Patent Application
20170224106
The present invention relates generally to a support structure that can be used to support shelving on posts. More particularly, the present invention relates to a support assembly for use in, for example, a knock-down shelving system to adjustably support shelves.
Current knock-down shelving systems include a plurality of support posts for supporting one or more shelves at corner support assemblies. These shelving systems have a sleeve or wedge member and an encircling collar both adapted to be secured to a generally cylindrical support post having a circular cross-section. The sleeve has an inner surface that is configured to embrace the support post and has an outer surface that is wedge shaped usually taking the form of a frusto-conical shape with a narrower diameter at the top and a larger diameter at the bottom. The collar has an outer surface that is secured to a shelf. The collar has an internal wedge surface formed to mate with the frusto-conical wedge surface of the sleeve but either inclined in the opposing direction or having a smaller upper opening which does not allow passage of the sleeve on the post. Thus, when the sleeve embraces the post and the collar embraces the sleeve, axial loading of the collar in one direction causes the collar's inward facing wedge surface to mate with the outward facing wedge surface on the sleeve, thereby urging the sleeve toward the post. Since the collar is of one piece and encircles the post it is restrained from radial expansion and has a fixed diameter, and since relative movement of the inclined surfaces of the sleeve and the collar want to increase in diameter as they move relative to one another in axially opposing directions, the non-expandable outer collar forces the sleeve inward and clamps the sleeve against the post and wedges the collar and sleeve into place on the post.
Such shelving systems are disclosed in U.S. Pat. Nos. 3,424,111 and 3,523,508, which use a plurality of cylindrical support posts each formed with a series of equally spaced, annular grooves on its outer surface. A basic shelving system includes four such posts to support one or more formed-wire shelves, with each shelf having a frusto-conically-shaped collar at each corner for receiving a support post. A two-piece interlocking sleeve fits around the support post. The sleeve has a circumferential rib on its interior surface for engaging one of the grooves on the support post and has a frusto-conically-shaped outer surface, which is widest at the bottom, designed to complement the shape of the shelf collars. The support posts fitted with sleeves are received in the collars of each shelf to assemble the shelving system. When assembled, the weight of the shelf and any items placed on the shelf pushes downward on the collar and sleeve, creating a radially-inwardly directed wedging force between the collars and sleeves, which brings the sleeves into tight contact with the posts. Similar wedging concepts are used in U.S. Pat. Nos. 4,811,670; 4,946,350; 5,271,337; 5,279,231 and 6,113,042. Some of these devices use over-center cams to ensure the collars are locked in place.
Further, the above described collars have a fixed diameter and because they encircle the post the must pass along the length of the post until they reach the sleeve with which they wedge against the post. That requires assembling the shelving from the bottom up or the top down since the collars cannot be positioned between two previously installed shelves. Further, a shelf cannot be inserted between pre-installed shelves since the collars cannot slide over previously installed sleeves or collars. Because the collars in these prior art connectors were tubular they had to be slid axially over one end of the post in order to mate with the sleeve and wedge the parts in place. To address this difficulty collars which encircles less than a full 360 degrees were developed, with some collars having open vertical slots like U.S. Pat. Nos. 6,302,284 and 6,257,426, and other collars mating with sleeves or other parts along generally vertical axes, as described in U.S. Pat. Nos. 6,068,143 and 4,656,952. But the open slotted collars provide a weaker connection than unslotted collars because the slot weakens the collar and sufficient weight on the shelf and collar may spread or splay the unconnected parts of the collar apart in the circumferential direction, releasing the support and reducing the clamping force on the sleeve. Making the collars to mate with shaped sleeves also required more expensive manufacturers and stronger sleeves. The collars using vertical joints to interconnect mating collar parts require precise alignment of the vertical joints making them difficult to align and assemble.
Still other connectors placed brackets on the outer, metal collars with the shelving rods engaging the brackets, as shown in U.S. Pat. Nos. 6,015,052 and 6,253,687. These collars required assembling the shelving from the bottom up since the collars cannot be positioned between two previously installed shelves. Further, a shelf cannot be inserted between pre-installed shelves since the collars cannot slide over previously installed sleeves or collars. Because the collars in these prior art connectors were tubular they had to be slid axially over one end of the post in order to mate with the sleeve and wedge the parts in place.
Two-part collars allow the connectors to be located at selected locations along the post without sliding the collars from the top of the post to the desired position. Such collars are shown in U.S. Pat. No. 8,887,647 to Sabounjian. These collar parts each have interlocking fingers made of metal to restrain separation of the collars. But the collar interconnections are difficult to make accurately and may be imperfectly mated by the user, resulting in inconsistent clamping pressure urging the inner sleeve against the post, which can in turn cause variations in the strength of the connection between the connector and the post. There is thus a need for an improved and more consistent shelving connector.
Two-part collars were also developed that use different interlocking mechanisms and also have slots in the collars so the slots can fit over and rest against saddles or supports on the inner sleeve that extend outward from the sleeve, with the saddles or supports extending axially along a length of the sleeve and collar to provide a localized area of support for the collar. Thus, the collars urge the sleeves inward against the post and also rest on protrusions, tabs or saddles extending outward from the sleeve. These collar parts are shown in Published application 2015/0289044 to Sabounjian. But these collar and sleeve parts are difficult to make consistently and difficult to connect consistently as the collars may abut the inner sleeves at various locations which results in uneven loading of the collar and uneven loading of the inner sleeve, causing variation in the load-carrying capability, light variations in the location of the shelf, and slight downward movement of the connectors as the load on the shelf increases. Also, the shear strength of the localized and outward extending protrusions is limited by the strength of the sleeve material, which is commonly a plastic material of relatively low strength compared to metal. The result is that the collar does not consistently rest against the outwardly extending protrusions, saddles or tabs so the load capacity of the connection may vary. There is thus a need for a connector having a sleeve and collar that may be made more consistently and provide a more consistent connection and more consistent load-carrying capacity.
Despite the use of these above-described shelving systems, a need exists for an improved connector and shelving system, especially one easier to assemble and more flexible in its assembly while achieving more consistent connections and more consistent load capacities. There is thus a need for an improved shelving connector that may be installed without having to slide the connector along the entire length of the post to the desired shelving position and that may be easily installed while carrying a predicted load.
A connector is provided for connecting to a post having grooves at intervals along a length of the post. The connector has an annular sleeve with two interlocking halves releasably joined together to form an inner passage conforming to the shape of the post with at least one rib extending from the sleeve to selectively engage one of the grooves in the post. The sleeve has a tapered outer surface with a smaller top and larger bottom and is preferably frusto-conical in shape. The sleeve surrounds a portion of the post during use with either a retaining wall or s extending from the bottom of the sleeve to position, retain or support a mating collar during use.
The annular collar has two interlocking halves with an interior passage configured to conform to the outer surface of the sleeve and is also preferably frusto-conical in shape. The collar part that is connected to the item to be connected to the post, such as a shelf, preferably has a first collar with two elongated flanges or ears extending outward from two opposing sides of the collar part. For a shelf with four corners a first collar part is at each corner, with each collar part having half of a frusto-conical body with two flanges extending radially outward from each of two sides of that body. The outwardly extending flanges or ears allow two different shelves to have the first collar part abut a different half of the same sleeve with the flanges of the collar parts on two different shelves being immediately adjacent each other. A connecting member interlocks the flanges by having two of the immediately adjacent ears or flanges (each connected to a different shelf) fit into the channel formed by a leg with a C-shaped cross-section sized to receive the flanges. The top portions of two such parallel legs are connected so a user can slide the two legs of the connecting member over a pair of flanges on each of the two opposing sides of the collar part or to remove the legs from the flanges.
