspended from the full-width wire rack by at least one S-shaped bracket.

2. The system of claim 1, further comprising a crossbeam boltlessly coupled to the first vertical support member and a second vertical support member.

3. The system of claim 2, wherein the crossbeam has a generally omega-shaped transverse cross-section.

4. The system of claim 1, wherein the full-width wire rack is repositionable along the first and second vertical supports.

5. The system of claim 1, wherein the partial-width wire rack has a first end and a second end, and wherein the first end is suspended from the full-width wire rack by at least one S-shaped bracket, and the second end of the partial-width wire rack is detachably connected to at least one of the first and second vertical support members of the storage rack.

6. The system of claim 5, wherein the partial-width wire rack has at least one downwardly turned prong configured to detachably engage a plurality of keyhole-shaped openings in at least one of the first and second vertical support members to detachably connect the partial-width rack to the storage rack.

7. The system of claim 1, wherein the S-shaped bracket comprises a vertical segment, a first end, and a second end, wherein the first end comprises a first downwardly turned hook portion and the second end comprises an upwardly turned hook portion.

8. The system of claim 7, wherein the downwardly turned hook portion is configured to be detachably coupled to at least one of the longitudinal rods on the full-width wire shelf.

9. The system of claim 7, wherein the upwardly turned hook portion is configured to be detachably coupled to the longitudinal rods of the partial-width wire shelf

10. The system of claim 7, wherein the downwardly turned hook portion and the upwardly turned hook portion are configured to face oppositely.

11. The system of claim 7, wherein the downwardly turned hook portion and the upwardly turned hook portion has a same dimension.

12. A system configured to convert a space between a first shelf panel and a second shelf panel on a storage rack into usable storage space, wherein the storage rack comprises: the system comprising:

(a) first and second vertical support members each having a plurality of key-hole shaped openings;

(b) a first wire rack having (i) a plurality of longitudinal rods, (ii) at least one transverse rod interconnected with at least some of the plurality of longitudinal rods, and (iii) at least one downwardly turned prong configured to detachably engage at least one of the plurality of keyhole-shaped openings in the vertical support member to detachably connect the wire rack to the storage rack; and

(c) a width defined by the distance between the first and second vertical support members,

a second wire rack having a plurality of interconnected longitudinal rods and transverse rods and at least one downwardly turned prong; and at least one S-shaped bracket having a first S-shaped end and a second S-shaped end, sized and dimensioned to hook at least one of the longitudinal rods and transverse rods.

13. The system of claim 13, wherein the first wire rack is a full-width wire rack

14. The system of claim 13, wherein the second wire rack is a partial-width wire rack.