BARREL RACK SYSTEM

Description

BACKGROUND

People have been storing liquids and non-liquid items in barrels for thousands of years. Today, barrels are used in large numbers in wineries, breweries, and distilleries. Storing these barrels requires a large space that both stores the barrels and provides personnel with access to the barrels. Often, this requires the barrels to be stacked vertically to take advantage of storage facilities with high ceilings. Existing racks are rigid and do not offer the end user the ability to customize the rack structures to fit an existing storage space. Furthermore, existing racks have failed under earthquake conditions, resulting in destroyed barrels, ruined product, and lost revenues. Thus, a need exists for a barrel rack that is modular, safe, and effective for the storage of barrels that can be customized to fit an existing space.

BRIEF SUMMARY

The invention may be directed to a barrel rack system that may be modular and customizable to fit an existing storage space. The barrel rack system may include first and second rack units, each defining a hexagonal storage cell that is configured to hold and store a barrel. The first and second rack units may be coupled together so that the hexagonal storage cells thereof are adjacent and parallel to one another. The first and second rack units, when coupled together, may collectively define an elevated storage cell that is capable of holding/storing yet another barrel. Additional rack units may be coupled to the first and second rack units horizontally and/or vertically to effectively conform the barrel rack system to the existing storage space.

In one aspect, the invention may be a barrel rack system comprising: at least one first rack unit and at least one second rack unit, each of the first and second rack units comprising: a first hexagonal frame and a second hexagonal frame, each of the first and second hexagonal frames comprising an inner surface that defines an opening, an outer surface opposite the inner surface, a front surface, a rear surface, a first lower side, a second lower side, a first upper side, and a second upper side; and a plurality of struts, each of the struts connected to and extending between the rear surfaces of the first and second hexagonal frames to maintain the first and second hexagonal frames in a spaced relation to define a storage cell between the opening of the first hexagonal frame and the opening of the second hexagonal frame; the first and second rack units being detachably coupled together so that the storage cells of the first and second rack units are adjacent to one another, and wherein an elevated storage cell is defined by the second upper side of each of the first and second hexagonal frames of the first rack unit and the first upper side of each of the first and second hexagonal frames of the second rack unit; at least one wheel coupled to at least: each of the first and second lower sides of each of the first and second hexagonal frames of each of the first and second rack units; the second upper side of each of the first and second hexagonal frames of the first rack unit; and the first upper side of each of the first and second hexagonal frames of the second rack unit; and wherein the wheels on the first and second lower sides protrude from the inner surface of the first and second hexagonal frames and the wheels on the first and second upper sides protrude from the outer surfaces of the first and second hexagonal frames so that barrels located in the storage cells and on the elevated storage cell are rotatably supported by the wheels.

In another aspect, the invention may be a barrel rack system comprising: a first rack unit and a second rack unit, each of the first and second rack units comprising: a first hexagonal frame and a second hexagonal frame, each of the first and second hexagonal frames comprising an inner surface that defines an opening and an outer surface opposite the inner surface; and a plurality of struts, each of the struts connected to and extending between the first and second hexagonal frames to form a storage cell having a cell axis, each of the storage cells configured to hold a barrel; the first and second hexagonal frames of the first rack unit coupled to the first and second hexagonal frames of the second rack unit, respectively, so that the cell axes of the storage cells of the first and second rack units are parallel to one another, and wherein an elevated storage cell is defined by portions of the outer surfaces of the first and second hexagonal frames of the first and second rack units, the elevated storage cell configured to hold another barrel; and a base component configured to be positioned on a floor surface, wherein the first and second rack units are positioned on and supported by the base component.

In yet another aspect, the invention may be a metal sheet configured to form at least a portion of a hexagonal frame of a modular barrel rack, the metal sheet comprising: a top surface, a bottom surface, and a longitudinal axis; a plurality of plate segments and a plurality of hinge portions, the plurality of hinge portions located between each pair of adjacent ones of the plurality of plate segments; the plurality of plate segments including at least a first plate segment and a second plate segment, the first and second plate segments comprising a hole that extends from the top surface of the metal sheet to the bottom surface of the metal sheet, wherein the hole is configured to receive a wheel; and wherein the plurality of plate segments are configured to be bent relative to one another at the plurality of hinge portions to form the at least a portion of the hexagonal frame from the metal sheet.

In a further aspect, the invention may be a barrel rack system comprising: a first rack unit defining a first hexagonal storage cell having a first cell axis, the first hexagonal storage cell being configured to store a first barrel; a second rack unit defining a second hexagonal storage cell having a second cell axis, the second hexagonal storage cell being configured to store a second barrel, the second rack unit being detachably coupled to the first rack unit so that the first and second cell axes are parallel; wherein upper portions of the first and second rack units collectively define an elevated storage cell having a third axis that is parallel to the first and second cell axes, the elevated storage cell being configured to store a third barrel.

In yet another aspect, the invention may be a method of manufacturing a barrel rack, the method comprising: forming a first hexagonal frame and a second hexagonal frame; attaching the first hexagonal frame to the second hexagonal frame with a first plurality of struts to form a first rack unit comprising a first storage cell having a first cell axis; forming a third hexagonal frame and a fourth hexagonal frame; attaching the third hexagonal frame to the fourth hexagonal frame with a second plurality of struts to form a second rack unit comprising a second storage cell having a second cell axis; and detachably coupling the second rack unit to the first rack unit so that the first and second cell axes are parallel to one another and upper portions of the first and second rack units define an elevated storage cell.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1A is a perspective view of a barrel rack system in accordance with an embodiment of the present invention;

FIG. 1B is a perspective view of the barrel rack system of FIG. 1A with a base component thereof omitted;

FIG. 2 is a front view of the barrel rack system of FIG. 1A, with the base component thereof omitted;

FIG. 3 is a front view of a metal sheet that is used to form a hexagonal frame of the barrel rack system of FIG. 1;

FIG. 3A is a front view of a pair of metal sheets that may be used to form the hexagonal frame of the barrel rack system of FIG. 1 in accordance with an alternative embodiment of the present invention;

FIG. 3B is a front view of a metal sheet that may be used to form the hexagonal frame of the barrel rack system of FIG. 1 in accordance with another alternative embodiment of the present invention;

FIGS. 4A-4F illustrate the process of bending and folding the metal sheet of FIG. 3 into the hexagonal frame;

FIG. 5 is a perspective view of the hexagonal frame formed by bending and folding the metal sheet as shown in FIGS. 4A-4F;

FIG. 6 is a perspective view of two rack units of the barrel rack system of FIG. 1 in a detached state;

FIG. 7 is a perspective view of the two rack units of FIG. 6 in an attached state;

FIG. 8A is a perspective view of a base component of the barrel rack system of FIG. 1;

FIG. 8B is a front view of the base component of FIG. 8A;

FIG. 9A is a perspective view of a base component in accordance with an alternative embodiment;

FIG. 9B is a front view of the base component of FIG. 9A;

FIG. 10 is a perspective view of a barrel rack system formed by attaching two of the barrel rack systems of FIG. 1 together;

FIG. 11 is a perspective view of a barrel rack system formed by attaching additional rack units to the barrel rack system of FIG. 10;

FIG. 11A is a close-up view of a wheel of the barrel rack system illustrating a locking mechanism in an unlocked state;

FIG. 12B is a cross-sectional view taken along line XIIB-XIIB of FIG. 12A;

FIG. 13A is a close-up view of the wheel of the barrel rack system illustrating the locking mechanism in a locked state;

FIG. 13B is a cross-sectional view taken along line XIIIB-XIIIB of FIG. 13A;

FIG. 14 is a top perspective view of a barrel rack system in accordance with another embodiment of the present invention;

FIG. 15 is a bottom perspective view of the barrel rack system of FIG. 14;

FIG. 16 is an exploded perspective view of the barrel rack system of FIG. 14;

FIG. 17A is an exploded perspective view of a hexagonal frame of the barrel rack system of FIG. 14;

FIG. 17B is an exploded front view of the hexagonal frame of FIG. 17A, with wheels coupled thereto;

FIG. 17C is an assembled front view of the hexagonal frame of FIG. 17A;

FIG. 18 is a perspective view of a manufactured part used to form the hexagonal frame of the barrel rack system of FIG. 14;

FIGS. 19A and 19B are perspective and side views of another component of the hexagonal frame of the barrel rack system of FIG. 14;

FIGS. 20A-20B illustrate the process of attaching the various components of the hexagonal frame to form the hexagonal frame;

FIGS. 20C-20D illustrate the process of attaching rack units that include the hexagonal frames of FIGS. 17A-17C together to form the barrel rack system of FIG. 14;

FIGS. 20E and 20F illustrate attaching the rack units of FIGS. 20C-20D to a base component;

FIG. 21 is a front view of the barrel rack system of FIG. 14;

FIGS. 22A and 22B illustrate the barrel rack system of FIG. 14 supporting barrels; and

FIGS. 23-25 illustrate additional configurations of a barrel rack system using the components of FIGS. 14-22B.

DETAILED DESCRIPTION

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

Referring to FIGS. 1A, 1B, and 2, a barrel rack system 1000 is illustrated in accordance with an embodiment of the present invention. In the exemplified embodiment, the barrel rack system 1000 comprises a first rack unit 100 and a second rack unit 200 that are detachably coupled together. The first and second rack units 100, 200 are non-integral with one another and are configured to be detachably coupled together with fasteners. As used herein, fasteners may include screws, nails, nuts, bolts, rivets, and the like. Specifically, the fasteners are items used to form a non-permanent joint or coupling between the first and second rack units 100, 200. The barrel rack system 1000 may also comprise a base component 500. The base component 500 is shown in FIG. 1A, but is omitted in FIGS. 1B and 2 for clarity. The first and second rack units 100, 200 may be positioned atop of the base component 500 and coupled thereto. The base component 500 may comprise wheels or casters so that the barrel rack system 1000 can be easily moved and relocated as needed. Alternatively, the base component 500 may have fixed fit which may be desirable in certain circumstances, discussed further below. The barrel rack system 1000 may be a modular system that can take on many different configurations, depending on the number of rack units that are coupled together. Thus, the barrel rack system 1000 may be customized to fit within an existing storage space, such as a warehouse, garage, or the like. That is, additional rack units may be coupled to the first and second rack units 100, 200 horizontally and/or vertically to maximize the number of barrels that can be stored in a particular space.

The first and second rack units 100, 200 may be identical to one another. Thus, while the description set forth herein may describe the first rack unit 100 in detail, it should be appreciated that the entire description of the first rack unit 100 is applicable to the second rack unit 100. The second rack unit 200 may not be described in detail in the interest of brevity, it being understood that the description of the first rack unit 100 is applicable. Features of the second rack unit 200 may be labeled in the same manner as the described feature of the first rack unit 100, except that the 200-series of numbers will be used for the features of the second rack unit 200 whereas the 100-series of numbers are used for the features of the first rack unit 100. Thus, the drawings may include numerals in the 200-series that are not explicitly used in the specification. For these numerals, it should be appreciated that the description of the feature with the same numeral in the 200-series is applicable.

