The present disclosure relates to storage system components using cantilevered brackets mounted by vertical supports.
Conventional configurable, modular storage systems typically rely on cantilevered brackets connected to a vertical or upright element to support shelves, drawers, and other modular storage components having standard dimensions that can be assembled into any number of different configurations to accommodate space limitations and storage needs. The components that comprises these systems typically include a vertical standard that is attached to a wall using fasteners, hung from a track on a wall (sometimes referred to as a “hang standard”), or attached to a base or footing (an “upright”). Two or more vertical standards are placed or located a predetermined distance apart. Each standard has a plurality of slots to which the brackets can be attached. To support a storage component, at least one cantilevered bracket is attached to each standard. A cantilevered bracket is typically attached to a standard by inserting one or more hooks located on one end of the bracket, into slots formed in the standard. A hook can be formed in any number of ways, but in one example it is formed using a tab having a notch in a bottom edge of the tab, into which a bottom edge of a slot slides when the tab is inserted into the slot and pushed down.
A pair of cantilevered brackets connected on a vertical standard can be used to support one or more components for storing or organizing items or acting as work surfaces, such as shelves, baskets, sliding drawers, and any other type of component for storing, organizing and displaying clothing, clothing accessories, books, papers, files, equipment, and decorative and useful objects. These components will generically be referred to as “storage components.” The end user selects and installs from a system's standard parts to assemble a combination of storage components that meets the user's needs and fits within the available space. Assembly is usually relatively easy and requires a minimal number of tools. The systems also typically allows for easy disassembly, adjustment, and re-use of parts to assemble different configurations. The components of such systems can also function as or be assembled to create desks, work surfaces, seating, and other furniture-like arrangements, depending on components and accessories that are available.
The following specification discloses embodiments of a storage system using cantilevered brackets mounted to vertical support members to support storage components.
Prior art brackets may, for example, use pairs of horizontally displaced hooks to stabilize the cantilevered bracket or structural member extending from the sides of the bracket at its connection interface to the vertical standard to act against the vertical standard. However, such approaches result in a wider bracket that cannot be easily hidden or incorporated into an aesthetically pleasing design, and they tend to prevent more than one bracket from being connected to the same standard.
In one aspect of the disclosure, storage components for a storage system are supported on vertical standards with thin cantilevered brackets that would otherwise tend to swing when hung on a vertical standard using a single column of one or more hooks inserted into a column of slots on the vertical standard. Despite the tendency of such brackets to swing when attached to the vertical standard, the cantilevered brackets are constructed and support the storage components in a sturdy and aesthetically pleasing manner that allow, if desired, more than one bracket to be connected at same level to the same standard.
Aspects of the various embodiments of the storage components described below retain ease of assembly from standardized parts with standardized dimensions using a minimal number of tools, as well as flexibility in arranging storage components to fit an available space and meeting the needs of a user that are characteristic of prior systems. Each of these aspects, singly and in combination with one or more of the other aspects, allow for or contribute to improved mechanical rigidity and strength and improved aesthetics as compared to prior systems.
In the following description like numerals refer to like elements.
The following description contemplates a storage or organization system comprising modular storage components that can be assembled into a number of different configurations depending on the needs of the end user and available space. The system includes standards that are held in a vertical orientation and cantilevered brackets that are connected to the vertical standards by a mechanical joint which will be referred to as an interface or connection interface. Although described with reference to representative examples of storage systems in which they may be used to particular advantages, the storage components described below can be adapted to other types of modular storage systems that make use of cantilevered brackets, including systems that are not wall mounted and that use vertical standards of different construction.