The collar parts with the outwardly extending flanges may also interlock by various connections when they connect to a corner post or a sleeve to which no other shelf connects, including interlocking connections using a male flange or ear extending along the side of one collar part entering a female channel on the corresponding side of the other collar part. Alternatively, the juncture of each outwardly extending flange with the collar body may be partially slotted with the slots on the two collar parts passing through each other so the first collar part fits into the slots of the second collar part and vice versa.
A retaining wall or may also be provided on the sleeve to guide and/or retain the collar on the sleeve during assembly and use. The retaining wall and s extend upward from a flange extending outward (preferably radially outward) from a bottom edge of each sleeve part, with the retaining flange extending upward parallel to the axis and offset from the sleeve surface to form a void volume between the bottom, offsetting flange and the top of the retaining member that extends along the circumferential length of that bottom flange. The retaining member is offset from the outer surface of the sleeve and there is a void space between the facing sides of the and the radially adjacent part of the sleeve, with the void space extending from the outwardly extending flange to the top of the. Since the retaining member preferably extends parallel to the axis and the outer surface of the sleeve is slanted or tapered the void volume is tapered in cross section being larger at the top and smaller at the bottom and curving around the surface of the sleeve for the circumferential or peripheral length of the retaining member.
A first collar part fastened to a shelf or other item fits over half the sleeve and fits into that offset of the so that the bottom edge of the first collar part fits into at least part of that void volume with the taper of the outer surface of the sleeve cooperating with the taper of the first collar part to wedge the sleeve against the post and hold them to the post and support the first collar part and shelf. The retaining member keeps the mating collar part in position during assembly and can free up a user's hand during assembly. A second collar part may have its bottom edge fit into the void volume formed by the on the second sleeve part with the first and second collar parts interlocking to prevent lateral or radial separation of the collar parts, while downward movement of the collar parts relative to the sleeve and post wedge the sleeve against the post and secure the sleeve and collar in a selected position on the post.
There is thus provided an improved sleeve for a wedging sleeve and collar connection on a post that has an outer surface with grooves at intervals along a length of the post and with a longitudinal axis extending along the length of the post. The collar has an annular configuration that mates with the outer surface of the sleeve to wedge the sleeve inward against the post as the collar moves downward along the axis relative to the sleeve during use. The connection is preferably for a shelf connected to a first collar part. The improved sleeve includes an annular sleeve having a tapered outer surface around the periphery of the sleeve which tapered surface is smaller at a top and larger at a bottom of the sleeve. The sleeve also has an inner surface forming an inner passage surrounding a short length of the post during use with at least one rib extending from the inner surface of the sleeve and configured to mate with one of the grooves in the post during use. The sleeve also has first and second interconnecting parts with each sleeve part having two opposing sides each extending along a portion of the longitudinal axis. In this embodiment each sleeve part has a retaining wall around a majority of the periphery of the bottom of each sleeve part where the retaining wall is offset radially outward from the bottom of the sleeve part a distance of a few millimeters or less with the distance being about a thickness of a bottom of the collar that is mating with the sleeve part during use. In further variations this sleeve advantageously has a frusto-conical outer surface and a generally cylindrical inner passage in order to engage a cylindrical post with grooves in it.
In another embodiment, the sleeve comprises an annular sleeve having a tapered outer surface that is smaller at a top and larger at a bottom of the sleeve and extends around a periphery of the sleeve and along a substantial length of the sleeve. The sleeve also has an inner surface forming an inner passage surrounding a short length of the post during use with at least one rib extending from the inner surface of the sleeve and configured to mate with one of the grooves in the post during use. The sleeve has first and second, interconnecting parts with each sleeve part having two opposing sides each extending along a portion of the longitudinal axis. In this embodiment each sleeve part has a bottom flange extending radially outward a distance less than a few millimeters from the bottom of the sleeve part, the distance being about a thickness of a bottom of the collar part that is mating with the sleeve part during use. The flange has a retaining member extending from an outward end of the bottom flange generally parallel to the longitudinal axis a distance along the longitudinal axis of less than about ⅔ a height of the sleeve. The height of the sleeve and retaining member are both measured relative to a bottom of the sleeve. The retaining member is not connected to the sleeve along a length of the retaining member as a void space is formed between the sleeve and the retaining member. The void space extends from the bottom flange to the top of the retaining member and along a circumferential length of the flange.
In further variations of this embodiment the sleeve also has a frusto-conical outer surface and a generally cylindrical inner passage. Further, the flange on each sleeve part advantageously extends along less than a majority of a circumference of the sleeve part and more than an arc of about °5 and this flange is not located at one of the two opposing sides of the sleeve part and it has a height of about ⅓ or less of the length of the sleeve along the longitudinal axis. The height is measured relative to a bottom of the sleeve. In this embodiment, the flange and advantageously extend along one of the opposing sides of the sleeve part and each retaining member extends along an arc of about °5 to about 10°. Moreover, the flange and retaining member advantageously extend along both of the opposing sides of the sleeve part so that when the two sleeve parts are interconnected there are two abutting retaining flanges on two opposing sides of the annular sleeve.
There is also provided a shelving connection for holding two shelves to a common post and sleeve at the same location along a length of that post. The post has an outer surface with grooves at intervals along a length of the post with a longitudinal axis extending along the length of the post. The shelving connection includes an annular sleeve having a tapered outer surface that is smaller at a top and larger at a bottom of the sleeve. The sleeve has an inner surface forming a passage surrounding a short length of the post with at least one rib extending from the inner surface of the sleeve and mating with one of the grooves in the post. The sleeve also has first and second interconnecting sleeve parts with each sleeve part having two opposing sides each extending along a portion of the longitudinal axis. The sleeve parts are clamped to the post and surround a short length of the post at a location of a shelf.
The shelving connection also includes a first shelf having a first collar part connected to a corner of the shelf. The first collar part has a tapered body with two opposing sides with a first flange extending outward from each side and extending along a length of each side generally parallel to the longitudinal axis. Each of the first flanges on the collar part of the first shelf is spaced apart about 180° or slightly less from the other first flange of the collar part of the first shelf. The tapered body of the first shelf defines a portion of a tapered interior passage configured to engage about half or slightly less of one side of the sleeve with a smaller passage at a top of that tapered body and a larger passage at a bottom of that tapered body.
The shelving connection also includes a second shelf having a first collar part connected to a corner of the second shelf. The first collar part on the second shelf also has two opposing sides with a first flange extending outward from each side and extending along a length of each side generally parallel to the longitudinal axis during use. Each of the first flanges on the first collar part of the second shelf is spaced apart about 180° or slightly less from the other first flange of the collar part of the second shelf. The tapered body of the first collar part on the second shelf defines a portion of a tapered interior passage configured to engage about half or slightly less of one side of the sleeve with a smaller passage at a top of that tapered body and a larger passage at a bottom of that tapered body.
The shelving connection has the first collar part of the first and second shelf each connected to opposing sides of the sleeve with a substantial portion of the first flanges on the first shelf being immediately adjacent a substantial portion of the first flanges on the second shelf. Further, the shelving connection has a retaining coupler with two parallel legs connected by a connecting member adjacent an upper end of the legs. Each leg comprising a separate, elongated member having a U-shaped cross-section with opposing sides spaced a distance apart sufficient to fit over and contact the immediately adjacent flanges and sufficiently strong to restrain those flanges from separating laterally when a predetermined load is applied to the shelf. The retaining coupler has no connection between a lower end of the two legs along a substantial length of the legs so that it can fit over various shelving connections to the first collar on at least one of the first or second shelf.
