Modular Storage Assemblies and Components Thereof

Abstract

A pole cup for a hang rod may include a wall-mountable member, and a cradle extending from the wall-mountable member. The cradle may include a substantially u-shaped sidewall defining a cavity for securely receiving an end of the hang rod such that the hang rod is retained in a downward first direction, in a lateral second direction, and in a lateral third direction opposed to the second direction, when the hang rod is positioned within the cavity. A pair of ribs extend from a cavity-facing surface of the substantially u-shaped sidewall. A modular storage assembly may include a hang rod and a pole cup. A method of installing a modular storage assembly may include mounting to a wall at least one bracket configured to support a shelf, installing trim for the shelf, and mounting a pole cup to a wall via the wall-mountable member.

Description

FIELD OF THE DISCLOSURE

This disclosure generally relates to modular storage assemblies, such as modular closet assemblies, and specifically relates to components of modular storage assemblies, such as pole cups.

BACKGROUND

Modular storage systems are known that provide for flexible and efficient storage of items in residential, workplace, and industrial settings. For example, such storage systems may optionally include a combination of shelves, drawers, hang rods, and other components to provide various storage options for goods such as clothes, accessories, shoes, linens, containers, and the like. Different sizes and shapes of shelves and drawers, different attachment and mounting mechanisms, and different storage components (e.g., wire baskets, shoe-stands, tie/belt racks, hang rods) may be configured in various combinations to provide a customizable storage assembly for any storage area (e.g., closet, shed, pantry, utility room, locker).

Often, consumers install the components of a customizable storage assembly themselves and therefore ease and simplicity of installation, modification, and removal is critical. Thus, modular storage assemblies and components that facilitate easy installation, modification, and removal are desirable.

SUMMARY

Pole cups, modular storage assemblies including pole cups, and methods of installing modular storage assemblies are described.

In embodiments, a pole cup for a hang rod includes a wall-mountable member, and a cradle extending from the wall-mountable member. The cradle may include a substantially u-shaped sidewall defining a cavity for securely receiving an end of the hang rod such that the hang rod is retained in a downward first direction, in a lateral second direction, and in a lateral third direction opposed to the second direction, when the hang rod is positioned within the cavity. A pair of ribs may extend from a cavity-facing surface of the substantially u-shaped sidewall. The pair of ribs may be configured to retain the hang rod in an upward fourth direction opposed to the first direction, when the hang rod is positioned within the cavity. The ribs may be sized and shaped to allow for the end of the hang rod to be snap fit into the cavity.

In embodiments, a modular storage assembly may include a hang rod and a pole cup.

In embodiments, a modular storage assembly may include a shelf, a wall-mounted bracket configured to support the shelf, a trim in communication with an end of the shelf, and a pole cup of claim 1. The trim may include a visual indication of an installation position for the pole cup.

In embodiments, a method of installing a modular storage assembly includes mounting to a wall at least one bracket configured to support a shelf, installing trim for the shelf, and mounting a pole cup to a wall via the wall-mountable member. The pole cup is mountable subsequent to installation of the trim.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar to identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale.

FIG. 1 is a perspective view of one embodiment of a modular storage assembly, as described herein.

FIG. 2A is a perspective view of one embodiment of a pole cup for a modular storage assembly, as described herein.

FIG. 2B is a front view of the pole cup of FIG. 2A.

FIG. 2C is a rear view of the pole cup of FIG. 2A.

FIG. 2D is a side view of the pole cup of FIG. 2A.

FIG. 2E is an upper view of the pole cup of FIG. 2A.

FIG. 3A is a perspective view of one embodiment of a pole cup for a modular storage assembly, as described herein.

FIG. 3B is a front view of the pole cup of FIG. 3A.

FIG. 3C is a cross-sectional view of the pole cup of FIG. 3A.

FIG. 3D is a side view of the pole cup of FIG. 3A.

FIG. 3E is a rear view of the pole cup of FIG. 3A.

DETAILED DESCRIPTION

The present disclosure includes non-limiting embodiments of modular storage assemblies, components thereof, and methods for installing such assemblies and components. The embodiments are described in detail herein to enable one of ordinary skill in the art to practice the modular assembles, components and associated methods of making, although it is to be understood that other embodiments may be utilized and that logical changes may be made without departing from the scope of the disclosure. Throughout the disclosure, depending on the context, singular and plural terminology may be used interchangeably.