The first rack unit 100 may comprise a first hexagonal frame 110, a second hexagonal frame 150, and a plurality of struts 190. The first and second hexagonal frames 110, 150 may be structurally identical to one another. The first and second hexagonal frames 110, 120 may be distinct from one another, and each may separately form an enclosed hexagon shaped frame. Thus, the first and second hexagonal walls 110, 120 do not share a common wall or boundary, but instead are both hexagon shaped frames independently of the other and even when not attached together. The first and second hexagon frames 110, 120 may be closed hexagonal shaped structures.

The first hexagonal frame 110 may comprise a first lower side 111, a second lower side 112, a first upper side 113, a second upper side 114, a first lateral side 115 that extends between the first lower side 111 and the first upper side 113, and a second lateral side 116 that extends between the second lower side 112 and the second upper side 114. Similarly, the second hexagonal frame 110 may comprise a first lower side 151, a second lower side 152, a first upper side 153, a second upper side 154, a first lateral side 155 that extends between the first lower side 151 and the first upper side 153, and a second lateral side 156 that extends between the second lower side 152 and the second upper side 154. Thus, each of the first and second hexagonal frames 110, 150 may have a hexagonal shape which includes six sides 111-116, 151-156 and six vertices or apexes defined at the intersection of each pair of adjacent sides. The first and second lower sides 111, 112 may intersect to form a first V-shape having a first apex 128. The first and second upper sides 113, 114 may intersect to form a second V-shape having a second apex 129. The first apex 128 may face downwardly and form a lowermost part of the first horizontal frame 110. The second apex 129 may face upwardly and form an uppermost part of the first horizontal frame 110. Moreover, while the above is described with reference to the first horizontal frame 110, the same may also be applicable to the second horizontal frame 150.

Each of the sides 111-116, 151-156 may be linear to form the hexagon shape of the hexagonal frames 110, 150. Each of the sides 111-116, 151-156 may have an outer surface that is flat and planar. The first and second hexagonal frames 110, 150 may define a hexagonal shape both along the exterior of the first and second hexagonal frames 110, 150 and along the interior of the first and second hexagonal frames 110, 150.

The first hexagonal frame 110 may comprise an inner surface 117, an outer surface 118 that is opposite the inner surface 117, a front surface 119, and a rear surface 120. The inner surface 117 may define and surround an opening 121. The first hexagonal frame 110 may be a closed geometric part having a hexagonal shape. The second hexagonal frame 150 may comprise an inner surface 157, an outer surface 158 that is opposite the inner surface 157, a front surface 159, and a rear surface 160. The inner surface 157 may define and surround an opening 161. The second hexagonal frame 150 may be a closed geometric part having a hexagonal shape.

There may be wheels coupled to each of the first and second hexagonal frames 110, 150 at specific locations to so that barrels held in the first and second rack units 100, 200 may be supported on the wheels. This allows the barrels to be rotated about their longitudinal axes which may be beneficial for performance of winemaking tasks or other tasks associated with the item stored in the barrel. For each of the first and second hexagonal frames 100, 200, a first wheel 11 is coupled to the first lower side 111, 151, a second wheel 12 is coupled to the second lower side 112, 152, a third wheel 13 is coupled to the first upper side 113, 153, and a fourth wheel 14 is coupled to the fourth upper side 114, 154. Each of the wheels 11-14 may be disposed within a hole that extends from the inner surface 117 of the hexagonal frame 110 to the outer surface 118 of the hexagonal frame 110 along the side on which the wheel 11-14 is located. Each of the wheels 11-14 may be coupled to the side 111-114 on which it is located at a central location along that side. In other embodiments, the wheels 11-14 may be located at a position that is offset from a central position along the side to which it is coupled. The first and second wheels 11, 12 may protrude from the inner surface 117m 157 of the first and second hexagonal frames 110, 150. The third and fourth wheels 13, 14, may protrude from the outer surface 118 of the first and second hexagonal frames 110, 150. This ensures that the barrels are supported by the wheels 11-14 when positioned at desired locations on the barrel rack system 1000, as described further below. The wheels 11-14 are coupled to the sides 111-114, 151-154 so that the wheels 11-14 are capable of rotation about a rotational axis that is parallel to a length of a barrel held by the first rack unit 100. This allows the barrel to be rotated when supported by the wheels 11-14. The wheels 11-14 may be freely rotatable in some embodiments. In other embodiments, there may be a locking mechanism associated with one or more of the wheels to lock the particular wheel and prevent its rotation. Details related to such a locking mechanism will be provided below with reference to FIGS. 13A-14B.

The first hexagonal frame 110 may be coupled to the second hexagonal frame 150 by the plurality of struts 190. The combination of the assembly which includes the first and second hexagonal frames 110, 150 that are coupled together via the struts 190 forms the first rack unit 100. The plurality of struts 190 may have a first end portion 191 that is coupled to the rear surface 120 of the first hexagonal frame 110 and a second end portion 192 that is coupled to the rear surface 150 of the second hexagonal frame 110. In an embodiment, the plurality of struts 190 may be welded to the first and second hexagonal frames 110, 150. In other embodiments, the plurality of struts 190 may be coupled to the first and second hexagonal frames 110, 150 with fasteners, such as screws, bolts, rivets, or the like. In still other embodiments, the plurality of struts 190 may be coupled to the first and second hexagonal frames 110, 150 using other techniques, including threaded screw engagement features, friction fit, male/female engagement, or the like. The plurality of struts 190 may be coupled to the first and second hexagonal frames 110, 150 at the apexes/vertices as shown, or elsewhere along the lengths of the various sides of the first and second hexagonal frames 110, 150. The plurality of struts 190 may extend between the first and second hexagonal frames 110, 150. The plurality of struts 190 may be elongated in a direction between the first and second hexagonal frames 110, 150. The plurality of struts 190 may maintain the first and second hexagonal frames 110, 150 spaced apart from one another so that a storage cell 50 is defined between the openings 121, 161 of the first and second hexagonal frames 110, 150. The storage cell 50 may be configured to hold a single barrel. Each of the rack units 100, 200 may define a distinct storage cell 50. Each of the storage cells 50 may comprise a cell axis A-A. Each of the storage cells 50 may have a length measured from the front surface 119 of the first hexagonal frame 110 to the front surface 159 of the second hexagonal frame 150 of between approximately 20 inches and 30 inches, more specifically between approximately 24 inches and 28 inches. Each of the storage cells 50 may have a width Wi of between approximately 25 inches and 35 inches, and more specifically between approximately 28 inches and 33 inches. Each of the storage cells 50 may be in the shape of a hexagonal cylinder.

The first and second rack units 100, 200 may be detachably coupled together to form the barrel rack system 1000. The first and second rack units 100, 200 may be detachably coupled together in a side-by-side configuration so that the storage cells 50 of the first and second rack units 100, 200 are adjacent to one another. When the first and second rack units 100, 200 are coupled together in the manner described, the cell axes A-A of the storage cells 50 of the first and second rack units 100, 200 may be parallel to one another. When the first and second rack units 100, 200 are coupled together, the second lateral side 116 of the first hexagonal frame 100 of the first rack unit 100 is adjacent to and perhaps in abutting contact with the first lateral side 215 of the first hexagonal frame 210 of the second rack unit while simultaneously the second lateral side 156 of the second hexagonal frame 150 of the first rack unit 100 is adjacent to and perhaps in abutting contact with the first lateral side 255 of the second hexagonal frame 250 of the second rack unit 200.

Fasteners 60 may be inserted through openings in the second lateral side 116 of the first hexagonal frame 110 of the first rack unit 100 and the first lateral side 215 of the first hexagonal frame 210 of the second rack unit 200 while fasteners 61 may be inserted through openings in the second lateral side 156 of the second hexagonal frame 150 of the first rack unit 100 and the first lateral side 255 of the second hexagonal frame 250 of the second rack unit 200. This may serve to detachably couple the first and second rack units 100, 200 together. By removing the fasteners 60, 61 (and any other fasteners being used to attach the first and second rack units 100, 200 together), the first and second rack units 100, 200 may be separated from one another. It should be readily appreciated that additional rack units may be coupled to the free sides of the first and second rack units 100, 200 to further build out the barrel rack system 1000 horizontally. Furthermore, additional rack units may be coupled to the first and/or second upper sides 113, 114, 153, 154, 213, 214, 253, 254 of the first and second rack units 100, 200 to further build out the barrel rack system 1000 vertically.

Focusing on the barrel rack system 1000 as shown in FIGS. 1 and 2, when the first and second rack units 100, 200 are coupled together, upper portions of the first and second rack units 100, 200 define an elevated storage cell 51 that is at least partially elevated above the storage cells 50 of the first and second rack units 100, 200. The elevated storage cell 51 may comprise a cell axis C-C that is elevated relative to the cell axes A-A of the storage cells 50. Specifically, the second upper side 114 of the first hexagonal frame 110 of the first rack unit 200 and the first upper side 213 of the first hexagonal frame 210 of the second rack unit 200 define a first V-shaped support portion of the elevated storage cell 51. Furthermore, the second upper side 154 of the second hexagonal frame 150 of the first rack unit 200 and the first upper side 253 of the second hexagonal frame 250 of the second rack unit 200 define a second V-shaped support portion of the elevated storage cell 51. Thus, an additional barrel may be positioned within the elevated storage cell 51 and supported by the second upper sides 114, 154 of the first and second hexagonal frames 110, 150 of the first rack unit 100 and the first upper sides 113, 153 of the first and second hexagonal frames 210, 250 of the second rack unit 200. The barrel positioned in the elevated storage cell 51 may be supported by the fourth wheels 14, 14 of the first rack unit 100 and the third wheels 13, 13 of the second rack unit 200.

Referring to FIG. 3, a metal sheet 300 is illustrated in accordance with an embodiment of the present invention. The metal sheet 300 is the “blank” that is used to form the hexagonal frames 110, 150, 210, 250 described above. That is, each of the hexagonal frames 110, 150, 210, 250 (and any others which may be included in the barrel rack system 1000) may be formed by folding and/or bending the metal sheet 300 into the desired hexagonal shape. The metal sheet 300 may be formed from steel in some embodiments, although other metals may be used in other embodiments including aluminum, iron, titanium, or the like.

The metal sheet 300 may include a top surface 301, a bottom surface opposite the top surface (not shown, but the metal sheet 300 looks identical in bottom plan view as it does in top plan view), a first end 302, a second end 303, a first side edge 304 extending between the first and second ends 302, 303, and a second side edge 305 extending between the first and second ends 302, 303. The metal sheet 300 may be a flat sheet, such that the top and bottom surfaces 301 are parallel to one another. The metal sheet 300 may have a thickness measured between the first and second surfaces 301 of between 1 mm and 10 mm. The metal sheet 300 may be elongated along a longitudinal axis B-B between the first and second ends 302, 303. Each of the first and second side edges 304, 305 may be elongated in a direction parallel to the longitudinal axis B-B.