In further variations, the shelving connection preferably has a frusto-conical outer surface and the collar has a frusto-conical interior passage to mate with a cylindrical post. In one alternative variation, each sleeve part has a retaining wall around a majority of the periphery of the bottom of each sleeve, with the retaining wall offset from the bottom of the sleeve a distance of about a thickness of a bottom of the collar part that is mating with the sleeve part during use. The retaining wall does not extend to each opposing side of the sleeve so the first and second flanges do not abut against a top of the retaining wall during use. In another alternative variation, the shelving connection may have each sleeve part include a retaining member offset from the bottom of the sleeve a distance of about a thickness of a bottom of the collar part that is mating with the sleeve part during use. This retaining member extends along less than a majority of a circumference of the sleeve part and more than an arc of about 5°, with each retaining member located intermediate the two opposing sides of the sleeve part and having a height along the longitudinal axis of less than about ⅓ a height of the sleeve. In a further variation, the shelving connection has each sleeve part with a retaining member extending along each opposing side of the sleeve part and offset from the bottom of the sleeve part a distance of about a thickness of a bottom of the collar part that is mating with the sleeve part during use, each retaining member extending along an arc of about °5 to about 10° and having a height generally parallel to and extending along the longitudinal axis that is less than about ⅔ a height of the sleeve.
There is also provided a connector for releasably fastening an outer, tapered collar to an inner, tapered sleeve on a post that has an outer surface with grooves at intervals along a length of the post and with a longitudinal axis extending along the length of the post. The outer, tapered collar has an annular configuration that mates with the outer surface of the sleeve to wedge the sleeve inward against the post as the collar moves downward along the axis relative to the sleeve during use. This connector includes any of the sleeves described herein, along with an annular collar having first and second separable and interlocking collar parts defining a tapered interior passage that is smaller at the top and larger at the bottom and configured to surround a length of the sleeve during use and mate with the tapered outer surface of the sleeve to wedge the sleeve against the post as the collar moves downward relative to the sleeve along the longitudinal axis during use. The first collar part includes first and second opposing sides extending along a portion of the longitudinal axis and a first, male flange extending in a direction outward from each first side and extending along a length of each first side. Each male flange has a length along the longitudinal axis about the same as the height of the sleeve or up to about ⅓ less. The length is measured from the bottom of the sleeve.
In further variations, this connector has a second collar part that includes a female channel extending outward from each of two opposing sides of the second collar part and extending along a length of the second collar part measured along the longitudinal axis. Each female channel has a C-shaped cross-section and is configured to slidably receive one of the male flanges during use. Each female channel extends along opposing sides of a different one of the male flanges during use. In one preferred variation, the connector has a sleeve with a frusto-conical outer surface and the collar has a frusto-conical interior passage.
In another preferred variation, the connector has each first male flange extending outward from a frusto-conical body along a juncture with a closed ended slot extending along that juncture and opening onto a top end of the first collar part. Further, the second collar part includes two opposing sides extending along a portion of the longitudinal axis and a second flange extending in a direction outward from each opposing side of the second collar part and further extending along a length of each opposing side of the second collar part. The second flange advantageously has a length along the longitudinal axis about the same as the height of the sleeve or up to about ⅓ less. The second flange preferably extends outward from the frusto-conical body along a juncture with a closed ended clot extending along that juncture and opening onto a bottom end of the second collar part which has a larger diameter than a top end of that second collar part. The slots of the first and second collar part and the configurations of the first and second flanges allowing each collar part to enter the slots of the other collar part to interlock the collar parts during use with each flange of the first collar part immediately adjacent a different flange of the second collar part. In a still further variation of this connector, the connector may include a retaining coupler having two parallel legs connected by a connecting member adjacent an upper end of the legs. Each leg may include a separate, elongated member having a U-shaped cross-section with opposing sides spaced a distance apart sufficient to fit over and contact the immediately adjacent flanges and sufficiently strong to restrain those flanges from separating laterally when a predetermined load is applied to the shelf. The retaining coupler has no connection between a lower end of each of the two legs along a substantial length of the legs.
These and other advantages and features of the invention will be better appreciated in view of the following drawings and descriptions in which like numbers refer to like parts throughout, and in which:
Referring to
As used herein the relative terms above and below, upper and lower, top and bottom are with respect to the relative positions along the longitudinal axis 18 of a post 12, which is typically in the vertical direction. The relative terms inward and outward, inner and outer are the relative directions toward and away from that axis 18 when the parts are orientated in the assembled position. These terms are provided with respect to the normal horizontal orientation of shelves and the vertical orientation of posts as shown in the attached figures in which the direction of gravity is down. The orientation of the shelving unit may change and if so the orientation of the actual unit may be transposed to correspond with the orientation of the figures for easier and consistent understanding.
The collars 16 have first and second parts 16a, 16b respectively, that are configured to interlock as best seen in
The sleeve halves 20a, 20b each have two opposing, first and second sides shown in the figures as generally vertical sides. The interior side or face 22 faces the post 12 and is cylindrical when the post 12 is circular in cross-section. The exterior side or face 24 faces away from the post and is tapered outward being narrower at its top and larger at its bottom. The arc subtended by each first and second side is preferably slightly less than 180° so the sleeve halves may be squeezed toward each other by the collar parts 16a, 16b and squeezed tightly against the post 12 during use.
Each sleeve part or half 20a, 20b is configured to engage the outer surface of post 12. Each sleeve part typically has an inwardly extending rib 26a sized and configured to mate with a corresponding groove 26b (
Each sleeve part 20a, 20b preferably has at least one bottom flange 30 extending outward from a bottom portion of the sleeve part and extending outward from the respective sleeve parts 20a, 20b sides from which the bottom flange 30 extends, so there are first and second bottom flanges 30, one on each sleeve half. The bottom flanges preferably extend in a direction radially outward relative to the post 12 and post axis 18 during use when the inner face 22 is generally vertical and parallel to the outer surface of the post 12. The bottom flanges 30 preferably extend radially outward a distance D1 about 2-3 mm, but the distance will vary depending on the thickness of the bottom of the mating collar part 16a, 16b as will become apparent later. The bottom flanges 30 preferably extend peripherally around or circumferentially around a portion of the outer periphery or circumference of the sleeve, but that peripheral or circumferential distance will vary with the load capacity to be carried, the materials and other factors as will become apparent later. In the depicted embodiment the bottom flanges 30 advantageously have a thickness along axis 18 of a few millimeters, but that distance will vary as described later. The bottom flanges 30 are preferably integrally molded with the remainder of sleeve part 20a, 20b, so as to form a single-piece, injection molded part of unitary construction and material.
Extending upward from the outer periphery of the bottom flanges are retaining members, which extend upward along the length of the sleeve 20 and generally parallel to the post 12 and its axis 18 to form a retaining member 32. The outer end of the bottom flanges 30 and the outer facing and inward facing surfaces of retaining members 32 are preferably slightly curved and more preferably are generally concentric with the inner surface 22 of sleeve part 20a, 20b which are preferably curved. The retaining members 32, are preferably inclined relative to the outer surface 24 of the sleeve parts 20a, 20b, and are generally parallel with the outer surface of post 12 and axis 18. In the depicted embodiment each retaining member 32 subtends an arc of about 20-30°. The bottom flanges 30 offset the retaining members 32 from the outer surface 24 of the sleeve parts 20a, 20b. Other than the bottom flange 30, there is no saddle, protrusion or support connecting the retaining members 32 to the sleeve 20 along the axial length of the retaining members 32. Instead, the bottom flanges 30 form an offset from the sleeve 20 with a void space 33 or gap separating the upwardly extending retaining members 32 from the adjacent side of the sleeve parts 20a, 20b so that the axial length of the retaining member 32 is cantilevered from the outwardly extending bottom flange 30. This is best seen in
The retaining members 32 could be less than about ⅓ the axial height of sleeve 20 and making them shorter helps reduce molding costs and position the interlocked collar 16 after substantial engagement with the sleeve 20. The retaining members 32 each preferably span a small arc of about 5-20 degrees, and preferably the height of the retaining member 32 is about 1 to about 2 times the circumferential width of the. That ratio is believed to keep the s shorter and easier to mold, while guiding and retaining the bottom end of each interlocking collar part 16a, 16b during assembly.