Modular storage assemblies and systems (terms used interchangeably herein), and components thereof, are described herein. In particular, a pole cup for securely retaining a hang rod within a modular storage assembly has been developed. Methods of installing such assemblies are also described. These storage assemblies may be any suitable configuration of components for storing items in residential, workplace, and industrial settings (e.g., in closets, sheds, utility rooms, pantries, and lockers). For example, the storage assemblies may include combinations of shelves, drawers, hang rods, attachment and mounting mechanisms, and storage components (e.g., shoe-stands, tie/belt racks). A user may design a particular storage assembly utilizing any suitable combination of components or a kit of components may be provided that includes the components for a pre-designed assembly. Beneficially, such storage assemblies and components may be combined in various operable configurations, to suit the desired storage needs and available space for the installation. Because these systems may be installed without the help of professional installers, ease of installation, removal, and reconfiguration or modification of the components is important.

One embodiment of such a modular storage assembly is shown in FIG. 1. Here, the assembly 100 includes a pole cup 200 for securely receiving and retaining one end of a hang rod 300. Additionally, the assembly 100 includes a wall bracket 400, which supports a shelf 500, with the shelf having a trim 600. This particular assembly configuration is used for exemplary purposes only, and it should be understood that any configuration of modular storage assembly and components is intended to be encompassed by the disclosure.

Various embodiments of pole cups, storage assemblies, and methods of installing the assemblies are described below.

Pole Cups

In certain embodiments, a pole cup for a hang rod is provided. The pole cup may be effective at securing an end of the hang rod at a wall or similar structure. In certain embodiments, a pair of pole cups is used to secure the opposed ends of a hang rod. FIG. 1 illustrates a pole cup 200 mounted on a wall and securing an end of hang rod 300. In other embodiments, one end of the hang rod is secured in the pole cup while the other end is secured by another component of the modular assembly, such as by a pole cup type structure positioned within the assembly (e.g., on a wall-mounted bracket or other component disposed at an intermediate position along the length of the assembly).

In one aspect, a pole cup for a hang rod includes a wall-mountable member, and a cradle extending from the wall-mountable member, the cradle having a substantially u-shaped sidewall defining a cavity for securely receiving an end of the hang rod such that the hang rod is retained in a downward first direction, in a lateral second direction, and in a lateral third direction opposed to the second direction, when the hang rod is positioned within the cavity, wherein a pair of ribs extend from a cavity-facing surface of the substantially u-shaped sidewall, the pair of ribs being configured to retain the hang rod in an upward fourth direction opposed to the first direction, when the hang rod is positioned within the cavity, and wherein the ribs are sized and shaped to allow for the end of the hang rod to be tightly fit (e.g., snap, friction, or interference fit) into the cavity.

Various embodiments of such pole cups are illustrated in FIGS. 2 and 3. As shown in FIG. 2A, pole cup 200 includes a wall-mountable member 202 and a cradle 204 extending from the wall-mountable member 202. The wall-mountable member 202 may have any suitable configuration, size, and shape that is effective to allow for secure mounting of the pole cup 200 to a wall or similar structure with sufficient structural integrity to support a hang rod and contents stored thereon (e.g., hanging clothes). For example, the pole cup and hang rod may be configured to support 25 pounds or more, such as 40 pounds or more, 50 pounds or more, 75 pounds or more, 100 pounds or more, 150 pounds or more, or 200 pounds or more, depending on the length and material of construction of the hang rod and the design of the pole cup.

For example, the wall-mountable member 202 may be generally planar in overall shape, with one or more apertures 212 therethrough for receiving a fastener for wall-mounting. As shown in FIG. 2A, in certain embodiments, the wall-mountable member 202 has two or more apertures 212 therethrough. For example, the apertures 212 may be configured to accommodate mechanical fasteners (e.g., screws, nails) to mount the pole cup 200 to a wall. As shown in FIG. 2C, the wall-mountable member 202 may include reinforcing ribs 213 to provide increased structural support on a rear surface of the member 202. Additionally, the front surface of the member 202 may include a tapered or blunt edge.