The metal sheet 300 may comprise a plurality of plate segments 310 and a plurality of hinge portions 350, with one of the plurality of hinge portions 350 being located between each pair of adjacent ones of the plate segments 310. In the exemplified embodiment, the plurality of plate segments 310, comprises six of the plate segments 310, each of which is configured to form one of the sides of the hexagonal frame once formed. Moving from left to right in FIG. 3, the plate segments 310 may include a first plate segment 310a, a second plate segment 310b, a third plate segment 310c, a fourth plate segment 310d, a fifth plate segment 310e, and a sixth plate segment 310f. The use of the terms “first,” “second,” “third,” “fourth,” “fifth,” and “sixth,” as it relates to the plate segments, is merely intended to distinguish among the plate segments. The numeral “310” is used herein to generically refer to the plate segments, even though they are labeled as 310a-f in the drawings. Each of the plate segments 310 has a first end portion 311 and a second end portion 312, with the plate segment 310 being elongated between the first and second end portions 311, 312.

Each of the plurality of plate segments 310a-f comprises a central axial portion 313, a first side axial portion 314 located on a first side of the central axial portion 313, and a second side axial portion 315 located on a second side of the central axial portion 313. Each of the central axial portion 313 and the first and second side axial portions 314, 315 may be elongated between the first and second end portions 311, 312 of the plate segments 310a-f. The metal sheet 300 may include a pre-weakened portion between the central axial portion 313 and each of the first and second side axial portions 314, 315 so that the first and second side axial portions 314, 315 can be bent or folded relative to the central axial portion 313. In other embodiments, there may not be a pre-weakened portion, but the first and second side axial portions 314, 315 may nonetheless be configured to be bent or folded relative to the central axial portion 313 as described further below with reference to FIGS. 4A and 4B.

In the exemplified embodiment, each of the first, third, fourth, and sixth plate segments 310a, c, d, f comprises a hole 320 that extends from the top surface 301 to the bottom surface. In the exemplified embodiment, the second and fifth plate segments 310b, 310e do not include one of the holes 320. In other embodiments, all of the plate segments 310a-f may include one of the holes 320. The hole 320 may be located along the central axial portion 313 of the plate segments 310a, c, d, f on which it is provided. In the exemplified embodiment, the hole 320 is square shaped, although the hole 320 may take on other shapes in other embodiments. The hole 320 should be sized and shaped, and thereby configured, to receive one of the wheels 11-14 therein to facilitate the coupling of the wheel 11-14 to the hexagonal frame formed from the metal sheet 300.

Each of the plate segments 310 that includes one of the holes 320 may further include a first aperture 321 that is axially aligned with the hole 320 and formed through the first side axial portion 314 and a second aperture 322 that is axially aligned with the hole 320 and formed through the second side axial portion 315. The first and second apertures 321, 322 and the hole 320 may be transversely aligned. The first and second apertures 321, 322 may be configured to receive a fastener that is used to secure a wheel positioned in the hole 320 to the metal sheet 300 (or to the hexagonal frame formed from the metal sheet 300, as described below).

One or more of the plate segments 310 may also include a third aperture 323 that is aligned with the hole 320 in that plate segment 310. In the exemplified embodiment, the plate segment 310d is illustrated with such a third aperture 323, although the third aperture 323 may be included on any of the plate segments 310 that includes one of the holes 320. The third aperture 323 may be configured to receive a set screw or the like that may engage the wheel positioned within the hole 320 to lock the wheel and prevent it from rotating. The set screw may be altered from a locked state whereby the set screw contacts the wheel and prevents its rotation and a n unlocked state whereby the set screw does not contact the wheel and the wheel is able to freely rotate. Further details about this will be discussed below with reference to FIGS. 13A-14B.

The metal sheet 300 may further comprise a first attachment hole 324 located along the central axial portion 313 adjacent to or along the first end portion 311 and a second attachment hole 325 located along the central axial portion 313 adjacent to or along the second end portion 312. In an embodiment, each of the plate segments 310a-f may include the first and second attachment holes 324, 325. Each of the attachment holes 324, 325 may extend through the metal sheet 300 from the top surface 301 to the bottom surface. Each of the attachment holes 324, 325 may be configured to receive a fastener to facilitate the attachment of one assembled hexagonal frame to another assembled hexagonal frame, as described herein. That is, the attachment holes 324, 325 may be configured to receive the fasteners 60, 61 described above to facilitate the attachment of the hexagonal frames of one rack unit to the hexagonal frames of another adjacently positioned rack unit.

The metal sheet 300 may further comprise a plurality of first notches 330 in the first side edge 304 and a plurality of second notches 331 in the second side edge 305. Each of the first notches 330 may be aligned with one of the second notches 331 so that an axis transverse to the longitudinal axis B-B intersects both of the first and second notches 330, 331. In the exemplified embodiment, each of the first notches 330 and each of the second notches 331 are V-shaped. Furthermore, each of the notches 330, 331 may be aligned with the hinge 350 so that the axis transverse to the longitudinal axis B-B intersects the one of the first and second notches 330, 331 and one of the hinges 350. The notches 330, 3310 may enable the metal sheet 300 to be bent at the hinges 350 after the first and second side axial portions 314, 315 are bent relative to the central axial portion 313.

Referring to FIG. 3A, an alternative embodiment is provided whereby instead of a single metal sheet 300, there are two metal sheets 300a, 300b. In this embodiment, the metal sheet 300 described above has been separated into two distinct metal sheets 300a, 300b, each including three of the plate segments. Thus, in this embodiment the first metal sheet 300a includes the first, second, and third plate segments 310a-c and the second metal sheet 300b includes the fourth, fifth, and sixth plate segments 310d-f. All other features of the metal sheet 300 are included in the two metal sheets 300a, 300b, including the holes, apertures, notches, and the like. Using two metal sheets 300a, 300b instead of one metal sheet 300 may result in easier fabrication and a reduction in costs. The metal sheet 300 may have a length of approximately 8-12 feet measured between the first and second ends 302, 303. The two-metal sheet variation including the metal sheets 300a, 300b may be half that length, such that each of the metal sheets 300a, 300b may be approximately 4-6 feet long.

Referring to FIG. 3B, a alternative embodiment for the metal sheets 300a, 300b is illustrated as a metal sheet 300c. There may be two of the metal sheets 300c used to form one of the hexagonal frames, as described herein. The metal sheet 300c is identical to the metal sheets 300a, 300b, except the two plate segments that include the hole 320c for receiving one of the wheels are located adjacent to one another. Thus, the metal sheet 300c includes a first plate segment 310g, a second plate segment 310h, and a third plate segment 310i. In this embodiment, the first plate segment 310g does not include one of the holes 320c, but the second and third plate segments 310h, 310i include one of the holes 320c for receiving one of the wheels. Of course, all of the plate segments 310g-i may include one of the holes 320c in other embodiments.

By forming the metal sheet 300c in the manner shown in FIG. 3B, the location of the weld seam between the two metal sheets 300c when connected may be modified. Specifically, with the metal sheets 300a, 300c as shown in FIG. 3A, the weld seam between the two metal sheets will be located at the location where numerals 128 and 129 are located. This will put one of the weld seams at the first apex 128 which is located in direct contact with the caster base when the rack is assembled. This may result in excess pressure at that weld seam. By forming the metal sheet 300c as shown in FIG. 3C, the weld seams may be located at points 338, 339, which will avoid the weld seam being located direction at the location of the “V” in the caster base where the hexagonal frame is positioned when the rack is assembled.

Referring now to FIGS. 4A-4F sequentially, the process used to form the hexagonal frame from the metal sheet 300 will be described. This process may be used to form any of the hexagonal frames 110, 150, 210, 250 described herein above.

First, as shown in FIG. 4A, the first side axial portion 314 is bent relative to the central axial portion 313 along each of the plate segments 310a-f. Next, as shown in FIG. 4B, the second side axial portion 315 is bent relative to the central axial portion 313 along each of the plate segments 310a-f. The first and second side axial portions 314, 315 are bent or folded relative to the central axial portion 313 along axes that are parallel to the longitudinal axis B-B of the metal sheet 300. Once the first and second side axial portions 314 are bent relative to the central axial portion 313, the metal sheet 300 is transformed from a flat plate into a plate having a U-shape, or a U-shaped transverse cross-sectional area.

Next, referring to FIGS. 4C-4F, the plate segments 310a-f are bent/folded one-by-one about the hinge portions 350. As seen in FIG. 4C, the plate segment 310f is being bent or folded relative to the plate segment 310e about the hinge portion 350. The plate segment 310f is bent/folded until edges of the first and second side axial portions 314, 315 of the plate segment 310f abut the edges of the first and second side axial portions 314, 315 of the plate segment 314e. This abutment of the edges of the first and second side axial portions 314, 315 forms a stopper which prevents further bending/folding of the plate segment 310f relative to the plate segment 310e. The same occurs during the bending/folding of each subsequent plate segment 310a-f. The plate segments 310a-f are continued to be bent/folded as described until the metal sheet 300 is transformed into a hexagonal-shaped member, as shown in FIG. 5.

FIG. 5 illustrates one of the first hexagonal frame 110 formed by folding the metal sheet 300 as described above. Each of the hexagonal frames 110, 150, 210, 250 described above with reference to the first and second rack units 100, 200, and any additional hexagonal frame used as part of the barrel rack system 1000, may be formed from one of the metal sheets 300 as described. The first hexagonal frame 110 is has six sides, including the first and second lower sides 111, 112, the first and second upper sides 113, 114, and the first and second lateral sides 115, 116. Each of the aforementioned sides is formed from one of the plate segments 310a-f. For example, in an embodiment the first plate segment 310a may form the first lower side 111, the second plate segment 310b may form the first lateral side 115, the third plate segment 310c may form the first upper side 113, the fourth plate segment 310d may form the second upper side 114, the fifth plate segment 310e may form the second lateral side 116, and the sixth plate segment 310f may form the second lower side 112. As such, the first and second lower sides 111, 112 and the first and second upper sides 113, 114 include the openings 320 for the wheels, and the first and second lateral sides 115, 116 are devoid of the openings 320. Of course, all sides could include the openings for the wheels in alternative embodiments.

Once the metal sheet 300 is bent/folded into the hexagonal shape of the hexagonal frame 110, the ends first and second ends 302, 303 may be welded to one another to maintain the hexagonal shape of the hexagonal frame 110. In alternative embodiments, other techniques may be used to attach the first and sixth plate segments 310a, 310f together, such as using fasteners, adhesives, clamps, or the like. The hexagonal frame 110 may have added structural rigidity owing to its U-shaped cross-section. Moreover, in embodiments that use two metal sheets 300a, 300b, the two metal sheets may be bent and folded as described to form a portion of the hexagonal frame. The two metal sheets 300a, 300b may then be coupled to each other, such as by welding, mechanical fasteners, or the like, to form the hexagonal frames.

