Patent Application
20230389699
The present invention features a shelving system comprising a Z-esque shaped support beam.
Boltless or riveted shelving systems are commonly used for storing various items in a space-efficient manner while decreasing clutter and are a popular storage option for any warehouse, factory, house, or garage because of their versatility and industrial strength. Typical shelving systems may include four vertical corner posts, any suitable number of horizontal support beams extending between pairs of posts, and corresponding shelves resting on and supported by the pairs of horizontal support beams. Additionally, boltless shelving systems are designed for easy assembly (i.e., minimal tools needed) and for quick and easy adjustments and reconfiguration of the shelving systems.
However, many boltless shelving systems have undesirably low load-bearing capacities or require a diagonal strut on the sides of the shelving system; thus limiting how much can be placed on the shelving system and the accessibility of said items. Therefore, there is a need for a shelving system with a high load-bearing capacity and increased accessibility.
It is an objective of the present invention to provide systems that allow for shelving with high load-bearing capacity and increased accessibility, as specified in the independent claims. Embodiments of the invention are given in the dependent claims. Embodiments of the present invention can be freely combined with each other if they are not mutually exclusive.
In some embodiments, the present invention features a Z-esque shaped support beam for supporting a shelf assembly (See
In some embodiments, the present invention may further feature a shelving unit comprising a plurality of corner posts and a plurality of shelf assemblies configured to be adjustably coupled to the corner posts. The shelf assemblies may comprise a first support beam and a second support beam. The first support beam is configured to extend between a first pair of corner posts and the second support beam is configured to extend between a second pair of corner posts. The shelf assemblies may further comprise a first side support beam, a second side support beam, and a plurality of shelves. Each side support beam is configured to extend between the first and second pair of corner posts. Additionally, each shelf is configured to extend between the first support beam and the second support beam.
Overall, the present invention relates to the construction of heavy-duty industrial racks. Due to the unique improvement made to the support beams (i.e., Z-esque shaped support beam design) the present invention has the following benefits compared to the current state of the art: 1) the shelving system described herein can handle 10-15× more weight while the shelf remains the same weight, 2) the package size is ½- to ⅓ of the competition which saves tremendously on shipping; 3) the lack of diagonal strut on the frames allows users to easily retrieve items from the side of the rack; 4) can be easily assembled by the user.
One of the unique and inventive technical features of the present invention is the Z-esque shaped support beam. Without wishing to limit the invention to any theory or mechanism, it is believed that the technical feature of the present invention advantageously prevents the support beams from twisting under load because the vertical force is applied straight above the center of mass of the beam profile. See
Furthermore, the prior references teach away from the present invention. For example, the shelving unit (i.e., Atlas) of the present invention features a plurality of shelves that are supported from all four sides (i.e., by support beams and side support beams; see
Furthermore, the inventive technical feature of the present invention contributed to a surprising result. For example, the shelving unit of the present invention is able to withstand high weight capacity (e.g., greater than 2800 lbs of weight per shelf) with no diagonal strut needed for structure integrity. Prior designs not only have a diagonal strut but often require both the diagonal and horizontal struts for the side frames welded to the vertical posts. The present invention (i.e., Atlas) requires no welding and thus further reduces manufacturing steps and complexity.
Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. Additional advantages and aspects of the present invention are apparent in the following detailed description and claims.
The features and advantages of the present invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:
Following is a list of elements corresponding to a particular element referred to herein:
Referring now to
In some embodiments, the Z-esque shaped support beam (100) for supporting a shelf assembly (see
In alternative embodiments, the first horizontal component (121) may extend from a top portion of the first vertical component (111), as shown in
In some embodiments, the first vertical component (111) further comprises a rivet. In some embodiments, wherein the second vertical component (112) further comprise a rivet. In some embodiments, the rivets are disposed on a front surface of the first vertical component (111) and/or a front surface of the second vertical component (112). In some embodiments, the rivets are disposed at or near an end of the support beam (100). Rivets as described herein are widely used and well known in the art to work in tandem with the specially designed keyhole slots (i.e., keyhole-shaped slots) punched in the posts to hold the beams and posts together.
In preferred embodiments, the height of the support beam (100; i.e., the distance between the top of the first vertical component (111) and the bottom of the second vertical component (112)) is about 3 inches. In some embodiments, the height of the support beam (100) is about 1.5 inches, or about 2.0 inches, or about 2.5 inches, or about 3.0 inches, or about 3.5 inches, or about 4.0 inches. or about 4.5 inches, or about 5.0 inches.