In the representative storage systems described below, the standards are supported in a vertical orientation. To connect the standard to a wall it can be fastened to the wall with any type of fastener—a screw, bolt, or nail, for example—held against the wall by one or more clips or brackets that are connected to the wall or hung from one or more cleats or rails that are connected to the wall. However, other ways of supporting the vertical standards could be used. For example, a base on the floor or bracing that extends from the floor, walls and/or ceiling, could be used alone or in combination to support standards. The vertical standards could also be supported at each end by a floor and a ceiling. Once the standards are placed, such systems usually, but need not always, allow reconfiguration of the storage components and the addition of new components. Non-limiting examples of components include shelves, drawers, cabinets, baskets, racks, desks, and hooks. However, such systems may include many more types of components and accessories that can be connected to the standards or otherwise supported by the brackets connected to the standards.
The size of each standard is long in one dimension and narrower and shorter, relative to its length in the first dimension, in each of the other two dimensions. Each of the standards will usually have on its front regularly spaced openings, for example, slots spaced at one or more uniform intervals, into which a horizontally extending piece of a cantilevered bracket's connection interface is inserted. Each cantilevered bracket is, usually, comprised of an elongated support member extending forwardly from a connection interface that includes a means by which it can be joined or connected to a vertical standard. The bracket's connection interface is configured to interfere with the standard to prevent the bracket from pivoting and translating downwardly once it is connected with a vertical standard. The connection interface may include one or more rearward extensions that are inserted into one or more corresponding openings on the vertical standard. The bracket is then moved or rotated to a locked position. A number of different configurations of the extension are possible and have been used to join cantilevered brackets to vertical standards in a manner that allows connection and removal of the cantilevered bracket without the aid of a tool or additional fastener. The connection interface allows for placement and, if desired, repositioning of the brackets to support different configurations of storage elements. Examples of such means for joining a bracket to a vertical standard include a horizontal member that is formed to resemble, in cross-section, a hook with a horizontal component that interferes with the standard to prevent vertical translation of the bracket and a vertical component that interferes with the standard to prevent pivoting and to transfer the moment created by a load on the horizontal support member of the bracket.
To install a typical, wall-mounted storage system, two vertical standards are mounted at predetermined distance from each other. A system may have one or more standard separation distances that correspond to the width or widths of its standard storage components. Some specific, non-limiting examples of such a system are described below. A cantilevered bracket is then connected at corresponding heights on each vertical standard so that they are level. A storage component such is then mounted between the brackets. Multiple storage components can be mounted to form a column or stack of two or more storage components by connecting additional pairs of brackets at different heights. The system can be expanded by adding another standard, allowing for two columns of storage components arranged side-by-side.
Each support ledge is located on the side surface 112 at a position that is lower than the top edge 110. The distance between the top edge 110 and an upper surface 115 of the support ledge 114 remains, in the embodiments shown in the drawings, substantially or uniform or constant along the length of the support ledge 114. Thus, the plane of the upper surface 115 of each ledge 114 is parallel to the top edge 110. This distance is, in a one, preferred embodiment, equal to a thickness of a shelf Ts so that a top surface 308 of shelf 300 and top surface 606 of shoe shelf 600 is aligned or flush with the top edge 110 when either of the shelves are supported by a ledge 114. In this embodiment, the upper surface 115 of the ledge 114 forms a right angle with the portion of the side surface 112 from which the ledge extends. The upper surface 115 and the portion of the side surface 112 between the ledge 114 and top edge 110 is substantially flat or planar (without visually perceptible curvature to an ordinary observer) where the side and bottom surface of the shelf (side 304 and bottom surfaces 306 of shelf 300, for example) engage the side surface 112 of the bracket and upper surface 115 of the ledge. This allows the shelf to fit close to or against both the ledge and the bracket in order to form a neat appearance and, optionally, to restrict shift of the shelf relative to the bracket in at least two directions or degrees of freedom of movement.
Although it is advantageous for the portion of the side surface 112 that is above the upper surface 115 to be flat and oriented vertically (when installed on a vertical standard) to receive a shelf, such as shelves 300 and 600, with flat side and top surfaces at right angles, an alternative embodiment may have at least these portions of side surfaces 112 slanted, curved or shaped in a manner that is complimentary to the side of the shelf. Furthermore, in alternative embodiments the side surfaces 112 could be made non-planar and/or not parallel to each other while still maintaining a thin profile as seen from the distal end of the brackets 100 and 200.