Referring to FIG. 6, the hexagonal frames 110, 150, 210, 250 may be formed using the techniques described above, and then may be coupled together with the struts 190 to form the first and second rack units 100, 200. Thus, after the first and second hexagonal frames 110, 150 are formed, the struts 190 may be welded or otherwise coupled to the first and second hexagonal frames 110, 150 to form the first rack unit 100. Similarly, after the first and second hexagonal frames 210, 25 are formed, the struts 290 may be welded or otherwise coupled to the first and second hexagonal frames 210, 250 to form the second rack unit 200.

In FIG. 6, the wheels 11-14 are shown already coupled to the first and second hexagonal frames 110, 150, 210, 250. The process of coupling the wheels 11-14 to the hexagonal frames 110, 150, 210, 250 will now be briefly described. Each of the wheels 11-14 may be positioned within one of the openings 320, only a couple of which are labeled to avoid clutter. After the wheels 11-14 are positioned in the openings 320, fasteners such as screws, bolts, nuts, bearings, and the like may be inserted into the first and second apertures 321, 322 to attach the wheels 11-14 to the hexagonal frames 110, 150, 210, 250. The wheels 11-14 remain capable of rotating after being coupled to the hexagonal frames 110, 150, 210, 250. The wheels 11-14 may be coupled directly to the hexagonal frames 110, 150, 210, 250 at the positions previously identified. In some embodiments, the wheels 11-14 may be coupled to the hexagonal frames 110, 150, 210, 250 at some, but not all, of the identified positions. For example, it may be acceptable to omit the wheels 13 of the first rack unit 100 and the wheels 14 of the second rack unit 200 if the location where those wheels are located is not intended to support a barrel. Furthermore, if there is no desire or need to rotate the barrel once stored, the wheels 11-14 may all be omitted.

Still referring to FIG. 6, the next step in the assembly of the barrel rack system 1000 is to attach the first rack unit 100 to the second rack unit 200. In the exemplified embodiment, this is achieved with the fasteners 60, 61, which may be screws, bolts, rivets, other mechanical fasteners, or the like. In the exemplified embodiment, the fasteners 60, 61 may include screws and nuts. The screws may be inserted through openings in the second lateral sides 116, 156 of the first and second hexagonal frames 110, 150 of the first rack unit 100 and through the first lateral sides 215, 255 of the first and second hexagonal frames 210, 250 of the second rack unit 200. FIG. 7 illustrates the first and second rack units 100, 200 coupled together with the fasteners 60, 61. Since the first and second rack units 100, 200 are coupled together with fasteners 60, 61, the first and second rack units 100, 200 can be easily decoupled/separated from one another. In alternative embodiments, the first and second rack units 100, 200 may be more permanently coupled together, such as by welding. However, the detachable coupling with fasteners such as screws and nuts allows for more customization and modularity in the construction and assembly of the barrel rack system 1000.

Referring to FIGS. 8A and 8B, the base component 500 is illustrated in accordance with an embodiment of the present invention. As noted above, the barrel rack system 1000 may comprise the first and second rack units 100 as previously described and the base component 500 on which the first and second rack units 100 are positioned. The base component 500 may comprise a first wheel support plate 510, a second wheel support plate 520, a first rack support member 530, and a second rack support member 540. The first wheel support plate 510 may have an upper surface 511 and a lower surface 512. The first wheel support plate 510 may be elongated from a first end 513 to a second end 514. The second wheel support plate 520 may have an upper surface 521 and a lower surface 522. The second wheel support plate 520 may be elongated from a first end 523 to a second end 524.

The base component 500 may comprise casters 501 coupled to the lower surfaces 512, 522 of the first and second wheel support plates 510 at or adjacent to the first and second ends 513, 514, 523, 524. Thus, in this embodiment there are four casters 501, although greater or fewer than four casters 501 may be used in other embodiments. The casters 501 allow the base component 500 to be movable along a floor surface upon which it is located.

The first rack support member 530 is positioned atop of the upper surfaces 511, 521 of the first and second wheel support plates 510, 520. The first rack support member 530 may be coupled to each of the first and second wheel support plates 510, 520. The first rack support member 530 may be coupled to the first ends 513, 523 of each of the first and second wheel support plates 510, 520. The first rack support member 530 may comprise a first end portion 533 and a second end portion 534, with the first rack support member 530 being elongated in a direction between the first and second end portion 533, 534. The first end portion 533 may rest atop the first wheel support plate 510 and the second end portion 534 may rest atop the second wheel support plate 520. The second rack support member 540 is positioned atop of the upper surfaces 511, 521 of the first and second wheel support plates 510, 520. The second rack support member 540 may be coupled to each of the first and second wheel support plates 510, 520. The second rack support member 540 may be coupled to the second ends 514, 524 of each of the first and second wheel support plates 510, 520. The second rack support member 540 may comprise a first end portion 543 and a second end portion 544, with the second rack support member 540 being elongated in a direction between the first and second end portions 543, 544. The first end portion 543 may rest atop the first wheel support plate 510 and the second end portion 534 may rest atop the second wheel support plate 520. The first and second rack support members 530, 540 may be welded to the first and second wheel support plates 510, 520. Alternatively, fasteners such as screws or the like may be used to attach the first and second rack support members 530, 540 to the first and second wheel support plates 510, 520.

Each of the first and second rack support members 530, 540 may be V-shaped plates. Specifically, the first rack support member 530 may comprise a first elongated portion 531 and a second elongated portion 532 that are angled relative to one another to form a V-shape. Similarly, the second rack support member 540 may comprise a first elongated portion 541 and a second elongated portion 542 that are angled relative to one another to form a V-shape. This provides a nesting space for the apexes of the hexagonal frames 110, 150, 210, 250 to be disposed within when the first and second rack units 100, 200 are positioned atop and supported by the base component 500. Each of the first and second elongated portions 531, 532 of the first rack support member 530 may comprise an attachment hole 535 located along each of the first and second end portions 533, 534. Similarly, each of the first and second elongated portions 541, 542 of the second rack support member 540 may comprise an attachment hole 545 located along each of the first and second end portions 543, 544, The attachment holes 535, 545 may receive a fastener for mechanically attaching the first and second rack units 100, 200 to the base component 500.

In an embodiment, the V-shaped plates may be manufactured as flat plates, and then bent/folded into the V-shape during the assembly process or a later step in the manufacturing process. This may optimize sheet yields and reduce waste. In some embodiments, the V-shaped plates may have drainage holes along the bend axis (where the apex of the “V” is located). These drainage holes may allow water, wine, or other liquid to drain out of the rack and onto a floor for drainage through floor drains.

Referring briefly to FIGS. 9A and 9B, an alternative embodiment of a base component 500a is illustrated. The base component 500a is identical to the base component 500 except that the base component 500a does not include any casters or wheels. Instead, the base component 500a comprises fixed feet 560a that are fixedly attached to the lower surfaces 512a, 522a of the first and second wheel support plates 510, 520. The fixed feet 560a may be attached to the lower surfaces 512a, 522a of the first and second wheel support plates 510, 520 with fasteners such as screws, nuts, bolts, rivets, or the like. Using the fixed feet 560a instead of the casters may allow the base component 500a to support more weight, thereby allowing the barrel rack system 1000 to be assembled higher in the vertical direction. Other than the fixed feet 560a replacing the casters, the base component 500a is identical to the base component 500 and therefore the description of the base component 500 is applicable to the base component 500a.

The casters 501 and the fixed feet 560a serve to elevate the first and second wheel support plates 510, 520 relative to the ground surface upon which the base component 500 is positioned. Furthermore, the casters 501 and the fixed feet 560a are spaced apart from one another by a minimum distance. The minimum distance may be greater than a distance between the two forks of a forklift. As such, a forklift may be capable of moving its forks in the space between the lower surfaces 512, 522 of the first and second wheel support plates 510, 520 and the ground upon which the casters 501 or the fixed feet 560a are located. Thus, a forklift may be capable of lifting the entire barrel rack system 1000 including the base component 500 and the first and second rack units 100, 200 in order to relocate the barrel rack system 1000 as desired. Moreover, a forklift may be capable of lifting the barrel rack system 1000 while the barrel rack system is supporting three barrels as described herein.

Referring to FIG. 10, a barrel rack system 1000a is illustrated in accordance with an embodiment of the present invention. The barrel rack system 1000a is the result of attaching two of the barrel rack systems 1000 described above together. Specifically, the barrel rack system 1000a includes four of the rack units 100a, 200a, 100b, 200b. The rack units 100a, 200a are supported on a first base component 500a and the rack units 100b, 200b are supported on a second base component 500b. The rack units 100a, 200a and the first base component 500a may be referred to herein as a first rack assembly and the rack units 100b, 200b and the second base component 500b may be referred to herein as a second rack assembly. The rack unit 200a may then be coupled to the rack unit 100b with fasteners such as screws, nuts, bolts, rivets, or the like. This may result in the first and second rack assemblies being coupled together to form the barrel rack system 1000a. In some embodiments, the rack unit 200a may be detachably coupled to the rack unit 100b with screws and nuts to allow for modularity and customizability as needs change within a particular storage space.

The barrel rack system 1000a may be capable of storing or holding seven barrels. Specifically, one barrel may be stored in the storage cells 50 of each of the four rack units 100a, 200a, 100b, 200b. A fifth barrel may be stored in the elevated storage cell 51a formed by the upper portions of the rack units 100a, 200a. A sixth barrel may be stored in the elevated storage cell 51b formed by the upper portions of the rack units 100b, 200b. Finally, a seventh barrel may be stored in the elevated storage cell 51c formed by the upper portions of the rack units 200a, 100b. Thus, while the barrel rack system 1000 is able to store three barrels, the number of barrels able to be stored more than doubles to seven when two of the barrel rack systems 1000 are attached to form the barrel rack system 1000a.

FIG. 11 illustrates yet another barrel rack system 1000b that is formed by attaching yet further rack units 100c, 100d, 100e to the previously described rack units 100a, 200a, 100b, 200b. The barrel rack system 1000b is configured to store nine of the barrels, as should be appreciated from the provided illustration. To stack the rack units vertically as shown, some of the wheels may be omitted. For example, the wheels on the upper sides of the rack units 100a, 200a, 100b, 200b may be omitted so that the rack units 100c, 100d, 100e stacked above can rest directly atop of the upper sides of the rack units 100a, 200a, 100b, 200b below. It should be appreciated that many other configurations for the overall barrel rack system are possible. The barrel rack system can be customized to fit within an existing storage space to maximize the number of barrels that can be stored while providing the winemaker or other personnel with access to the barrels for the performance of winemaking tasks (or other duties, depending on what is stored in the barrels). Furthermore, additional rack units can be added to an existing system as needed or desired as the winery, distillery, or storage facility grows and expands. The honeycomb structure formed by the hexagonal shaped storage cells evenly disperses weight loads.