The bottom flange 30 and retaining member 32 are located between the vertical edges or sides of each sleeve, and preferably, but optionally located at the middle of each first and second sleeve 20a, 20b, about half way between the free edges of each sleeve. If more than one bottom flange 30 and retaining member 32 is formed on each sleeve 20a, 20b, they are preferably located so that when the sleeve parts 20a, 20b are assembled to surround a short length of the post then the bottom flanges 30 and retaining members 32 are symmetrically located about the axis 18 and preferably equally spaced about the axis 18 and still have the above proportions. By locating the retaining members 32 at the middle of each sleeve, many interlocking collar mechanisms will automatically require that the juncture of first and second collar parts 16a, 16b be located near or at the juncture of the sleeve parts 20a, 20b when the parts are mated for use. As best seen in
Referring to
Referring to
The locking tabs 34 and mating locking recesses 36 are preferably configured to form a snap-fit or friction fit to releasably hold the sleeve halves 20a, 20b together. The locking tabs 34 may extend tangential from the curve of sleeve 20, but preferably the tabs curve about axis 18 with the same curvature as either of the sleeves 20a, 20b and the recesses 36 may be configured with a conforming curvature. The locking tabs and recesses 34, 36 prevent relative movement of the sleeve halves 20a, 20b along the direction of the longitudinal axis 18. In the depicted embodiment, the locking tabs 34 have a cross section about 2 mm thick by about 10 mm high and extend from the substantially straight side of the sleeve halves 20a, 20b a distance of about 4 mm. The locking recesses are preferably slightly deeper than the length of the locking tabs 34, with a depth of about 5 mm believed suitable when the locking tab 34 extends about 4 mm from the straight side of the sleeve. The dimensions will vary with the post 12 and the load to be carried.
Referring to
The collar parts 16a, 16b may be interlocked by various means, with
Referring to
The depicted collar parts 16a, 16b have a frusto-conical wall, or at least an inside that has a tapered, frusto-conical shape that is smaller in diameter at the top and larger at the bottom. The inclination of the frusto-conical wall is preferably about the same as that of the outer surface 24 of the sleeve 20, or slightly more. Each collar part 16a, 16b has substantially straight sides preferably extending along a slightly conical surface and encircling longitudinal axis 18 edges. The opposing sides of each collar part 16 may subtend an arc of about 180° or slightly less. Each collar part 16a, 16b has a lower bottom edge that is preferably continuous between opposing sides of the collar part, and in substantially the same plane.
The collar 16 preferably has first collar part 16a connected to a shelf 14 (
As illustrated in
In more detail, the two sleeve halves 20a, 20b may be snapped around a vertical post 12 with the locking tabs 34 mating with the locking recesses 30 to hold the first and second sleeve parts together around the post. The interlocked sleeve parts 16a, 16b are as shown in
A second collar part 16b is then mated with each of the first collar parts by positioning the second collar part 16b above the selected sleeve 20 and first collar part 16a, and moving the second collar part 16 downward so the male flange 50 on the first collar part 16a slide into the female channel 54 in the second collar part to interlock the collar parts. The interlocking of the male flange 50 and female channel 52 prevent radial separation of the collar parts and compress the sleeve 20 against the post 12. The second collar parts 16b may be attached separately, preferably by manipulating the collar parts with a manipulating tab 46 on the collar part 16b, or two second collar parts 16b may be connected to opposing ends of end frame 44 so two collars are not only separately connected, but tied to each other to help restrain adjacent posts 12 from splaying at the location of the end frame. The shelf 14 could have second collar parts 16b connected at each corner of the shelf instead of the first collar parts 14a, in which case the locking would be achieved by adding the first collar part 16a either separately to the corners, or by using a connecting end frame 44 having a first collar part on each end of the end frame.
The parts may be removed and the shelves taken off the posts 12 by reversing the order of above described steps. Thus, a user may pull upward on the collar part 16a, 16b using manipulating tab 46, or pull upward on the locking bar or end frame 44, or pull upward on a shelf 14 to disengage the male flanges 50 from the female channel 52 on each collar 16 at each corner of a shelf. Once all collar parts 16a, 16b are removed from a sleeve 20, the sleeve halves 20a, 20b may be pulled apart and removed from the post. Optionally, one or more sleeves 20 may be removed as they become accessible.
As the weight on the shelf 14 increases the gripping forces on the collar parts 16a, 16b and sleeve 20 increase because the inclined generally conical surfaces of the collar part 16a, 16b are trying to move downward over the inclined, generally conical surface of sleeve 20, and the smaller diameter of the upper portion of collar 16 wedges against the larger diameter of the lower portion of the sleeve 20. The bottom radial flanges 30 abut the bottom of the collar parts 16a, 16b during maximum loads and do not allow the collar 16 to pass unless the bottom flanges 30 are sheared off or the collar parts deform to slide over the flanges, or some combination thereof. The bottom flanges 30 thus provide part of the load carrying capability of the connection formed by sleeves 20 and collars 16, although preferably only during maximum loading so as to allow the collar to move slightly downward as the load increases toward maximum rated capacity or possibly event toward maximum design capacity.
By eliminating the outwardly extending saddles or protrusions of the prior art, all of the force the shelf 14 exerts on one connector goes to wedge the outer collar 16 against the inner sleeve 20 and post 12, with the force being exerted in a more uniform manner as the force is more uniformly distributed around the circumference or periphery of the collar 16 onto the sleeve 20 and post 12. The frusto-conical shaped inner surface of collar parts 16a, 16b thus mate with the correspondingly shaped frusto-conical outer surface of sleeve 20 to urge the sleeve against the post 12 during use. The mating parts of the collar parts 16a, 16b and sleeve halves 20a, 20b advantageously have the same slope or a slight interference fit, with slopes of about 2-10 degrees and with 2-5 degrees being preferred suitable and interference fits formed by slopes of 1-3 degrees difference in slope and these fits are used herein to define the preferred mating of these parts. The retaining member 32 helps retain the collar part 16a, 16b in position during installation. Because the void space 33 allows the collar 16 to approach and contact the outward extending bottom flanges 30 the retaining member 32 guides the collar more securely than in the prior art. The members 32 also restrain radial outward movement of the bottom portion of collar parts 16a, 16b.
Moreover, as seen in
It is believed that one benefit of the retaining member 32 is to control or limit the position of the bottom edge of collar parts 16a, 16b at the middle of each collar part and help keep that middle edge from moving radially inward or outward. Because the male flange 50 does not always fit perfectly within the female channel 52 the mating of the flanges 50 and channels 52 on each pair of collar parts 16a, 16b may cause deformation of the collar, which the retaining member helps control by controlling the position of the bottom periphery of each collar part and by controlling the radial movement at that middle location. By restraining the location of the middle portion of the bottom edge of the collar part 16a, 16b it is believed that a tighter connection is achieved between the mating flanges 50 and channels 52. By locating the bottom flange 30 and retaining member 32 in the middle of the collar part 16a, 16b it is believed that the shape of the bottom of the conical collar 16 is maintained as the interlocking flanges 50 and channels 52 are opposite each other and the restraining members 32 are opposite each other, restraining the generally circular periphery of the collar 16 at four equally spaced locations. Retaining the circular shape at the bottom of the collar is believed to help prevent undesirable deformation of the collar, to help ensure engagement of the flanges 50 and channels 52, and to provide a more secure connection with the post 12 during heavy loading. The slight interference fit between the collar 16 and retaining member 32 is also believed to help secure the collar in position and restrains movement of the collar as would loosen the connection.