In some embodiments, the length of the support beam (100; i.e., the distance from a first end of the support beam (100) to a second end of the support beam (100)) is about 12 inches, or about 18 inches, or about 24 inches, or about 30 inches, or about 36 inches, or about 42 inches, or about 48 inches, or about 54 inches, or about 60 inches, or about 66 inches, or about 72 inches, or about 78 inches, or about 84 inches.
In some embodiments, the support beam (100) is made from steel.
In a non-limiting embodiment, the Z-esque shaped support beam (100) for supporting a shelf assembly may comprise a first beam component (111) having a first edge, a second edge, and a first rivet and a second rivet attached to a same surface of the first beam component (111), where the first rivet and the second rivet are disposed on opposing ends of the support beam (100). The support beam (100) also comprises a second beam component (112) having a first edge, a second edge and a third rivet and a fourth rivet attached to a same surface of the second beam component (112), where the third rivet and the fourth rivet are disposed on opposing ends of the support beam (100), where the first beam component (111) and the second beam component (112) are coplanar in a first plane. The support beam (100) further comprises a shelf support component (121) extending from the first beam component (111) such that the first beam component (111) and the shelf support component (121) are perpendicular to each other, where a first edge of the shelf support component (121) is connected to the second edge of the first beam component (111). The support beam (100) also includes a third beam component (122) extending from the second beam component (112) such that the third beam component (122) and the second beam component (112) are perpendicular to each other, and such that the third beam component (122) and the shelf support component (121) are parallel to each other, where a first edge of the third beam component (122) is connected to the second edge of the second beam component (112). The support beam (100) also includes a diagonal beam component (130) connecting the shelf support component (121) to the second beam component (112), where a first edge of the diagonal beam component (130) is connected to a second edge of the shelf support component (121) and a second edge of the diagonal beam component (130) is connected to the first edge of the second beam component (112). In some embodiments, the first and second rivets are attached to the surface of the first beam component (111) and the third and fourth rivets are attached to the surface of the second beam component (112) such that all the rivets project in the same direction that is opposite of a direction of extension of the shelf support component (121) and the third beam component (122). In some embodiments, the first edge of the first beam component (111) projects away from the first edge of the second beam component (112).
In alternative embodiments, the first edge of the first beam component (111) projects towards the first edge of the second beam component (112), as shown in
According to other embodiments, the present invention may further feature a shelving unit (200) comprising a plurality of corner posts (210) and a plurality of shelf assemblies configured to be adjustably coupled to the corner posts (210). The shelf assemblies may comprise a first support beam (221) and a second support beam (222). The first support beam (221) is configured to extend between a first pair of corner posts (210) and the second support beam (222) is configured to extend between a second pair of corner posts (210). The shelf assemblies may further comprise a first side support beam (231), a second side support beam (232), and a plurality of shelves. Each side support beam is configured to extend between the first and second pair of corner posts (210). Additionally, each shelf is configured to extend between the first support beam (221) and the second support beam (222).
In some embodiments, the first support beam (221) and the second support beam (222) comprise a first vertical component (111) and a second vertical component (112) in a single vertical plane, a first horizontal component (121) extending from a bottom portion of the first vertical component (111), a second horizontal component (122) extending from a bottom portion of the second vertical component (112), and a diagonal component (130) extending from a portion of the first horizontal component (121) and connecting to a top portion of the second vertical component (112). In some embodiments, the first horizontal component (121) and the second horizontal component (122) are parallel to each other.
In certain embodiments, the length of the first support beam (221) and/or the second support beam (222) (i.e., the distance between a first end of the support beam and a second end of the support beam) is about 72 inches. In some embodiments, the length of the first support beam (221) and/or the second support beam (222) ranges from about 36 inches to 108 inches, or about 36 inches to 96 inches, or about 36 inches to 84 inches, or about 36 inches to 72 inches, or about 36 inches to 60 inches, or about 36 inches to 48 inches, or about 48 inches to 108 inches, or about 48 inches to 96 inches, or about 48 inches to 84 inches, or about 48 inches to 72 inches, or about 48 inches to 60 inches, or about 60 inches to 108 inches, or about 60 inches to 96 inches, or about 60 inches to 84 inches, or about 69 inches to 72 inches, or about 72 inches to 108 inches, or about 72 inches to 96 inches, or about 72 inches to 84 inches, or about 84 inches to 108 inches, or about 84 inches to 96 inches, or about 96 inches to 108 inches.
In certain embodiments, the height of the first support beam (221) and/or the second support beam (222) (i.e., the distance between the top of the first vertical component (111) and the bottom of the second vertical component (112)) is about 3 inches. In some embodiments, the height of the support beam (100) is about 1.5 inches, or about 2.0 inches, or about 2.5 inches, or about 3.0 inches, or about 3.5 inches, or about 4.0 inches. or about 4.5 inches, or about 5.0 inches.