Referring to FIGS. 12A-13B, a locking mechanism for the wheels 11-14 will be described in accordance with an embodiment of the present invention. As discussed above with reference to FIGS. 3 and 3A, the metal sheet 300 or metal sheets 300a, 300b that are used to form the hexagonal frames 110, 150, 210, 250 may include a plurality of holes 320 each configured to receive one of the wheels 11-14 and a third aperture 323 that is in axial alignment with one or more of the holes 320 (axial alignment meaning an axis transverse to the longitudinal axis of the metal sheet 300, 300a, 300b would intersect the third aperture 323 and the hole 320). When the metal sheet 300 is folded and bent into the U-shape as described, the third aperture 323 is aligned with the wheel 11.

A locking member 390 may be inserted into the third aperture 323. The locking member 390 may be a set screw in some embodiments, although the invention is not to be so limited and other components may be used. The locking member 390 may be alterable between a first position (FIGS. 12A and 12B) whereby the locking member 390 is not in contact with the wheel 11 and the wheel 11 is therefore freely rotatable, and a second position (FIGS. 13A and 13B) whereby the locking member 390 is in contact with the wheel 11 to prevent the wheel 11 from rotating. If the locking member 390 is a set screw, the locking member 390 may be altered between the first and second positions by screwing the set screw in first and second opposing rotational directions.

In some embodiments, there may be one of the locking member 390 for each of the wheels 11-14. In other embodiments, there may be one of the locking members 390 for only one of the wheels associated with each storage cell 50, 51. Thus, for example if the storage cell 50 of the first rack unit 100 includes two of the wheels 11 and two of the wheels 12 (see FIG. 1), there may be one of the locking members 390 located along one (or associated therewith) of the wheels 11, 12, while the other three wheels do not have any locking member located therealong (or associated therewith). Alternatively, there may be one of the locking members 390 located along (or associated with) two of the wheels 11, 12, three of the wheels 11, 12, or all four of the wheels 11, 12. By locking just one or two of the four wheels 11, 12 supporting a single one of the barrels, rotation of the barrel may be prevented or made substantially more difficult.

Furthermore, FIGS. 12A and 13A illustrate a pair of gussets 340 that are coupled to the hexagonal frame and extend between the first and second axial side portions 314, 315. The gussets 340 may be welded to the first and second axial side portions 314, 315 or coupled thereto using other means, such as fasteners like bolts, screws, nuts, rivets and the like. The pair of gussets 340 includes two gussets located on opposite sides of the wheel 11, and more specifically on opposite sides of the axis of rotation of the wheel 11. A pair of gussets 340 may be included for each wheel. The gussets 340 may be included to prevent bowing of the hexagonal frame during the tightening of the wheel. In alternative embodiments, the gussets 340 may be omitted.

Referring to FIGS. 14-16, a barrel rack system 2000 is illustrated in accordance with an alternative embodiment of the present invention. The overall appearance of the barrel rack system 2000 is similar to the overall appearance of the barrel rack system 1000 described above. However, the components used to form the barrel rack system 2000 and the methods for assembling the barrel rack system 2000 differ from the components and methods associated with the barrel rack system 1000 described above. Certain features of the barrel rack system 1000 are applicable to the barrel rack system 2000 and will not be described in detail herein with regard to the barrel rack system 2000. Thus, it should be appreciated that for features between the barrel rack systems 1000, 2000 which are the same, the description of the barrel rack system 1000 is applicable to the barrel rack system 2000.

The barrel rack system 2000 generally comprises a first rack unit 2100, a second rack unit 2200, and a base component 2500. The first rack unit 2100 defines a generally hexagonal storage cell 2050 having a cell axis Z-Z. The second rack unit 2200 defines a generally hexagonal storage cell 2050 having a cell axis Y-Y. The first and second rack units 2100, 2200 are coupled together so that upper portions of the first and second rack units 2100, 2200 define an elevated storage cell 2051. The elevated storage cell 2051 may have a cell axis X-X that is parallel to and elevated relative to the cell axes Z-Z, Y-Y. The first and second rack units 2100, 2200 are configured to be positioned atop the base component 2500 so that the base component 2500 supports the first and second rack units 2100, 2200. The first and second rack units 2100, 2200 may be detachably coupled to the base component 2500 with fasteners such as screws, nuts, bolts, or the like. Alternatively, the first and second rack units 2100, 2200 may be welded to the base component 2500 or coupled to the base component 2500 with rivets. However, the detachable coupling with screws, nuts, bolts or the like may be desirable to allow for customization and expansion of the barrel rack system 2000 over time. The first and second rack units 2100, 2200 may be detachably coupled together so that the first and second cell axes Z-Z, Y-Y are parallel to one another.

The first rack unit 2100 comprises a first hexagonal frame 2110, a second hexagonal frame 2150, and a plurality of struts 2190 coupled to and extending between the first and second hexagonal frames 2110, 2150. The plurality of struts 2190 may be welded to the first and second hexagonal frames 2110, 2150 or the plurality of struts 2190 may be detachably coupled to the first and second hexagonal frames 2110, 2150 with fasteners as described previously. The second rack unit 2200 comprises a first hexagonal frame 2210, a second hexagonal frame 2250, and a plurality of struts coupled to and extending between the first and second hexagonal frames 2210, 2250. The plurality of struts 2290 may be welded to the first and second hexagonal frames 2210, 2250, or the plurality of struts may be detachably coupled to the first and second hexagonal frames 2210, 2250 with fasteners as described previously. Each of the first and second hexagonal frames 2110, 2150, 2210, 2250 may have an L-shaped cross-sectional area.

The first and second hexagonal frames 2110, 2150, 2210, 2250 of the first and second rack units 2200 may be identical in construction, structure, and function. Certain details will be provided for the first hexagonal frame 2110, it being understood that the discussion related to the first hexagonal frame 2110 is applicable to each of the other hexagonal frames 2150, 2110, 2250. However, a general description will be provided for each of the hexagonal frames 2110, 2150, 2210, 2250 to help provide context for the later description.

The first hexagonal frame 2110 of the first rack unit 2100 comprises a first lower side 2111, a second lower side 2112, a first upper side 2113, a second upper side 2114, a first lateral side 2115 extending between the first lower side 2111 and the first upper side 2113, and a second lateral side 2116 extending between the second lower side 2112 and the second upper side 2114. The various sides of the first hexagonal frame 2110 form a hexagonal shape and define a hexagonal shaped opening. The first and second lower sides 2111, 2112 form a lowermost apex of the first hexagonal frame 2110 of the first rack unit 2100 and the first and second upper sides 2113, 2114 form an uppermost apex of the first hexagonal frame 2110 of the first rack unit 2100. The second hexagonal frame 2150 of the first rack unit 2100 comprises a first lower side 2151, a second lower side 2152, a first upper side 2153, a second upper side 2154, a first lateral side 2155 extending between the first lower side 2151 and the first upper side 2153, and a second lateral side 2156 extending between the second lower side 2152 and the second upper side 2154. The various sides of the second hexagonal frame 2150 form a hexagonal shape and define a hexagonal shaped opening. The first and second lower sides 2151, 2152 form a lowermost apex of the second hexagonal frame 2150 of the first rack unit 2100 and the first and second upper sides 2153, 2154 form an uppermost apex of the second hexagonal frame 2150 of the first rack unit 2100.

The first hexagonal frame 2210 of the second rack unit 2200 comprises a first lower side 2211, a second lower side 2212, a first upper side 2213, a second upper side 2214, a first lateral side 2215 extending between the first lower side 2211 and the first upper side 2213, and a second lateral side 2216 extending between the second lower side 2212 and the second upper side 2214. The various sides of the first hexagonal frame 2210 form a hexagonal shape and define a hexagonal shaped opening. The first and second lower sides 2211, 2212 form a lowermost apex of the first hexagonal frame 2210 of the second rack unit 2200 and the first and second upper sides 2213, 2214 form an uppermost apex of the first hexagonal frame 2210 of the second rack unit 2200. The second hexagonal frame 2250 of the second rack unit 2200 comprises a first lower side 2251, a second lower side 2252, a first upper side 2253, a second upper side 2254, a first lateral side 2255 extending between the first lower side 2251 and the first upper side 2253, and a second lateral side 2256 extending between the second lower side 2252 and the second upper side 2254. The various sides of the second hexagonal frame 2250 form a hexagonal shape and define a hexagonal shaped opening. The first and second lower sides 2251, 2252 form a lowermost apex of the second hexagonal frame 2250 of the second rack unit 2200 and the first and second upper sides 2253, 2254 form an uppermost apex of the second hexagonal frame 2250 of the second rack unit 2200.

As noted, the first and second hexagonal frames 2110, 2150 are maintained in a spaced apart manner by the plurality of struts 2190 which are coupled to the rear surfaces of each of the first and second hexagonal frames 2110, 2150. The space or volume defined by the interior of the first and second hexagonal frames 2110, 2150 and the inner surface of the plurality of struts 2190 forms the hexagonal storage cell 2050 of the first rack unit 2100. The hexagonal storage cell 2050 may be open between the struts 2190 such that the faces of the hexagonal cylinder shape formed by the first and second hexagonal frames 2110, 2150 and the struts 2190 are generally open. In other embodiments, the hexagonal storage cells 2050 may be closed cells, by adding additional panels or the like to close the exterior thereof. The first and second hexagonal frames 2210, 2250 are similarly maintained in a spaced apart manner by the struts 2290 to define the hexagonal storage cell 2050 of the second rack unit 2200.

A first wheel 2011 may be coupled to the first lower side 2111 of the first hexagonal frame 2110 of the first rack unit 2200 and a second wheel 2012 may be coupled to the second lower side 2112 of the first hexagonal frame 2110 of the first rack unit 2100. In this embodiment, the first and second wheels 2011, 2012 may be coupled directly to the first and second lower sides 2111, 2112 of the first hexagonal frame 2110, as described in more detail below. Moreover, a third wheel 2013 may be coupled to the second upper side 2114 of the first hexagonal frame 2110. In this embodiment, there is no wheel coupled to the first upper side 2113, although a wheel may be coupled to the first upper side 2113 in other embodiments. As described further below, in this embodiment the third wheel 2013 is formed as part of or coupled to a component that is distinct from the first hexagonal frame 2110, and thus the third wheel 2013 may not be coupled directly to the second upper side 2114. The second hexagonal frame 2150 has a similar configuration whereby a first wheel 2014 is coupled to the first lower side 2151, a second wheel 2015 is coupled to the second lower side 2152, and a third wheel 2016 is coupled to the second upper side 2154. Furthermore, the first and second wheels 2014, 2015 may be coupled directly to the first and second lower sides 2151, 2152 of the second hexagonal frame 2150.