Because the sleeves 20a, 20b may be snapped onto the post 12 at any suitable location and the collar need not pass along the length of the post in order to connect to the sleeve 20, the shelves 14 may be connected in any order to the posts 12. No bottom-up assembly is required. Shelves may be inserted between two adjacent shelves without removing the upper shelves. The ease of assembly is believed to be superior to prior art designs. The slight interference fit is optional.
The collars 16 are preferably split collars having first and second parts 16a, 16b each of which do not extend more than 180° around the circumference of the posts 12 and preferably extend about 178-179.5° around the circumference of the post. But the collar parts 16 could extend further and enclose a majority of the circumference of the post 12 and sleeve 20, particularly for collar parts connected to shelves 14 where only one shelf connects to one sleeve. If so, the other collar part 16 engaging the other pair of abutting bottom flanges 30 would have a correspondingly smaller circumferential size so as to avoid the sides of the collar parts 16a, 16b overlapping or otherwise preventing a tight clamp to the post 12. Smaller sized collar parts 16b are believed suitable for collar parts on the end frames 44 or single collars 16 not connected to a shelf or an end frame but used to lock the free pair of abutting bottom flanges 30 and keep them from splaying and tightening the connection to the post.
The collar parts 16a, 16b preferably surround or extend around about half or slightly less than half of the circumference of sleeve 20, or about 180° or slightly less, along a short length of the post but along a substantial length of the sleeve 20 and preferably the full axial length of sleeve 20. The use of a collar part encircling about 185°-270° of the circumference of the post 12 and sleeve 20 is believed possible, with the other locking collar part encircling the remaining portion of the 360° circumference of the post and sleeve. If the collar part 16a, 16b encircles, extends around or surrounds much more than about 185°-190° of the circumference, then the collar part may no longer be flexible enough to allow opposing sides of the collar part to spread apart to fit around the post 12 and sleeve 20 laterally from the side of the post, and may require the collar part to be positioned by sliding it axially from one end of the post along the length of the post 12 and axis 18 (which is not desirable). If the collar part 16a, 16b encircles more than 180° of the post and the same sleeve then two identical collar parts cannot abut opposing sides of the same sleeve on the same post at the same location along a length of the post and clamp the same sleeve 20 against the post sufficiently to hold the sleeve, collar and connected shelf in place on that common post.
The connector 10 can be used in various other types of support systems, such as cabinets, closets, rolling carts, rolling racks, posts with outwardly extending arms and the like, with the described shelving system being only one example of use for the connector 10. Moreover, the connector 10 can be used in conjunction with many shelf configurations and is not limited to use with a corner of a shelf 14, or for that matter, a corner of any supported part.
The sleeves 20a, 20b may be made of a suitable plastic. ABS, polyethylene and polyurethane plastics are believed suitable. The sleeves are preferably molded as a single piece of material to form an integrally molded part. The posts 12, collar parts 16a, 16b and shelves 14 are preferably made of metal, but one or more of them may be made of a sufficiently strong plastic material. Depending on the weight which each shelf 14 or shelving unit is designed to support, the dimensions of parts and material used will vary.
A simplified shelving unit would include four corner posts 12, at least one and preferably more shelves 14 with collar parts 16 of any type as described herein at each location on the shelf (generally corners) where the shelf is to connect to the post 12. For a rectangular shelf 14 with four collar parts 16a, 16b, one at each corner to connect to four posts, two end frames 44 would be needed for each shelf, or four single collar parts 16a, 16b for each shelf. A shelving kit may be provided that preferably includes those parts and more preferably includes two, three, four, five or six shelves 14 with corresponding numbers of collar parts 16a, 16b on each shelf, and twice the number of end frame connectors 44 as there are shelves (or four times the number of single collar parts 16a, 16b), and four times the number of sleeves 20 as there are shelves.
A kit may include the above combination of parts and combinations thereof. Thus, a simple shelving kit may have two shelves 14, which if rectangular in shape have a collar part 16a of any type described herein at each corner of the shelf. The kit would further include eight sleeves 20 and eight collar parts 16b of any type described herein that are either separated, or with pairs of collar parts 16b joined to form end frames 44. Each additional rectangular shelf added to the kit would preferably include four collar parts 16a, four collar parts 16b and four sleeves 20. If two shelving units are joined horizontally together by having two shelves 14 with two collar parts 16a at one end fasten to the same sleeves 20 each on two corresponding posts 12, then the number of end frames 44 may be reduced by half, as may the number of single piece collars that surround or encircle a short length of the post and sleeve, if such single piece collars are used instead of end frames 44 or individual collar parts 16b.
While it is believed desirable to have an interference at the bottom of the void volume 33 between the collar 16 and v 32, that is believed optional. On the other than, a large clearance fit is believed undesirable. Thus a clearance of less than about 0.5 mm is believed desirable. The offset will vary with the materials of which the parts and shelves are made, and the load to be carried on the shelves and posts. Likewise, the dimensions of the sleeves and parts thereof will vary with the materials and loads to be carried by the parts.
Referring to
Moreover, the location of the outwardly extending flanges and associated axially extending retaining members 32 is changed so that each of the two opposing edges of the first sleeve part 20a have a retaining member 32 and each of the two opposing edges of the second sleeve part 20b have a retaining member 32, with each retaining member of each sleeve placed immediately adjacent to and preferably abutting a different retaining member of the other sleeve during use.
Additionally, the sleeves 20a, 20b have an outwardly extending bottom flange 30 extending between the bottom flanges 30, and preferably not extending in an outward direction as much as the bottom flange 30. Advantageously, the bottom flange 30 extends outward a distance about the same as the thickness of the collar 16 or slightly more, so as to form a ledge against which the bottom of the collar 16 may rest during use and especially during maximum loading. The bottom flange 30 may extend radially outward the same distance as bottom flange 30 for ease of manufacturing. The bottom flange 30 may be used with the sleeves 20 and collars 16 of
The bottom flange 30 provides an outward extending ledge at the bottom of the sleeve 20 which requires more axial force to shear off the combination of the lips and flanges, than just to shear off the bottom flanges 30 by themselves. The use of two bottom flanges 30 on each sleeve allows more variation in the molding of the sleeves as the circumferential length of the bottom flanges 30 may vary, with an included angle of 5-10° believed suitable for each bottom flange 30 for a total included angle of about 10-20°. The bottom flange 30 and multiple bottom flanges 30 thus provide a means to increase and vary the axial load carrying capacity of the shelving connection by increasing the force required for the collar 16 to pass by the sleeve 20. The bottom flange 30 may be used on the embodiment of
Further, by locating the retaining members 32 on each of two opposing sides the bottom flanges 30 are located at the junction of the first and second sleeve parts 20a, 20b. The retaining members 32 may interfere with the interlocking of some collar parts 16a, 16b. Thus, as seen in
The collars 16a, 16b of
Referring to
The bottom flange 30 extends outward a distance about the radial thickness of the bottom of collar parts 16a, 16b or slightly greater. The retaining wall 38 may have a height or length parallel to axis 18 that is about half of the length of the sleeve 20, but is preferably shorter and more preferably is very short compared to the axial height of the sleeve 2, advantageously about 1 to 5 times the thickness of the collar parts 16a 16b at the bottom of the collar or about 1 to 6 times the width of the bottom flange 30. A height of about 1-3 mm is believed suitable for plastic sleeves used with shelves 14 to hold 100-200 pounds. The retaining walls 38 are preferably square in cross-section (with rounded corners) but need not be so. When shelves are loaded the collars 16 sometimes slide slightly downward on the posts 12 relative to the sleeves 20, and under heavy load at or near the maximum rated load capacity of the shelves, the collars 16 may move further downward. When the weight on each collar meets or exceeds the rated maximum load capacity then the collars typically move further downward. The retaining wall 38 is preferably high enough that the bottom edge of the collar parts 16a, 16b are below the upper edge of the retaining wall 38 at the maximum rated load capacity of the collar and sleeve connection and preferably contacting the bottom flange 30 at that maximum rated load capacity.