Although ledge 114 is shown as a single element that is attached to the side surface, in alternative embodiments the ledge could comprise two or more segments that are separated and, optionally, spaced apart to support the shelf. Using one, single ledge offers the advantage of simplified fabrication of the cantilevered. References to a “ledge” in the description and claims contemplate and are intended to refer to either a unitary or a segmented ledge unless specifically indicated otherwise.
Each of the brackets 100 and 100′ (
Although several different arrangements are possible, in this example rear extension includes a slot 124 that receives a lower transverse edge defining the opening or slot in a front wall of the vertical standard 310. The extension thus forms a hook-like portion that, when in a locked position, cooperates with an inside surface (not visible) of a front wall of the vertical standard below the opening in which the rearward extension is inserted. In alternative embodiments, the rearward extension could instead include, for example, a portion that extends upwardly from an end of the rearward extension to catch an inside surface of the front wall of the vertical standard above the opening.
The connection portion 116 also includes a second rearward extension 126 that is below the first one and is optional. It cooperates with a lower slot (not visible) on the vertical standard and acts primarily to maintain vertical alignment of the bracket with the vertical standard. In this example, pushing the rearward extension 120 down to lock it aligns the tab-like rearward extension 126 with the lower slot, allowing it to enter the slot. The dimensions and location of the tab may be chosen to allow its upper edge to cooperate with the top edge of the slot to help to prevent unintended upward shifting of the bracket after it is in a locked position. Depending on its size, it may also be used to transfer some of the load on the cantilevered bracket to the vertical standard. A lower extension 118 extends the back edge 122 to below the bottom edge 128 of the elongated member 104. The extension accommodates the second rearward extension 126, the bottom of which is below the bottom edge 128 of the elongated member. The spacing between the rearward extensions 120 and 126 is the same as, or a multiple of, the spacing between the slots on the vertical standard.
The elongated support 104 is, in this example, fabricated or cut from a single sheet or plate of rigid material such as steel or other metal that is oriented vertically so that one edge of it forms the top edge 110 of the bracket. The sheet has a uniform thickness TB. The elongated support 104 thus has a uniform thickness. The top edge 110 and the bottom edge 128 of the elongated support 104 are parallel. However, in alternative embodiments, they need not be. The elongated support 104 thus has a height H that is consistent along the length of the elongated support 104 portion of the bracket except for corners and where the support transitions to the connection portion 116 of the bracket. Lower extension 118 is an example of the height of the bracket changing near the transition of the elongated support 104 to the connection portion 116. The connection portion 116 of the bracket can be formed from the same sheet of materials by cutting it to form the rearward extensions 120 and 126, as well as the lower extension. Thus, the entire bracket, except for the ledges 114, can be cut from a single sheet of material. The thickness and other dimensions of the bracket are sufficient to resist bending, twisting or other deformation when the proximal end is connected with a vertical support and is subjected to a maximum expected or rated load from a storage component and its contents supported by the bracket.