A first wheel 2121 may be coupled to the first lower side 2211 of the first hexagonal frame 2210 of the second rack unit 2200 and a second wheel 2122 may be coupled to the second lower side 2212 of the first hexagonal frame 2210 of the second rack unit 2200. In this embodiment, the first and second wheels 2121, 2122 may be coupled directly to the first and second lower sides 2211, 2212 of the first hexagonal frame 2210. Moreover, a third wheel 2123 may be coupled to the first upper side 2213 of the first hexagonal frame 2210. In this embodiment, there is no wheel coupled to the second upper side 2214 of the first hexagonal frame 2200, although a wheel may be coupled to the second upper side 2214 in other embodiments. As described further below, in this embodiment the third wheel 2123 may be formed as part of or coupled to a component that is distinct from the first hexagonal frame 2210, and thus the third wheel 2213 may not be coupled directly to the first upper side 2213. The second hexagonal frame 2250 of the second rack unit 2200 may comprise a first wheel 2224 coupled to the first lower side 2251, a second wheel 2225 coupled to the second lower side 2252, and a third wheel 2226 coupled to the first upper side 2253.

In the exemplified embodiment, each of the hexagonal frames 2110, 2150, 2210, 2250 may be formed by a plurality of components that are coupled together. The components will be described with reference to the first hexagonal frame 2110, but the description may be applicable to each of the hexagonal frames 2110, 2150, 22102250.

Referring to FIGS. 16 and 17A-17C, the components of the hexagonal frames 2110, 2150, 2210, 2250 will be described with specific reference to the first hexagonal frame 2110 of the first rack unit 2100. The first hexagonal frame 2110 may comprise a first frame component 2130, a second frame component 2131, and a third frame component 2132. In the exemplified embodiment, each of the first, second, and third frame components 2130, 2131, 2132 are L-shaped members. Specifically, the first frame component 2130 comprises a first arm portion 2133 and a second arm portion 2134 that is angled relative to the first arm portion 2133. The second frame component 2131 comprises a first arm portion 2135 and a second arm portion 2136 that is angled relative to the first arm portion 2135. The third arm portion 2132 comprises a first arm portion 2137 and a second arm portion 2138 that is angled relative to the first arm portion 2137. In one embodiment, the first and second frame components 2130, 2131 may be formed as a singular integral structure that comprises the arm portions 2133, 2134, 2135, 2136, rather than being formed from two separate parts that are coupled together.

Furthermore, each of the first, second, and third frame components 2130, 2131, 2132 may have an L-shaped cross-sectional area. although the invention is not to be so limited and other cross-sectional area shapes may be used, including a U-shaped cross-sectional area as with the previously described embodiment. Specifically, the first frame component 2130 comprises a frontal portion 2140 and an outer portion 2141 that are bent at an approximately 90° angle relative to one another. The frontal portion 2140 may form a portion of the front surface of the hexagonal frame 2110 and the outer portion 2141 may form a portion of the outer surface of the hexagonal frame 2110. Similarly, the second frame component 2131 may comprise a frontal portion 2142 and an outer portion 2143 and the third frame component 2132 may comprise a frontal portion 2144 and an outer portion 2145.

The first frame component 2130 may comprise connection holes 2139 formed through the outer portion 2141 along both of the first and second arm portions 2133, 2134 to facilitate attachment to another one of the hexagonal frames or frame components, as discussed herein. The second frame component 2131 may comprise connection holes 2146 formed through the outer portion 2143 along both of the first and second arm portions 2135, 2136 to facilitate attachment to another one of the hexagonal frames or frame components, as discussed herein. The first and second frame components 2130, 2131 may be identical to one another. Thus, in some embodiments the invention may be referred to as including at least one first frame component 2130, or including two of the first frame components 2130, without referencing the identically structured second frame component 2131.

Each of the frame components 2130-2132 may have connection flanges at each opposing end thereof to facilitate coupling the frame components 2130-2132 together. Thus, the first frame component 2130 may comprise a first connection flange 2170 at a distal end of the first arm portion 2133 and a second connection flange 2171 at a distal end of the second arm portion 2134. The second frame component 2131 may comprise a first connection flange 2172 at a distal end of the first arm portion 2135 and a second connection flange 2173 at a distal end of the second arm portion 2136. The third frame component 2132 may comprise a first connection flange 2174 at a distal end of the first arm portion 2137 and a second connection flange 2175 at a distal end of the second arm portion 2138. Each of the connection flanges 2170-2175 may comprise an aperture that is configured to receive a fastener (screw, bolt, nut, etc.) to facilitate the attachment of the first, second, and third frame components 2130-2132 together. The frame components 2130-2132 may be arranged as shown in FIG. 17B so that the various connection flanges 2170-2175 are adjacent to one another in pairs, and then fasteners 70 (screws, bolts, nuts, etc.) may be inserted into/through the various apertures of the connection flanges 2170-2175 to couple the frame components 2130-2132 together to form the hexagonal frame 2110 having a hexagonal shape. In alternative embodiments, the frame components 2130-2132 may be coupled together using other techniques, including welding, clamps, screwed connections, or the like.

The first and second frame components 2130, 2131 may be devoid of any wheels and devoid of any wheel mounting structure. However, the third frame component 2132 may comprise a first wheel mounting structure 2180 located on the first arm portion 2137 and a second wheel mounting structure 2185 located on the second arm portion 2138. The first wheel mounting structure 2180 may comprise a first mounting flange 2182 extending from the frontal portion 2144 of the first arm portion 2137 and a second mounting flange 2183 extending from the outer portion 2145 of the first arm portion 2137 and being aligned with the first mounting flange 2182. The first wheel 2011 may be configured to be positioned between the first and second mounting flanges 2182, 2183. The first and second mounting flanges 2182, 2183 may comprise apertures 2184 to receive wheel mounting fasteners 71 for securing the wheel to the first arm portion 2137 of the third frame component 2132. The second wheel mounting structure 2185 may comprise a first mounting flange 2186 extending from the frontal portion 2144 of the second arm portion 2138 and a second mounting flange 2187 extending from the outer portion 2145 of the second arm portion 2138. The second mounting flange 2187 may be aligned with the first mounting flange 2186. Each of the first and second mounting flanges 2186, 2187 may comprise an aperture 2188 to receive wheel mounting fasteners 72. The second wheel 2102 may be configured t be positioned between the first and second mounting flanges 2186, 2187 and coupled to the second arm portion 2138 with the fasteners 72. Each of the first and second wheels 2011, 2012 may be freely rotatable. In some embodiments, a locking mechanism such as described above with reference to the previous embodiment may be incorporated into this embodiment to selectively lock the wheels and prevent their rotation. For example, a set screw may be incorporated into the third frame component 2132 adjacent to the wheels 2011, 2012 to be alterable between a first position where the set screw does not contact the wheel and a second position where the set screw contacts the wheel and prevents or impedes its rotation.

Referring to FIG. 17B, the first, second, and third frame components 2130, 2131, 2132 are illustrated in preparation for attachment to form the first hexagonal frame 2110. The fasteners 70 are illustrated between the adjacently positioned frame components 2130, 2131, 2132. Moving from FIG. 17B to FIG. 17C, the frame components 2130-2132 are placed into abutment with one another and then affixed together with the fasteners 70. The first and second wheels 2011, 2012 are mounted to the third frame component 2132 as described previously. As noted above, the first and second frame components 2130, 2132 may be combined into a single, integral structure that includes the four sides as shown. When the first, second, and third frame components 2130, 2131, 2132 are coupled together to form the hexagonal frame 2110 as shown in FIG. 17C, the first frame component 2130 forms the first lateral side 2115 and the first upper side 2113, the second frame component 2131 forms the second lateral side 2116 and the second upper side 2114, and the third frame component 2132 forms the first and second lower sides 2111, 2112.

Referring to FIG. 18, a manufactured part 2195 which comprises two of the first frame components 2130 that are coupled together in a spaced apart manner with two of the struts 2190 is illustrated. As noted previously, the struts 2190 may be welded to the first frame components 2130. Alternatively, the struts 2190 may be attached to the first frame components 2130 using fasteners, threaded connections, friction fit, or the like. It should be appreciated that a manufactured part that includes two of the second frame components 2131 that are coupled together in a spaced apart manner with two of the struts 2190 may also be used in accordance with the invention described herein, and this would be structurally identical to the manufactured part shown in FIG. 18. During manufacturing, the first frame components 2130 and the struts 2190 may be separately formed using conventional metal fabrication techniques. Next, the struts 2190 may be welded to two of the first frame components 2130 to form the manufactured part 2195 that will form one-third of the finished rack unit. Another one-third of the finished rack unit may be formed from two of the second frame components 2131 and a set of struts 2190 that are welded thereto.

Referring to FIGS. 19A and 19B, the third frame component 2132 with the first and second wheels 2011, 2012 coupled thereto is illustrated. In one embodiment, two of the third frame components 2132 may be coupled together with the struts similar to the manufactured part 2195 shown in FIG. 18. However, in other embodiments the struts may only be coupled to the first and second frame components 2130, 2131 and not also to the third frame components 2132.

Referring sequentially to FIGS. 20A-20F, the assembly of the barrel rack system 2000 will be described in accordance with an embodiment of the present invention. FIG. 20A illustrates one of the manufactured parts 2195 in preparation for being coupled to one of the third frame components 2132. Specifically, the first connection flange 2174 of the third frame component 2132 is adjacent to the first connection flange 2170 of the first frame component 2130. The fasteners 70, such as a screw and a nut, are then inserted into the apertures of the connection flanges 2170, 2174 to couple the third frame component 2132 to the first frame component 2130. As noted, the manufactured part 2195 includes two of the first frame components 3120, and thus while only one of the third frame components 2132 is illustrated in this view, a second one of the third frame components 2132 would similarly be coupled to the other one of the first frame components 2130.

Referring to FIG. 20B, a second manufactured part 2196 that comprises two of the second frame components 2131 that are coupled together with two of the struts 2190 is illustrated in preparation for being coupled to the manufactured part 2195 and to the third frame components 2132 from FIG. 20A. Specifically, one end of each of the second frame components 2131 of the second manufactured part 2196 is coupled to the free end of the first frame components 2130 of the manufactured part 2195 (with the fasteners 70) and the opposite end of each of the second frame components 2131 of the second manufactured part 2196 is coupled to the free end of the third frame components 2132 (with the fasteners 70). The result of this is the formation/assembly of one of the rack units. It should be appreciated that while a specific order of assembly is described, the invention is not to be limited to that order in all embodiments that the assembly may occur in alternative ways. For example, in one embodiment the first, second, and third frame components 2130-2132 may be coupled together to form one of the hexagonal frames before the struts 2190 are coupled thereto.