As the collar 16 slides downward the bottom flange 30 provides extra resistance to axial motion. The bottom flange 30 thus provides resistance to axial movement of the collar 16 past the flange as the bottom of the collar will contact the flange as the shelf and collar move downward relative to the sleeve. Thus, the bottom flange 30 resists downward motion of the collar relative to the sleeve, forcing the collar 16 to shear off the bottom flange 30 or deform over the bottom flange 30 and wall 38, or both. The retaining wall 38 is believed to provide resistance to non-circular deformation of the bottom of the collar 16 thus helping to maintain the collar bottom in its circular shape. The retaining wall 38 is also believed to resist outward motion or deformation of the collar past the retaining wall, helping to maintain the circular shape of the bottom of the collar parts 16a, 16b when the collar contacts the wall. The outwardly extending bottom flange 30 also provides a stiffening structure around the periphery of the bottom of the sleeve parts 20a, 20b to reduce deformation of that part of the sleeve 20a, 20b. The retaining wall 38 cooperates with the bottom flange 30 to provide an L-shaped cross-section that further stiffens the bottom of the sleeves 20a, 20b at periphery of the sleeves, especially against radial deformation.
The bottom flange 30 and retaining wall 38 extend from side-to-side on each sleeve part 20a, 20b, with a gap 40 in the wall as needed for those interlocking collars that extend into the location of the wall. The depicted embodiment has the wall 38 end shortly before the gap 40. The depicted gap 40 occurs on opposing sides of the sleeve 20a, 20b, but may be located anywhere between the sides or edges of the sleeves with the sleeve rotated on the post 12 to align with the first collar occur part 16a on the shelf.
In use, the first collar part 16a, having male flange 50 is preferably fastened to the shelf 14 and the second collar part 16b is slid downward onto the sleeve 20 on a post 12 to interlock the collar parts and compress the sleeve against the post 12. Preferably, the collar parts rest on the bottom flange 30 during use, but may be offset slightly above that flange until the shelf 14 to which the connector is connected is loaded to its rated load capacity at which maximum load capability the collar abuts the bottom flange 30 to further resist relative movement of the collar and sleeve. If the shelf 14 is connected to the second collar part 16b that contains the female channel 52, the assembly sequence is the same except that after the second collar part 16b connects the shelf 14 to the post, then the first collar part is moved along axis 18 to slide the male flange 50 into the female channel 52.
The collars of
For a shelving rack with four posts 12 and shelves 14 vertically aligned on the posts, the shelf may have either collar part 16a, 16b on each of its four corners. Representative corner connector assemblies are shown in
Referring to
Referring to
The retaining coupler 80 has two elongated legs 82a, 82b joined by a connecting member 84 that connects an upper end of each leg 82a, 82b. The legs 82a, 82b are separate parts configured to be placed on opposing sides of a plane through a side rail of the shelf 14 and preferably joined only by connecting member 84. Advantageously, the legs 82 and connecting member 84 are a single piece, integrally formed part having a U-shaped cross section with opposing sides 86 of the “U” being spaced apart a distance to fit over two contacting male flanges 50 or ears 50 as shown in
A snug fit or tight fit between the legs 82a, 82b and the immediately adjacent flanges 50 is preferred and a slight interference fit is possible but less desirable because of the difficulty in installing and/or removing the retaining coupler 80. Thus, the spacing between two opposing sides 86 of a leg 82 is preferably about twice the thickness of two flanges 50, assuming the flanges 50 of the two adjoining collars 16a are the same thickness. As seen in
The legs 82a, 82b are preferably long enough to engage the full length of two adjacent and preferably abutting flanges 50 of two first collar parts 16a connected to a post 12 and sleeve 20. But the length of the legs 82a, 82b could be shorter, although preferably the legs 62 are long enough to extend over a substantial length of the two immediately adjacent flanges 50 (or 64, 74 as discussed later). As used herein, a substantial length of the immediately adjacent flanges refers to an engagement length of at least half and preferably over 90%. Further, the flanges 50 on the first collar parts 16a connected to each of a first shelf 14 and a second shelf 14, are each connected to opposing sides of the sleeve with a substantial portion of the first flanges on the first shelf being immediately adjacent a substantial portion of the first flanges on the second shelf. Preferably, when the shelves 14 are at their design load capacity, the flanges 50 are fully aligned from the top to the bottom of each flange, with a leg 84 holding the flanges together and resisting separation in the lateral direction, generally orthogonal to the axis 18. The flanges 50 and legs 84 may move parallel to axis 18.
In use, a sleeve 20 is placed on a post at a desired location. The ends of two shelves 14 each having a male collar part 16a are placed on that sleeve 20 so the two flanges 50 on opposing sides of each collar part 16a contact a flange on the other collar part other or are immediately adjacent to together, to achieve the collar configuration generally shown in
Because the retaining coupler 80 locks two flanges together on each opposing side of the sleeve 20 and post 12, the retaining coupler may be referred to as a locking collar. The locking collar 80 has two legs 82a, 82b, each of which engages and holds together two flanges of two adjacent collar parts 16a, so the locking collar 80 holds together two pairs of flanges of two different collars 16a, each leg holding two flanges together. The locking collar 80 has the legs 66 made of sufficiently strong and sufficiently thick material to maintain the flanges 50 in position and restrain the flanges from moving apart from each other in a direction orthogonal to the face of the flanges 50. The flanges 50 may slide along the length of a leg 82 as that is needed for installation and removal of the locking collar 80. Metal locking collars 80 are preferred but plastic ones are believed suitable. Locking collars with sides 86 having a thickness of about 2 mm ( 5/64 inch) and overlapping about 5 mm (about 13/64 inch) with the flanges 50, are believed when made of metal, preferably steel.
In
A more detailed description of the interlocking flange and collar follows. The flange 50 extends along a substantial axial length of each side or distal edge of the collar part 16a on which it is located, joining the typically curved exterior body of the collar part 16a along juncture 49. The flange 50 preferably extends along more than half that length, and preferably extends more than 80% of that length and more preferably extends about the full length of the (vertical) side or distal edge of the collar on which the flange is located. The flange 50 thus preferably extends outward from the side of the semicircular body portion of the collar part, with the juncture 49 located at the transition between the flange and the curved body part. The flange 50 preferably extends radially outward relative to the longitudinal axis 18 during use so the flange 50 is parallel with the axis 18. The flange 50 is preferably short in the outward direction, preferably about 2-10 times the thickness of the flange and more preferably about 2-5 times the thickness of the flange. As used herein, the outward direction means away from the longitudinal axis 18 when the parts are in their use configuration.
Each outwardly extending flange 50 has two opposing side faces 51a, 51b joined by an outward facing distal edge 51c. The edge 51c is generally aligned with the post axis 18 during use, but may be slightly inclined relative to that axis, usually with the upper end closer to the axis than the lower end during use. The front face 51a faces a direction toward the main portion of the mating collar part while the rear face 51b faces away from the mating collar part. As the distal edges of the collar parts 16a are preferably aligned with the axis 18 during use, the flange 50 generally extends vertically relative to the floor during use when the shelves 14 are horizontal. Thus, the first collar 16a has two flanges 50, one extending along each of the opposing distal ends of the collar and forming juncture 49 with the collar.