As shown in FIG. 2A, the pole cup 200 also includes a cradle 204 extending from the wall-mountable member 202. The cradle 204 is configured to receive an end of a hang rod and secure the end therein. In certain embodiments, as shown in FIG. 2A, the cradle 204 includes a substantially u-shaped sidewall 206 that defines a cavity 208 in which the end of the hang rod is securely received. As used herein, the phrase “u-shaped sidewall” is used to refer to a single wall or a series of walls that extend from a front surface of the wall-mountable member a suitable length to retain an end of the hand rod therein during regular use (e.g., about 0.5 inch, about 0.75 inch, about 1 inch). In some embodiments, as shown in FIG. 2A, the u-shaped sidewall 206 has a variable depth, with each end of the sidewall 206 having a tapered profile. As used herein, the term “about” is used to encompass a range of ±5 percent of the numerical value it is used to define.

For example, the u-shaped sidewall may have an inner surface (i.e., cavity-facing surface) that is substantially u-shaped, while the opposed outer surface may have any suitable shape (e.g., may also be u-shaped as illustrated in the Figures, or may be rectangular, ridged, or otherwise shaped). As shown in FIG. 2B, the u-shaped sidewall 206 is configured such that a hang rod installed therein is retained in a downward first direction A, in a lateral second direction B, and in a lateral third direction C opposed to the second direction B, when the hang rod is positioned within the cavity.

In certain embodiments, as shown in FIGS. 2A and 2B, the cradle 204 includes a pair of ribs 210 extending from the inner surface of the substantially u-shaped sidewall 206. The ribs 210 are configured to retain the hang rod in an upward fourth direction D opposed to the first direction A, when the hang rod is positioned within the cavity. That is, the ribs may be configured to retain the hang rod in the cavity under regular use conditions (e.g., absent an atypical upward force on the hang rod). The directions A, B, C, D, as illustrated in FIG. 2B, are referred to herein as downward, lateral, and upward directions for ease of illustration. Such directions are relevant to the pole cup installed in a regular position (i.e., with the opening to the cavity facing upward); however, it should be understood that alternative installation configurations and alternative configurations of the sidewall are possible to achieve the desired hang rod retention.

The ribs 210 are sized and shaped to allow for the end of the hang rod to be snap fit into the cavity 208. For example, the ribs 210 may be formed in any suitable shape, such as an elongated, substantially linear shape, as shown in the FIGS. For example, the ribs may have a curved, blunt, pointed, or tapered surface profile. The ribs 210 may extend from the inner surface of the sidewall 206 along at least a portion of the depth, or length, thereof. For example, the ribs 210 may extend longitudinally across at least 50 percent of the depth, at least 75 percent of the depth, at least 95 percent of the depth, or at least 99 percent of the depth of the sidewall 206. Generally, the ribs 210 extend along the sidewall 206 in a direction substantially perpendicular to the plane of the wall-mountable member 202.

In some embodiments, as shown in FIG. 2, the u-shaped sidewall 206 is formed by an upper portion and a lower portion, which are divided by the ribs 210. For example, the inner-surface of the lower portion is semi-circular, and configured to retain snugly the end of a round hang rod therein. That is, the semi-circular lower portion may have a radius that is essentially the same as the radius of the outer surface of the hang rod. For example, the upper portion of the sidewall 206 may include substantially linear wall portions extending upwardly from the ends of the semi-circular lower portion. These substantially linear wall portions may be angled slightly outward to provide a funnel opening in which a user can more easily introduce the end of the hang rod into the cavity. These substantially linear wall portions may have the same depth as the lower portion, or may have a decreasing depth from the edge of the lower portion. That is, as shown in FIG. 2D, the depth of the sidewall 206 may decrease along the upper portion. In certain embodiments, as shown in FIG. 2B, the surface profile of the ribs 210 may be continuous with the surface of the semi-circular lower portion of the sidewall 206, such that the surface of the ribs 210 continues the arc of the semi-circular portion.

In certain embodiments, the cavity-facing inner surface of the substantially u-shaped sidewall 206 is substantially smooth other than the pair of ribs 210. That is, the pair of ribs 210 may be the sole surface feature disposed on the otherwise smooth inner surface of the sidewall 206. In certain embodiments, the substantially u-shaped sidewall 206 does not contain any aperture extending therethrough. That is, the pole cup does not require any mechanical fastener to retain the hang rod in the cavity. Instead, the pole cup retains the hang rod in the cavity in the absence of any additional hardware or fastener connecting the hang rod to the pole cup. Beneficially, this design requires no hardware or modifications to a hang rod (e.g., an aperture for receiving a fastener) to install the hang rod in the pole cup, while achieving an effective snap fit that retains the hang rod in the cavity in all directions. Moreover, a hang rod can be installed in the presently described pole cups in any orientation, without the need for rotating the rod to align with a fastener mechanism.