FIG. 20C illustrates the first and second rack units 2100, 2200 that have been formed in accordance with the steps previously described. Each of the first and second rack units 2100, 2200 defines one of the hexagonal storage cells 2050 owing to the hexagonal shape of the hexagonal frames 2110, 2150, 2210, 2250. Moreover, the first and second hexagonal frames 2110, 2150 are maintained spaced apart by the struts 2190 such that the hexagonal storage cell 2050 of the first rack unit 2100 is defined between the first and second hexagonal frames 2110, 2150. Similarly, the first and second hexagonal frames 2210, 2250 are maintained spaced apart by the struts 2290 such that the hexagonal storage cell 2050 of the second rack unit 2200 is defined between the first and second hexagonal frames 2210, 2250.

Next, the first and second rack units 2100, 2200 may be coupled together using fasteners 73, which may include screws and nuts as shown. The fasteners 73 may take on other forms such as being bolts, rivets, or the like. Moreover, the first and second rack units 2100, 2200 may be welded together in other embodiments. However, the use of the fasteners 73 may be preferred to allow for customization and modularity in the assembly of the barrel rack system made from the various rack units. As described above, in some embodiments the second lateral sides 2116, 2156 of the first and second hexagonal frames 2110, 2150 of the first rack unit 2100 may be coupled to the first lateral sides 2215, 2256 of the first and second hexagonal frames 2210, 2250 of the second rack unit 2200.

Referring to FIG. 20D, the first and second rack units 2100, 2200 are illustrated coupled together as previously described. The first rack unit 2100 defines the first storage cell 2050, the second rack unit 2200 defines the second storage cell 2050, and the upper portions of the first and second rack units 2100, 2200 define the elevated storage cell 2051. In particular, in this embodiment the elevated storage cell 2051 is defined by the second upper side 2114 of the first hexagonal frame 2110 of the first rack unit 2100, the second upper side 2154 of the second hexagonal frame 2150 of the first rack unit 2100, the first upper side 2213 of the first hexagonal frame 2150 of the second rack unit 2200, and the first upper side 2253 of the second hexagonal frame 2250 of the second rack unit 2200. However, the various upper sides 2114, 2153, 2213, 2253 do not have any wheels mounted directly thereon. Thus, if there is a desire to rotate the barrel that may be supported within the elevated storage cell 2051, then wheels may be added, as described.

In this embodiment, there are two additional ones of the third frame components 2132a, 2132b coupled to the first and second rack units 2100, 2200 to form the support for the barrel that is positioned in the elevated storage cell 2051. Specifically, as noted previously, each of the third components 2132a, b comprises the first arm portion 2137a, b and the second arm portion 2138a, b. The wheel 2013, 2016 is coupled to the first arm portion 2137a, b and the wheel 2123, 2226 is coupled to the second arm portion 2138a, b. The third frame components 2132a, b are coupled to the first and second rack units 2100, 2200 as follows. The first arm portion 2137a of one of the third frame components 2132a is positioned atop the second upper side 2114 of the first hexagonal frame 2110 of the first rack unit 2100 while the second arm portion 2138a of the one of the third frame components 2132a is positioned atop the first upper side 2213 of the first hexagonal frame 2210 of the second rack unit 2200. The first and second arm portions 2137a, 2138a may then be secured to the first hexagonal frames 2110, 2210 of the first and second rack units 2100, 2200 with fasteners 74, which may include screws and nuts or any other fastener as described herein.

Similarly, another one of the third frame components 2132b may be coupled to the second hexagonal frames 2150, 2250 of the first and second rack units 2100, 2200. Specifically, the first arm portion 2137b of the third frame component 2132b may be positioned atop the second upper side 2154 of the second hexagonal frame 2150 of the first rack unit 2100 while the second arm portion 2137b of the third frame component 2132b is positioned atop the first upper side 2253 of the second hexagonal frame 2250 of the second rack unit 2200. The third frame component 2132b may then be coupled to the second hexagonal frames 2150, 2250 with fasteners 75 which may be screws and nuts or other fastener devices.

FIG. 20E illustrates the first and second rack units 2100, 2200 with the additional third frame components 2132a, b coupled thereto. As such, the wheels 2013, 2016, 2123, 2226 are located along the elevated storage cell 2051 so that the barrel supported within the elevated storage cell 2051 may be rotated. Locking mechanisms as described may be included to lock the wheels and prevent or impede their rotation. In this embodiment, the elevated storage cell 2051 is an open cell, meaning it is not defined by an enclosed hexagonal frame like the first and second storage cells 2050. However, while perhaps not needed in all embodiments, additional ones of the first and/or second frame components 2130, 2131 may be coupled to the third components 2132a, 2132b to form hexagonal frames that define and/or surround the elevated storage cell 2051.

FIG. 20E further illustrates the base component 2500. The base component 2500 may have an identical structure to the base component 500 described above with reference to FIGS. 8A and 8B or the base component 500a described above with reference to FIGS. 9A and 9B. As noted previously, the first and second rack units 2100, 2200 may be positioned on the base component 2500 and coupled thereto with fasteners (or welding or other techniques). One of the apexes of the first and second rack units 2100, 2200 may form a lowermost part of the first and second rack units 2100, 2200.

FIG. 20F illustrates the barrel rack system 2000, in a view which is identical to the one provided as FIG. 14. After assembly, the first and second rack units 2100, 2200 are coupled together and then mounted to the base component 2500. The barrel rack system 2000 may then be wheeled to a desired location within a storage space. Alternatively a forklift may be used to lift the barrel rack system 2000 and move it to a desired location.

FIG. 21 is a front view of the barrel rack system 2000. FIG. 21 provides a good illustration of the various first, second, and third frame components 2130, 2131, 2132 that are coupled together to form the first hexagonal frames 2110, 2210 of the first and second rack units 2100, 2200. Furthermore, FIG. 21 illustrates the additional third frame component 2132 coupled to the first hexagonal frames 2110, 2210 of the first and second rack units 2100, 2200. The first, second, and third frame components 2130, 2131, 2132 nest together in such a way that the barrel rack system 2000 may be expanded by continuing to attach additional ones of the first, second, and third frame components 2130, 2131, 2132 to build additional storage cells.

FIGS. 22A and 22B illustrate the barrel rack system 2000 described herein supporting three barrels 10a, 10b, 10c. Specifically, a first barrel 10a is stored in the storage cell 2050 of the first rack unit 2100, a second barrel 10b is stored in the storage cell 2050 of the second rack unit 2200, and a third barrel 10c is stored in the elevated storage cell 2051 defined by upper portions of the first and second rack units 2100, 2200. As seen, the various barrels 10a-c rest atop the wheels so that the barrels 10a-c may be rotated while remaining stored on the barrel rack system 1000. Specifically, the barrel 10a is supported on the wheels 2011, 2012, 2013, 2014, the barrel 10b is supported on the wheels 2121, 2122, 2224, 2225, and the barrel 10c is supported on the wheels 2013, 2123, 2016, 2260. As long as the wheels associated with each barrel 10a-c are not locked as described herein, the barrels 10a-c may be able to be rotated about their axis. If a locking mechanism is included to lock one or more of the wheels associated with any one of the barrels 10a-c, and that locking mechanism is altered into the locked state, rotation of the barrel 10a-c may be impeded or prevented. This may be beneficial to allow winemaking activities to be performed while the barrels 10a-c remain located on the barrel rack system 2000.

FIG. 23 illustrates a barrel rack system 2300 in accordance with another configuration. In this embodiment, two of the barrel rack systems 2000 are coupled together to form a larger barrel rack system 2300. Specifically, the second rack unit 2200 of one of the barrel rack systems 2000 is coupled to the first rack unit 2100 of another one of the barrel rack systems 2000 is in a side-by-side manner to form the barrel rack system 2300. The second rack unit 2200 of the one of the barrel rack systems 2000 may be coupled to the first rack unit 2100 of the another one of the barrel rack systems 2000 using fasteners such as screws, bolts, nuts, or the like.

FIG. 24 illustrates yet another barrel rack system 2400 in accordance with another configuration. In this embodiment, additional rack units 2100a-c are coupled to the upper ends of the first and second rack units 2100, 2200 of the barrel rack system 2300 to form an expanded barrel rack system 2400.

FIG. 25 illustrates still another barrel rack system 2600 in accordance with still another configuration. In this embodiment, two additional rack units 2100d-e have been added atop the rack units 2100a-c of the barrel rack system 2400. Furthermore, in this embodiment the base component 2500a is used instead of the base component 2500. It may be preferable to use the base component 2500a with fixed feet instead of the base component 2500 with casters when the base component 2500a is supporting rack units stacked three or more units high.

It should be appreciated that there are countless different arrangements and configurations for the rack units 2100, 2200 to form barrel rack systems with different shapes and sizes and different storage capacities, depending on building space, storage needs, or other factors as desired.

As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by reference in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Thus, the spirit and scope of the invention should be construed broadly as set forth in the appended claims.