The first support beam (221) and/or the second support beam (222) may further comprise rivets disposed at or near an end of the first support beam (221) and the second support beam (222). In some embodiments, the first support beam (221) and/or the second support beam (222) comprises two rivets, wherein one rivet is disposed at or near a first end of the support beam and another rivet is disposed at or near a second end of the support beam. In preferred embodiment, the first support beam (221) and/or the second support beam (222) comprises four rivets, wherein two rivets are disposed at or near a first end of the support beam and two rivets are disposed at or near a second end of the support beam. In some embodiments, the rivets are disposed on a front surface of the first vertical component (111) and/or a front surface of the second vertical component (112).
In some embodiments, the first side support beam (231) and the second side support beam (232) comprise a first vertical component (111) and a second vertical component (112) in a single vertical plane, a first horizontal component (121) extending from a bottom portion of the first vertical component (111) and a diagonal component (130) extending from a portion of the first horizontal component (121) and connecting to a top portion of the second vertical component (112). The first side support beam (231) and the second side support beam (232) may further comprise a second horizontal component (122) extending from a bottom portion of the second vertical component (112). In some embodiments, the first horizontal component (121) and the second horizontal component (122) are parallel to each other.
Without wishing to limit the present invention to any theory or mechanism it is believed that the second horizontal component (122) of the side support beam can be removed without hurting weight capacity, thus allowing for savings on material and shipping weight. Additionally, a side support beam without a second horizontal component (122) allows for an increase in the open space between the side support beams (see
In certain embodiments, the length of the first side support beam (231) and/or the second side support beam (232) (i.e., the distance between a first end of the side support beam and a second end of the side support beam) is about 24 inches. In some embodiments, the length of the first support beam (221) and/or the second support beam (222) ranges from about 12 inches to 36 inches, or about 12 inches to 30 inches, or about 12 inches to 24 inches, or about 12 inches to 18 inches, or about 18 inches to 36 inches, or about 18 inches to 30 inches, or about 18 inches to 24 inches, or about 24 inches to 36 inches, or about 24 inches to 30 inches, or about 30 inches to 36 inches.
In certain embodiments, the height of the of the first side support beam (231) and/or the second side support beam (232) (i.e., the distance between the top of the first vertical component (111) and the bottom of the second vertical component (112)) is about 3 inches. In some embodiments, the height of the support beam (100) is about 1.5 inches, or about 2.0 inches, or about 2.5 inches, or about 3.0 inches, or about 3.5 inches, or about 4.0 inches. or about 4.5 inches, or about 5.0 inches.
The first side support beam (231) and/or the second side support beam (232) may further comprise rivets disposed at or near an end of the first side support beam (231) and the second side support beam (232). In some embodiments, the first side support beam (231) and/or the second side support beam (232) comprises two rivets, wherein one rivet are disposed at or near a first end of the side support beam and one rivets are disposed at or near a second end of the side support beam. In other embodiment, the first side support beam (231) and/or the second side support beam (232) comprises four rivets, wherein two rivets are disposed at or near a first end of the side support beam and two rivets are disposed at or near a second end of the side support beam. In some embodiments, the rivets are disposed on a front surface of the first vertical component (111) and/or the second vertical component (112). Side support beams comprising a single rivet at each end of said beam are for low capacity shelving units (200)
In some embodiments, the support beams and the side support beams are made from steel.
In some embodiments, the shelf assembly further comprises a central shelf support (240) centrally disposed between the first support beam (221) and the second support beam (222). In some embodiments, the central shelf support (240)) comprises a first end (241) and a second end (242), wherein the first end (241) is configured to attach to the first support beam (221) and the second end (242) is configured to attach to the second support beam (222).
In some embodiments, the shelving unit (200) of the present invention provides for shelves with a “split design” (i.e., the shelving unit (200) of the present invention provides for short shelves (260)) that allow for the storage of objects taller than the shelf opening (see
The plurality of shelves may comprise a long shelf (250) that is configured to extend between the first side support beam (231) and the second side support beam (232). Additionally, the plurality of shelves may comprise a short shelf (260) that is configured to extend between the first side support beam (231) or the second side support beam (232) and the central shelf support (240). The shelf assemblies described herein may comprise only long shelves (250) or only short shelves (260). In some embodiments, the shelf assemblies described herein comprise both long shelves (250) and short shelves (260).
In some embodiments, the plurality of shelves are made of wire mesh. Non-limiting examples of materials that may be used to create the plurality of shelves described herein include but are not limited to wire mesh, particle board, wood, sheet metal (solid or punched), or plastic. Any material that can hold weight may be used to create the plurality of shelves in accordance with the present invention.