The male flange 50 is received in a female channel 52 configured to enclose the sides and distal edge of the flange 50. The female channel 52 is connected to the second collar part, 16b. The depicted channel 52 has a cross-sectional shape that has a “U” shaped cross section with two outwardly aligned and preferably parallel sides 54a, 54b joined by a distal edge 56. The first side 54a extends outward from the collar part 16 with the second side 54b extending inward and with the distal edge 56 joining the outward edges of those sides. The sides 54a, 54b with end 56 form a channel having a U-shaped cross section with an elongated opening facing the axis 18 with the channel having open ends at the top and bottom of the collar part. The bottom of the channel is open. The body forming channel 52 preferably extends radially outward relative to axis 18 when the parts are assembled for use so as to place the faces 54a, 54b general parallel with the male flange 50 so as to enclose the flange.
The channel 52 preferably has spaced apart sides 54a, 54b forming a narrow slot or groove within which the male flange 50 is enclosed during use. The channel side 54a is located toward the mating collar part while the channel side 54b is located away from the mating collar part and closer to the main body of the collar part from which it extends. The inside surfaces of the sides 54a, 54b face each other. Each channel side 54a extends from an opposing, distal circumferential end of the collar part, and forms juncture 53 where it joins that collar part. The channel side 54a preferably extends radially outward from a side of a semi-circular collar part, with juncture 53 extending along the transition from the curved body portion of the collar part and the side 54a. The channel 52 has to receive the flange 50 so the sides 54a, 54b extend outward more than the flange 50. Thus the sides 54 extend in the outward direction, a few millimeters more than the flange 50. The sides 54a, 54b allow the male flange 50 to pass closely between them are thus spaced apart a distance greater than the thickness of the flange 50, but preferably close enough to form a snug fit and preferably with no gap greater than a few mm. Thus, the female channel 52 extends outward from each of two opposing sides of a collar part and extends along a substantial length of that second collar part measured along the longitudinal axis 16. Each female channel 52 has an open bottom configured to slidably receive one of the male flanges 50 during use, with each female channel 52 extending along opposing sides 54a, 54b of a different one of the male flanges during use. The second collar part 16b′ is preferably formed of a single piece of material, such as metal bent to the desired shape or molded plastic. The channel 52 preferably form a U-shaped cross-section to as to enclosed opposing sides of the male flange 50 and restrain relative movement of the flange and channel in the lateral plane or direction.
In use, the first collar part 16a, having male flange 50 is preferably fastened to the shelf 14 and the second collar part 16b is slid downward onto the sleeve 20 on a post 12 to interlock the collar parts and compress the sleeve against the post 12. Preferably, the collar parts rest on the bottom flange 30 during use, but may be offset slightly above that flange until the shelf 14 to which the connector is connected is loaded to its rated load capacity. If the shelf 14 is connected to the second collar part 16b that contains the female channel 52, the assembly sequence is the same except that after the second collar part 16b connects the shelf 14 to the post, then the first collar part is moved along axis 18 to slide the male flange 50 into the female channel 52.
Placing the male flange 50 in the female channel 52 interlocks the collars 16a to both clamp the sleeve parts 20 against the post 12, and to further inhibit separation of the sleeve parts and collar parts. Preferably, when the male flange 50 is received in the female channel formed by opposing sides 54a, 54b, the face 51b of the male flange 50 contacts the inner face of side 54a. It is useful to have the face 51b of the male flange 50 contact the inner face of the side 54a of channel 52 as that can hold the parts together and preferably urge the parts together, but the parts must easily and removably interconnect. Thus, while the side 54a is preferably parallel to the male flange 50, the side 54b need not be parallel to that flange and may be slightly curved or inclined to form a slight interference fit as the male flange 50 fits into the channel 52.
The flange 50 preferably contacts the sides 54a, 54b of the channel 52 to prevent relative movement of the parts from moving laterally apart along an axis perpendicular to the faces of the flange 50 and sides 54. The contact between the outward facing edges 51c, 56 of the flange 50 and channel 52 prevents the relative movement of the parts along the radial direction of the flange 50 and sides 54. Combinations of those contacting parts inhibit relative separation of the collar parts 16a and sleeve parts 20a, 20b along intervening directions. The retaining members 32, sleeves 20 and post 12 keep the parts from moving in the plane orthogonal to axis 18. The ribs and grooves 26a, 16b on the pole and collar restrain movement along the pole 12 and its axis 18.
Because the flange 50 and channel 52 can each extend the axial length of the respective collar parts 16a, an increased length of the interlocking parts that resist separation is achieved. Because the flange 50 has the same thickness as the collar the flange forms a strong and stiff resistance to separation of the interlocked collar parts and the sleeve parts held inside the collar parts. Because the sides 54a, 54b and distal end 56 of channel 52 preferably have the same thickness as the collar from which the sides and end extend they form a strong and stiff resistance to separation of the interlocked collar parts and the sleeve parts held together by the interlocked collar parts.
The flange 50 and channel 52 preferably extend for about the same axial distance relative to axis 18 during use of the parts, and are aligned to mate and contact each other during use. But one could be shorter or the other could be longer, so for example, the male flange 50 may extend less than the full length of the first collar part measured along axis 18 during use, while the female channel 52 may extend the full length of the second collar part, or the female channel 52 may extend less than the axial length of the first collar part. The relative lengths could be reversed. Thus, for example, the male flange 50 could extend from the top of the collar part 16a′ toward the bottom, but end before the bottom of the collar part, preferably between about 60-90% of the length of the first collar part, while the female channel 52 may extend the full length of the second collar part 16b′ or extend about 60-90% of the length of the second collar part, from the top of the second collar part toward its bottom. The collars 16 preferably extend the full length of the sleeve 20 measured either along axis 18 or along the tapered surface of the sleeve parts 16a, 16b, but the collars 16 may be slightly shorter, preferably less than 5% shorter.
The collar parts 16a have inclined sides to form a frusto-conical passage through the joined collar parts which passage extends along axis 18 during use, with each collar part extending about half way around that axis during use. Referring to
The collars 16 having different interlocking mechanisms, including the interlocking mechanisms shown herein, and interlocking mechanisms not shown, including those of U.S. Pat. No. 8,887,647, the complete contents of which are both incorporated herein by reference.
The lip 31 and retaining wall 38 of the sleeve 20 shown herein may be used with sleeves having other configurations, including sleeves configured as in U.S. Publication No. 2015/0289644, the complete contents of which are incorporated herein by reference. The lip 31 corresponds to bottom flange 30 except the lip 31 lacks the retaining member 32 or short wall 38 associated with bottom flange 30. Optionally, as shown in broken lines in
Each flange 60 has two opposing sides or faces 61a, 61b and a distal edge 61c. The side 61a is on the same side of the collar part 16a″ as the interior of the collar part and side 61b is on the same side of the collar part 16a″ as exterior side. A closed-end slot 62 extends along a length of the normal juncture 59 of the flange 60 to the side of distal edge of the collar part 16a″ to which the flange 60 is connected. In the depicted orientation the slot 62 extends upwardly. The slot 62 preferably extends about half the axial length of the collar part 16a″, but may extend shorter or longer, preferably varying within about 15% of the length of the collar part 16a″.
The slot 62 separates a portion of the flange 60 from the collar part 16a″ to form a free end 64 on the flange 60, with the base of the flange 60 being connected to the collar part 16a″. Because the collar part 16a″ is frusto-conical the slot 62 is preferably inclined at the same angle as the inner surface of the collar part 16a″, resulting in the two slots 62 on each collar part 16a″ being slightly inclined toward each other (
Each collar part 16a″ thus has a bottom portion 66 and a top portion 68 each with a frusto-conical inner surface and preferably a parallel frusto-conical exterior surface. An outwardly extending flange 60 extends outward from each diametrically opposing side of the base portion 66 along a juncture 69 between the flange 60 and the curved, preferably semi-circular body portion of the collar part. The flanges 64 extend past the location of the longitudinal axis centerline 18 during use and thus the faces 61b about 180° apart while the faces 61a are more than 180° apart. The slot 62 extends from the top toward the bottom of the collar part 16a″ to separate the top flange 64 from the upper portion 68. In particular the slot 62 aligns with the juncture 59 of the outwardly extending flange 60 and separates part of that flange from the curved body portion of the collar par 16a″ to form flange 64, while the juncture 59 connects the bottom of the flange to the collar part.