The pole cup may be formed of suitable materials such as metals, metal alloys, and plastics. For example, the pole cup may be formed of an aluminum alloy.

One embodiment of a pole cup 250 is illustrated in FIGS. 3A-3E, with dimensions provided in inches [mm]. This pole cup may have the features described above with reference to FIG. 2.

Modular Assemblies

Modular storage assemblies are also provided herein. As described above, these assemblies generally may include any combination of components as desired for the particular storage capacity of the assembly and as appropriate for the floorplan and volume of the storage area.

In certain embodiments, a modular storage assembly includes a pole cup and a hang rod. For example, the pole cup may be any suitable embodiment of pole cup described herein. The hang rod may be any suitable dimensions and construction to be installed within the storage assembly and provide the desired storage capacity (e.g., for hanging clothes, shoe/tie/belt racks, other storage containers).

For example, the hang rod may have a round cross-sectional shape with a suitable diameter to allow an end of the hang rod to be positioned within the cavity of the pole cup. In certain embodiments, the hang rod has a diameter of from about 0.5 inches to about 2 inches. For example, the diameter of the hang rod may be about 1 inch, about 1.25 inches, about 1.5 inches, or about 1.75 inches. In certain embodiments, the cavity has a diameter measured across the substantially u-shaped sidewall that is about the diameter of the hang rod, to accommodate the hang rod snugly therein. In certain embodiments, the hang rod has a length of from about 1 foot to about 12 feet. For example, the length of the hang rod may be from about 2 to about 10 feet, such as about 3 feet, about 4 feet, about 5 feet, about 6 feet, about 8 feet, about 10 feet, or any length therebetween.

As discussed above with reference, in certain embodiments the wall-mountable member has at least one aperture extending therethrough. In such embodiments, the assembly includes at least one fastener configured to be positioned in the aperture to mount the pole cup to a wall. For example, the at least one fastener may be a screw or nail.

In certain embodiments, as shown in FIG. 1, a modular storage assembly 100 includes one or more of the following components: a shelf 500, at least one wall-mounted bracket 400 configured to support the shelf 500, a trim 600 in communication with an end of the shelf 500, a pole cup 200, and a hang rod 300.

Any suitable types of these components may be employed in the assembly. For example, the shelf 500 may be any suitable plank or other style shelf. The wall-mounted bracket 400 may be any suitable L-bracket, reinforced L-bracket, or other bracket type that is configured for secure mounting to a wall or similar structure. The wall-mounted bracket(s) 400 should be suitable to support a shelf, as well as the goods to be stored thereon.

The trim 600 may be a decorative component, similar to a baseboard or crown molding, which is positioned at the end of a shelf 500 and trims the edges of the shelf 500. In certain embodiments, the assembly 100 is configured such that the pole cup 200 is installed adjacent or near the trim 600. In such embodiments, the trim 600 may include a visual indication of an installation position for the pole cup. That is, the visual indication on the trim 600 may show a user the preferred installation position of the pole cup. For example, the visual indication may be an indentation, a bump or other raised feature, or simply a marking on the surface of the trim. In some embodiments, the visual indication is a molded indentation in the trim 600.

Methods of Installation

Methods of installing the modular storage assemblies and components described herein are also provided. The methods may include installing any embodiments of the assemblies and components that have been described herein.

In certain embodiments, a method of installing a modular storage assembly includes mounting to a wall at least one bracket configured to support a shelf, installing trim for the shelf, and mounting a pole cup to a wall via the wall-mountable member, wherein the pole cup is mountable subsequent to installation of the trim. As described above, the bracket may have any suitable bracket design, and may be configured to be mounted to a wall via one or more suitable fasteners (e.g., screws, nails). The trim may be installed separately from or in conjunction with installation of the shelf on the bracket. Beneficially, the pole cup may be installed prior to or after installation of the bracket, trim and/or shelf. In particular, the pole cup may be mounted to a wall, via the wall-mountable member, after installation of the shelf and/or trim. In certain embodiments, the method further includes installing a hang rod by positioning an end of the hang rod in the cradle of the pole cup and securing it therein. The second end of the hang rod may be positioned in a second opposed pole cup or in another suitable cradle of the assembly, as discussed above.