In some embodiments, the shelving unit (200) of the present invention has up to 4 shelves. In other embodiments, the shelving unit (200) of the present invention has up to 5 shelves. In further embodiments, the shelving unit (200) of the present invention has up to 6 shelves. However, the capacity of the shelving unit (200) does not change as the number of shelves increases or decreases.
In some embodiments, the shelving unit (200) of the present invention is adjustable.
In some embodiments, the shelving unit (200) comprises four corner posts (210). The corner posts (210) may comprise a first side perpendicularly attached to a second side such that a right angle is formed. In some embodiments, the corner posts (210) comprise keyhole-shaped slots. In some embodiments, the keyhole-shaped slots are disposed on the first side and the second side of the corner posts (210). In some embodiments, the sides of the keyhole-shaped slots are not parallel but at a slight angle (like a V) so the rivets sit higher than the bottom of the keyhole.
In preferred embodiments, the keyhole-shaped slots are spaced 3 inches apart. In some embodiments, the keyhole-shaped slots are spaced about 1.5 inches apart, or about 2.0 inches apart, or about 2.5 inches apart, or about 3.0 inches apart, or about 3.5 inches apart, or about 4.0 inches apart.
In some embodiments, pressure may be applied to the support beam (i.e., the support beam is hit with a mallet) such that the rivets disposed on the support beam “bite” into the sides of the keyholes.
In some embodiments, the corner posts (210) are about 36 inches tall. In other embodiments, the corner posts (210) are about 72 inches tall. In some embodiments, the height of the corner posts (210) is about 24 inches, or about 30 inches, or about 36 inches, or about 42 inches, or about 48 inches, or about 54 inches, or about 60 inches, or about 66 inches, or about 72 inches, or about 78 inches, or about 84 inches, or about 90 inches, or about 96 inches, or about 102 inches, or about 108 inches, or about 114 inches, or about 120 inches, or about 126 inches, or about 132 inches, or about 138 inches, or about 144 inches.
In some embodiments, the corner posts (210) are made of steel.
In some embodiments, the shelving system of the present invention may be used in multiple configurations. Two (or more) single shelving units (200) as described herein may be configured to create larger systems (e.g., either side-by-side or stacked). For example, with simple brackets attached to the outside of the corner posts (210) and, using two shelving units (200) as described herein configured side-by-side an 18 ft storage space may be created (see
The present invention (i.e., Atlas) has two packaging options. One with the side frame pre-assembled (packaging option #1) and the other with the side frame components disassembled (packaging option #2), which allows the customers to assemble the side frame themselves. The former is easier to assemble than most boltless/riveted consumer shelving units (200) because the end frames are pre-assembled. However, the latter is still fairly easy to assemble.
The welded package-rack units of the prior arts come in a 9″ thick box. Whereas, the box of the present invention (i.e., Atlas) can be reduced to about 6″ thick (i.e., the box is reduced by ½) in the packaging option #2 (i.e., when the side frames are not preassembled). On the other hand, with packaging option #1 (i.e., when the side frames are pre-assembled) of the present invention (i.e., Atlas) the box can be reduced to just over 3.5″ thick (i.e., the box is reduced by ˜⅓). Note, for packaging option #1, the left-to-right dimension of the rack may need to be reduced to about 63″-66″ in order to better accommodate all the components between the top and bottom preassembled beams. Currently, the long horizontal support beams are about 71″ long and may be shortened so they can fit between the top and bottom beams.
In summary, the prior art's preassembled (i.e., welded) side frames prevented them from packing things as tightly as the present invention (i.e., Atlas). For example, package rack has welded frames so everything has to be stacked in the box making the box 9″ tall. The present invention can better utilize the box since everything is packed between the posts (less air).
As used herein, the term “about” refers to plus or minus 10% of the referenced number.
Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims. In some embodiments, the figures presented in this patent application are drawn to scale, including the angles, ratios of dimensions, etc. In some embodiments, the figures are representative only and the claims are not limited by the dimensions of the figures. In some embodiments, descriptions of the inventions described herein using the phrase “comprising” includes embodiments that could be described as “consisting essentially of” or “consisting of”, and as such the written description requirement for claiming one or more embodiments of the present invention using the phrase “consisting essentially of” or “consisting of” is met.
The reference numbers recited in the below claims are solely for ease of examination of this patent application, and are exemplary, and are not intended in any way to limit the scope of the claims to the particular features having the corresponding reference numbers in the drawings.
This application is a non-provisional and claims benefit of U.S. Provisional Application No. 63/347,807 filed Jun. 1, 2022, the specification of which is incorporated herein in its entirety by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63347807 | Jun 2022 | US |