Claims

1. A barrel rack system comprising: at least one first rack unit and at least one second rack unit, each of the first and second rack units comprising: a first hexagonal frame and a second hexagonal frame, each of the first and second hexagonal frames comprising an inner surface that defines an opening, an outer surface opposite the inner surface, a front surface, a rear surface, a first lower side, a second lower side, a first upper side, and a second upper side; anda plurality of struts, each of the struts connected to and extending between the rear surfaces of the first and second hexagonal frames to maintain the first and second hexagonal frames in a spaced relation to define a storage cell between the opening of the first hexagonal frame and the opening of the second hexagonal frame;the first and second rack units being detachably coupled together so that the storage cells of the first and second rack units are adjacent to one another, and wherein an elevated storage cell is defined by the second upper side of each of the first and second hexagonal frames of the first rack unit and the first upper side of each of the first and second hexagonal frames of the second rack unit;at least one wheel coupled to at least: each of the first and second lower sides of each of the first and second hexagonal frames of each of the first and second rack units;the second upper side of each of the first and second hexagonal frames of the first rack unit; andthe first upper side of each of the first and second hexagonal frames of the second rack unit; andwherein the wheels coupled to the first and second lower sides protrude from the inner surface of the first and second hexagonal frames and the wheels on the first and second upper sides protrude from the outer surfaces of the first and second hexagonal frames so that barrels located in the storage cells and on the elevated storage cell are rotatably supported by the wheels.
2. The barrel rack system according to claim 1 wherein each of the first and second lower sides of each of the first and second hexagonal frames comprises a hole that extends from the inner surface to the outer surface, and wherein the at least one wheel that is coupled to each of the first and second lower sides of each of the first and second hexagonal frames of each of the first and second rack units is disposed within the hole so that at least a portion of the at least one wheel protrudes from the inner surface.
3. (canceled)
4. The barrel rack system according to claim 1 wherein each of the first and second hexagonal frames further comprises a first lateral side extending between the first lower side and the first upper side and a second lateral side extending between the second lower side and the second upper side, and wherein the second lateral sides of the first and second hexagonal frames of the first rack unit are adjacent to the first lateral sides of the first and second hexagonal frames of the second rack unit, respectively, wherein the first and second rack units are coupled together with first fasteners that extend through the second lateral side of the first hexagonal frame of the first rack unit and the first lateral side of the first hexagonal frame of the second rack unit and second fasteners that extend through the second lateral side of the second hexagonal frame of the first rack unit and the first lateral side of the second hexagonal frame of the second rack unit.
5. (canceled)
6. The barrel rack system according to claim 1 wherein each of the first and second hexagonal frames is formed from a flat metal sheet having a top surface and a bottom surface, the flat metal sheet comprising a plurality of plate segments and a plurality of hinge portions located between adjacent ones of the plurality of plate segments, wherein the flat metal sheet is configured to be bent at each of the plurality of hinge portions to form at least a portion of one of the first and second hexagonal frames.
7. The barrel rack system according to claim 6 wherein the plurality of plate segments comprises at least a first plate segment and a second plate segment, the first and second plate segments comprising a hole that extends from the top surface of the metal sheet to the bottom surface of the metal sheet, wherein the hole is configured to receive a wheel.
8. The barrel rack system according to claim 6 wherein the flat metal sheet comprises a longitudinal axis, and wherein each of the plurality of plate segments comprises a central axial portion and first and second side axial portions located on opposite sides of the central axial portion, wherein each of the first and second side axial portions is configured to be bent relative to the central axial portion to form a U-shaped section of the metal strip prior to bending the flat metal sheet at each of the plurality of hinge portions.
9. The barrel rack system according to claim 1 further comprising: a base component that is configured to rest atop of a floor surface, the base component comprising a first V-shaped rack support member and a second V-shaped rack support member;each of the first and second hexagonal frames comprising a plurality of sides and a plurality of apexes; andwherein the base component is configured to support the first and second rack units by resting one of the apexes of each of the first and second hexagonal frames of the first rack unit on the first V-shaped rack support member and resting one of the apexes of each of the first and second hexagonal frames of the second rack unit on the second V-shaped rack support member.
10. (canceled)
11. (canceled)
12. The barrel rack system according to claim 1 further comprising at least one wheel lock mechanism, each of the at least one wheel lock mechanism associated with one of the at least one wheel, the wheel lock mechanism configured to lock the one of the at least one wheel and prevent or impede rotation of the one of the at least one wheel, wherein the wheel lock mechanism comprises a locking member that is alterable between a first position whereby the locking member is not in contact with the one of the at least one wheel and the one of the at least one wheel can freely rotate and a second position whereby the locking member contacts the one of the at least one wheel and prevents or impedes rotation of the one of the at least one wheel.
13.-16. (canceled)
17. The barrel rack system according to claim 1 further comprising a first rack assembly comprising a first one of the first rack units and a first one of the second rack units and a second rack assembly comprising a second one of the first rack units and a second one of the second rack units, wherein the second one of the first rack units is coupled to the first one of the second rack units to form the barrel rack system, and wherein the barrel rack system is capable of holding seven barrels.
18. (canceled)
19. A barrel rack system comprising: a first rack unit and a second rack unit, each of the first and second rack units comprising: a first hexagonal frame and a second hexagonal frame, each of the first and second hexagonal frames comprising an inner surface that defines an opening and an outer surface opposite the inner surface; anda plurality of struts, each of the struts connected to and extending between the first and second hexagonal frames to form a storage cell having a cell axis, each of the storage cells configured to hold a barrel;the first and second hexagonal frames of the first rack unit coupled to the first and second hexagonal frames of the second rack unit, respectively, so that the cell axes of the storage cells of the first and second rack units are parallel to one another, and wherein an elevated storage cell is defined by portions of the outer surfaces of the first and second hexagonal frames of the first and second rack units, the elevated storage cell configured to hold another barrel; anda base component configured to be positioned on a floor surface, wherein the first and second rack units are positioned on and supported by the base component.
20. The barrel rack system according to claim 19 wherein each of the first and second hexagonal frames comprises a plurality of sides and a plurality of apexes, and wherein the first and second rack units are oriented so that one of the apexes forms a bottommost portion of the first and second rack units and is in contact with the base component, wherein the base component comprises a first V-shaped rack support member and a second V-shaped rack support member, wherein the one of the apexes of the first and second hexagonal frames of the first rack unit rests atop of the first V-shaped rack support member and wherein the one of the apexes of the first and second hexagonal frames of the second rack unit rests atop of the second V-shaped rack support member, and wherein fasteners affix the first and second hexagonal frames of the first and second rack units to the first and second V-shaped rack support members.
21. (canceled)
22. The barrel rack system according to claim 19 further comprising: for each of the first and second rack units, the first hexagonal frame comprising a first pair of wheels and the second hexagonal frame comprising a second pair of wheels, wherein the barrel held in the storage cell is supported on the first and second pairs of wheels so that the barrel is able to be rotated while remaining positioned in the storage cell.
23. The barrel rack system according to claim 22 further comprising at least one wheel lock mechanism, each of the at least one wheel lock mechanism associated with one of the wheels of one of the first and second pairs of wheels, the at least one wheel lock mechanism configured to lock the one of the wheels and prevent or impede rotation of the one of the wheels, wherein the at least one wheel lock mechanism comprises a locking member that is alterable between a first position whereby the locking member is not in contact with the one of the wheels and the one of the wheels can freely rotate and a second position whereby the locking member contacts the one of the wheels and prevents rotation of the one of the wheels, thereby preventing rotation of the barrel positioned in the storage cell.
24. (canceled)
25. The barrel rack system according to claim 22 wherein for each of the first and second rack units, the first hexagonal frame comprises a first pair of holes extending from the inner surface of the first hexagonal frame to the outer surface of the first hexagonal frame and the second hexagonal frame comprises a second pair of holes extending from the inner surface of the second hexagonal frame to the outer surface of the second hexagonal frame, and wherein each of the wheels of the first pair of wheels is coupled to the first hexagonal frame within one of the holes of the first pair of holes and wherein each of the wheels of the second pair of wheels is coupled to the second hexagonal frame within one of the holes of the second pair of holes.
26. The barrel rack system according to claim 19 further comprising: for each of the first and second rack units, the first and second hexagonal frames further comprising a first lower side and a second lower side that form a V-shape;a first wheel coupled to the first lower side of the first hexagonal frame and a second wheel coupled to the second lower side of the first hexagonal frame;a third wheel coupled to the first lower side of the second hexagonal frame and a fourth wheel coupled to the second lower side of the second hexagonal frame; andwherein the barrel that is positioned within the storage cell is supported on the first, second, third, and fourth wheels so that the barrel is able to be rotated while remaining positioned in the storage cell;the first and second hexagonal frames further comprise a first upper side and a second upper side, wherein the first and second rack units are coupled together so that: (1) the second upper side of the first hexagonal frame of the first rack unit and the first upper side of the first hexagonal frame of the second rack unit form a V-shape; and (2) the second upper side of the second hexagonal frame of the first rack unit and the first upper side of the second hexagonal frame of the second rack unit form a V-shape;a fifth wheel coupled to the second upper side of the first hexagonal frame of the first rack unit and a sixth wheel coupled to the first upper side of the first hexagonal frame of the second rack unit;a seventh wheel coupled to the second upper side of the second hexagonal frame of the first rack unit and an eighth wheel coupled to the first upper side of the second hexagonal frame of the second rack unit; andwherein the additional barrel located at the elevated storage cell is supported on the fifth, sixth, seventh, and eighth wheels so that the additional barrel is able to be rotated while remaining located at the elevated storage cell.
27.-36. (canceled)
37. A barrel rack system comprising: a first rack unit defining a first hexagonal storage cell having a first cell axis, the first hexagonal storage cell being configured to store a first barrel;a second rack unit defining a second hexagonal storage cell having a second cell axis, the second hexagonal storage cell being configured to store a second barrel, the second rack unit being detachably coupled to the first rack unit so that the first and second cell axes are parallel;wherein upper portions of the first and second rack units collectively define an elevated storage cell having a third axis that is parallel to the first and second cell axes, the elevated storage cell being configured to store a third barrel.
38. The barrel rack system according to claim 37 wherein the first rack unit comprises a plurality of first wheels upon which the first barrel is configured to be supported when positioned in the first hexagonal storage cell, wherein the second rack unit comprises a plurality of second wheels upon which the second barrel is configured to be supported when positioned in the second hexagonal storage cell, and wherein the upper portions of the first and second rack units comprise a plurality of third wheels upon which the third barrel is configured to be supported when positioned in the elevated storage cell.
39. The barrel rack system according to claim 37, further comprising: the first rack unit comprising a first hexagonal frame, a second hexagonal frame, and a first plurality of struts connected to and extending between the first and second hexagonal frames;the second rack unit comprising a third hexagonal frame, a fourth hexagonal frame, and a second plurality of struts connected to and extending between the third and fourth hexagonal frames; andwherein the first hexagonal frame of the first rack unit is detachably coupled to the third hexagonal frame of the second rack unit and the second hexagonal frame of the first rack unit is detachably coupled to the fourth hexagonal frame of the second rack unit.
40. The barrel rack system according to claim 39 wherein each of the first, second, third, and fourth hexagonal frames comprises a first lower side and a second lower side that define a lower apex, and wherein at least one wheel is coupled to each of the first and second lower sides of each of the first, second, third, and fourth hexagonal frames, wherein the first and second barrels stored in the first and second hexagonal storage cells are supported by the wheels so that the first and second barrels can be rotated about an axis that is parallel to the first and second cell axes; wherein each of the first, second, third, and fourth hexagonal frames comprise a first upper side and a second upper side that intersect to form an upper apex, and wherein the elevated storage cell is defined by the second upper side of each of the first and second hexagonal frames and the first upper side of each of the third and fourth hexagonal frames, wherein each of the first, second, third, and fourth hexagonal frames comprises a first lateral side that extends between the first upper side and the first lower side and a second lateral side that extends between the second upper side and the second lower side, and wherein the second lateral sides of the first and second hexagonal frames are detachably coupled to the first lateral sides of the third and fourth hexagonal frames to couple the first and second rack units together, further comprising at least one wheel coupled to the second upper side of each of the first and second hexagonal frames and to the first upper side of each of the third and fourth hexagonal frames so that the third barrel located in the elevated storage cell is rotatably supported by the wheels.
41.-43. (canceled)
44. The barrel rack system according to claim 37 wherein the first and second rack units are non-integral with one another and are detachably coupled together with fasteners.
45.-55. (canceled)

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 63/423,104, filed Nov. 7, 2022 and U.S. Provisional Patent Application Ser. No. 63/504,634, filed May 26, 2023, the contents of which are hereby incorporated herein by reference in their entirety.

Provisional Applications (2)

	Number	Date	Country
	63423104	Nov 2022	US
	63504634	May 2023	US

BARREL RACK SYSTEM

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Abstract

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CROSS-REFERENCE TO RELATED APPLICATION

Provisional Applications (2)