The first collar portion 16a″ with upward slots 62 is connected to a shelf 14 and during use is orientated so the larger diameter of the conical shape of the collar portion 16a″ is downward and the smaller diameter is at the top during use so as to mate with and wedge sleeve 20 against post 12 during use.
Referring to
A closed-end slot 72 extends along a length of the normal juncture 69 of the flange 70 to the side of distal edge of the collar part 16b″ to which the flange 70 is connected. In the depicted orientation the slot 72 extends downward. The slot 72 preferably extends about half the axial length of the collar part 16b″, but may extend shorter or longer, preferably varying within about 15% of the length of the collar part 16b″.
The slot 72 separates a portion of the flange 70 from the collar part 16b″ to form a free end 74 on the flange 70, with the base of the flange 70 being connected to the collar part 16b″. Because the second collar part 16b″ is frusto-conical the slot 72 is preferably inclined at the same angle as the inner surface of the collar part 16b″, resulting in the two slots 72 on each collar part 16b″ being slightly inclined toward each other (
Each collar part 16b″ thus has a bottom portion 78 and a top portion 76 each with a frusto-conical inner surface and preferably a parallel frusto-conical exterior surface. An outwardly extending flange 70 extends outward from each diametrically opposing side of the top portion 76 along juncture 69. The flanges 74 extend past the location of the longitudinal axis centerline 18 during use and thus the faces 71a are about 180° apart while the faces 71b are more than 180° apart. The slot 72 extends from the top 76 toward the bottom 78 of the collar part 16b″ to separate the flange 74 from the bottom portion 78 while the remaining portion of juncture 69 connects the flange 74 to the body part.
As indicated above and as shown in broken lines in
The second collar portion 16b″ may be used independently, or a different collar portion 16b″ may be connected to each opposing end of end frame 44 to interlock a pair of first collar portions 16a as shown in
Referring primarily to
The free ends 64, 74 are cantilevered from the respective collar parts 16a″ and 16b″ and when the slots 62, 72 are interlocked by relative movement along axis 18, the free ends engage the flange on the other collar part to prevent lateral separation of the collar parts. Depending on the length of the slots 62, 72 and flanges 60, 70 different engagement lengths can be achieved. Preferably the slots 62, 72 extend about half the length of flanges 60, 70 and the slots are wide enough to allow insertion of the mating collar part into the respective slots in each collar part. Thus, the juncture of base portion 66 and flange 60 fits into slot 72 and slot 72 is configured to snugly receive the juncture of base portion 66 and flange 60. Likewise, the juncture of top portion 7 and flange 70 fits into slot 62 and slot 62 is configured to receive the juncture of top portion 76 and flange 70. The flanges 60 extend upward and slots 62 open upward, with flanges 70 extending downward and slots 72 opening downward, so the junctures of the parts may interlock with the slots.
The joinder of collar part 16a″ to shelf 14 cooperate with flanges 60, 70 to prevents rotation of the collar parts about axis 18 during use as flanges 60, 70 abut to restrain rotation about axis 18 during use as well as to prevent lateral movement during use. The flanges 60, 70 and flange 50 and channel 52 abut each other and when connected to sleeve 20 and post 18, restrain rotation in the plane orthogonal to the axis 18 during use, and provide means for restraining rotation about an axis in the plane orthogonal to the axis 18 during use. The interlocking of first and second collar parts 16a, 16b by the flanges 15 mating with the U-shaped channel 52, and the interlocking of the collar parts by flanges 60 and 70 and interlocking slots 62, 72, provide interlocking collar means for interlocking the collar parts and preventing lateral separation of those interlocked collar parts, in a plane transverse to axis 18 of post 12 during use.
As seen in
The configuration and use of the retaining connector 84 to connect and restrain lateral movement of the flanges 60, 70 of the collar parts 16a″ and 16b″ is the same as described regarding flanges 50 of collar parts 16a, 16b, and is not repeated in detail. The interlocking flanges 60, 70 are substantially parallel and immediately adjacent each other when interlocked and typically contact each other at the end of slots 62, 72 when interlocked, with the facing portions of the flanges contacting each other, as seen in
In use, a sleeve 20 is placed on a common post at a desired location. The ends of two shelves 14 each having a male collar part 16a are placed on that sleeve 20 so the two flanges 50 on opposing sides of each collar part 16a contact a flange on the other collar part other or are immediately adjacent each other, to achieve the collar configuration generally shown in
Further, while
A kit may include the above combination of parts and combinations thereof. Thus, a simple shelving kit may have at least two shelves 14, which if rectangular in shape have an interlocking collar part 16a, 16a″ of any type described herein at each corner of the shelf. The kit would further include eight sleeves 20 and eight interlocking collar parts 16b, 16b″ of any mating type described herein that are either separated, or with pairs of collar parts 16b or 16b″ joined to form end frames 44. Each additional rectangular shelf added to the kit would preferably include four interlocking collar parts 16a, 16a″, four interlocking collar parts 16b, 16b″ and four sleeves 20. If two shelving units are joined horizontally together by having two shelves 14 with two collar parts 16a or 16a″ at one end fastening to the same sleeve 20 on the same post 12, then the number of end frames 44 may be reduced by half, as may the number of single piece collars that surround or encircle a short length of the post on which the sleeve is located, if such single piece collars are used instead of end frames 44 or individual collar parts 16b or 16b″.
If two shelving units are joined horizontally together then the end of the shelf sharing posts 12 in common with another shelf preferably has collar parts configured to abut each other and optionally to be interlocked by retaining coupler 80. Thus, each shelf in may have four first interconnecting collar parts 16a or 16a″ of the same type and orientation, with the collar parts 16a, 16a″ on the inner posts and common sleeves 12 abutting each other and preferably interlocked by retaining coupler 80. The collar parts 16a, 16a″ on the outer posts are held to the posts by mating second collar parts 16b, 16b″ of the same type used on the shelf 14.
The collar parts 16a, 16a″ and 16b, 16b″ are preferably made of sheet metal that is of substantially uniform thickness and then cut and bent to the desired shape and typically connected to metal shelves 14 by molten metal joining techniques such welding, soldering, brazing etc. The collar parts could be made of suitably strong molded plastics and connected to shelves 14 by adhesives or suitable mechanical connections, or the parts could be integrally molded with plastic shelves, formed at the same time and as a unitary part with the plastic shelves. The post 12 is preferably cylindrical in shape with a circular cross-section, but need not be so, as the sleeve 20 and collar 16 may surround or extend around a short length of the post on which the sleeve is located and have relative outer and internal tapers selected to wedge inward against posts 12 having various shaped cross-sections, including rectangular (e.g., square) and oval cross-sections.
The above description shows a shelf 14 connected to one of the first or second collar parts 16, 16″ but various items may be connected to one of the collar parts in a manner the same as or similar to the described connection of the shelves to the collar parts. Thus, the connection described is not limited for use with shelves. For example, the rods connected to the first collar part 16 or 16″ could be connected to an item other than a shelf, and could form a connecting arm for use with various devices connected to post 12 at selective locations along the length of the post.
The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention. Further, the various features of this invention can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein.
The application claims the benefit under 35 U.S.C. §119(e) to Provisional Patent Application No. 62/292,141 filed Feb. 5, 2016, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62292141 | Feb 2016 | US |