This configuration provides a benefit of flexibility of installation, such that the pole cup and hang rod can be installed separate from and after installation of the shelf, which allows users to later modify their assembly to include a hang rod, without requiring removal of some or all of the shelf, trim, and bracket, to accommodate installation of the pole cup. In known storage assemblies, the pole cup and other components are often configured such that the pole cup must be installed prior to the installation of the brackets, shelf, or trim, and therefore said additional components must be disassembled to accommodate any later addition of a hang rod to the assembly.

In certain embodiments, as discussed above, the trim may be installed prior to installation of the pole cup and may include a visual indication of an installation position for the pole cup thereon, to facilitate proper placement and installation of the pole cup by the user.

As can be seen in FIG. 1, in a typical assembly 100 configuration, the pole cup 200 may be mounted to a wall that is substantially perpendicular to the wall on which the bracket 400 is mounted.

Beneficially, the pole cup design described herein provides for flexible installation of the pole cup throughout the assembly installation process, and allows for secure installation and retention of a hang rod therein, via the u-shaped design and ribs. In contrast to known pole cups, the present design does not require additional hardware or a particular orientation of the hang rod for securement within the pole cup. Additionally, the open cavity design of the u-shaped sidewall allows for easy introduction and removal of an end of the hang rod into the cavity, which feature full circular pole cup designs lack.

While the disclosure has been described with reference to a number of embodiments, it will be understood by those skilled in the art that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not described herein, but which are commensurate with the spirit and scope of the disclosure. Conditional language used herein, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, generally is intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements or functional capabilities. Additionally, while various embodiments of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims

1. A pole cup for a hang rod, comprising:

a wall-mountable member; and

a cradle extending from the wall-mountable member, the cradle comprising a substantially u-shaped sidewall defining a cavity for securely receiving an end of the hang rod such that the hang rod is retained in a downward first direction, in a lateral second direction, and in a lateral third direction opposed to the second direction, when the hang rod is positioned within the cavity,

wherein a pair of ribs extend from a cavity-facing surface of the substantially u-shaped sidewall, the pair of ribs being configured to retain the hang rod in an upward fourth direction opposed to the first direction, when the hang rod is positioned within the cavity, and wherein the ribs are sized and shaped to allow for the end of the hang rod to be snap fit into the cavity.

2. The pole cup of claim 1, wherein the wall-mountable member is substantially planar.

3. The pole cup of claim 1, wherein the wall-mountable member comprises at least one aperture extending therethrough for accommodating a fastener to mount the pole cup to a wall.

4. The pole cup of claim 1, wherein the cavity-facing surface of the substantially u-shaped sidewall is substantially smooth other than the pair of ribs.

5. The pole cup of claim 1, wherein the substantially u-shaped sidewall does not contain any aperture extending therethrough.

6. The pole cup of claim 1, wherein the pole cup is formed of aluminum.

7. A modular storage assembly, comprising:

a hang rod; and

the pole cup of claim 1.

8. The modular storage assembly of claim 7, wherein:

the hang rod has a cross-sectional diameter, and

the cavity has a diameter measured across the substantially u-shaped sidewall, the diameter of the cavity being substantially equal to the diameter of the hang rod.

9. The modular storage assembly of claim 8, wherein the diameter of the hang rod is 1 inch, 1.25 inches, 1.5 inches, or 1.75 inches.

10. The modular storage assembly of claim 7, wherein:

the wall-mountable member comprises at least one aperture extending therethrough, and

the assembly further comprises at least one fastener configured to be positioned in the aperture to mount the pole cup to a wall.

11. The modular storage assembly of claim 10, wherein the at least one fastener is a screw or nail.

12. A modular storage assembly, comprising:

a shelf;

a wall-mounted bracket configured to support the shelf;

a trim in communication with an end of the shelf; and

the pole cup of claim 1,

wherein the trim comprises a visual indication of an installation position for the pole cup.

13. The modular storage assembly of claim 12, wherein the visual indication is molded in the trim.

14. A method of installing a modular storage assembly, comprising:

mounting to a wall at least one bracket configured to support a shelf;

installing trim for the shelf; and

mounting the pole cup of claim 1 to a wall via the wall-mountable member,

wherein the pole cup is mountable subsequent to installation of the trim.

15. The method of claim 14, wherein the trim comprises a visual indication of an installation position for the pole cup.

16. The method of claim 15, wherein the visual indication is molded in the trim.

17. The method of claim 14, further comprising installing a shelf on the at least one bracket and in communication with the trim.

18. The method of claim 14, further comprising installing a hang rod by positioning an end of the hang rod in the cradle.