Examples of the material from which the elongated support element can be made include metals, such as steel, plastics, and composites materials. Each ledge 114 are, in the example, formed from a “L” shaped piece. One portion of it is placed against and attached to the side surface with the other portion extending outwardly. Assembly of a shelf component of a storage system using the cantilevered brackets 100 and 100′ is illustrated by
Extending upwardly from the upper surface 115 of each ledge is at least one post 130. The posts extending in a direction normal to the upper surface. In the illustrated examples, there are two posts 130, and there can be more if desired. The posts 130 are inserted into pockets or openings 314 formed through the bottom surface 306 of shelf 300 and the bottom (not visible) of shoe shelf 600. There are at least the same number of openings as posts, though there can be more openings than posts. Thus, there are at least two openings, one on each end, of the shelf. The posts and pockets are aligned such that the sides 304 of the shelf 300 closely fit against the side surfaces 112 of the elongated supports 104 of the brackets 100 and 200 and the front side surface 302 of the shelf 300 has a predetermined relationship with a front edge 132 of the elongated support 104. Similarly, a front surface 604 of the shoe shelf 600 also has a predetermined relationship with the front edge 132 of bracket 500. The top surfaces 308 and 606 of the shelves 300 and 600 also have a predetermined relationship with the top edge 110 of the brackets 300 and 500. That relationship is determined by the position of the ledge 114 relative to the top edge 110 and the thickness of the shelf. In one embodiment, the predetermined relationship of the top surface and the front side surface of the shelf with the top and front edges of the bracket are that they are aligned or flush with each other. However, in alternative embodiments, the posts and openings can be aligned to create a different relationship between the front side surface 304 and the front edge 132 of the elongated member. The predetermined relationship of the top surface 302 and the top edge 110 can also be changed is something other than a flush arrangement is desired.
The shelves 300 and 600 may incorporate in the openings a locking mechanism that cooperates with the posts to retain or lock the shelf on the posts. One example is a cam lock nut that is comprised of a cam surface that engages a shoulder formed by a waist on the post. When rotated, the cam acts against the shoulder and pulls the shelf down the post and locks it. The locking increases the rigidity of the connection between the shelf and the bracket.
Posts 130 may be omitted in alternative embodiments. However, they offer the advantages noted, and offer particular advantage when used with brackets such as 100 and 200 that are connected to a vertical standard using a single hook. A cantilevered bracket with a single connection point will tend to swing side-to-side, especially when it is connected with an embodiment of a vertical standard with slots is wide enough to accommodate hooks from two, abutting brackets. Conventional approaches of stabling swinging such as the use two hooks and a double column of slots on the vertical standard, or a flange or other stabilizing structural member to resist swinging, will typically result in a wider, less attractive bracket. Connecting the shelf to the bracket with posts 130 will tend to prevent or reduce the swinging of brackets 100 and 200.
If side-by-side shelves at the same level are desired for an installation, a third vertical standard can be mounted and cantilevered bracket with ledges 114 on each side can be placed on the middle standard, thereby enabling a single, thin profile bracket to be used to support the end of two shelves. Cantilevered bracket 200 is an example of such a bracket for a horizontal shelf. However, alternatively, because of their thin profiles, the cantilevered brackets with a single ledge could also be inserted into the same set of slots on the same vertical standard, with their respective side surfaces 112 that do not have ledges abutting each other.
The construction of the cantilevered brackets and manner and means by which they support shelving allow for a thin profile and more aesthetically pleasing shape that fit better with the shelf. This results in improved aesthetics and rigidity that reduces movement and rattling of the components that prior systems exhibited, while maintaining ease of installation. The result is a highly configurable storage system that appears and feels similar to furniture or custom or “built in” shelving. Other storage components with a planar member that can be supported between two brackets can be substituted for the horizontal shelf.
The holder 404 is hung from the ledge 114 of the cantilevered brackets 100 and 200 by the strap 406 and a tab 408 that is at a right angle at the top of the strap. Each hanging bracket is installed by passing the tab 408 through a slot 134 formed between the ledge and the side surface 112 to which it is attached, and then pivoting the hanging bracket 402 so that the tab 408 moves into a depression 136 formed in the upper surface 115 of the ledge and the extension 406 is against the side surface 112 of the cantilevered bracket. The depression accommodates the tab so that it does not interfere with a shelf when installed on the ledges of the bracket. The extension 406 and tab 408 acts like a hook to transfer the load of the closet rod to the ledge 114 and thus also to the cantilevered bracket. Two hanging brackets are installed, one on each of the pair of cantilevered brackets that supports the shelf under which the closet rod will be installed. Once the pair of hanging brackets are installed, the closet rod is inserted into the holders as shown in
In one embodiment, the holder 404 and tab 408 are made of a rigid material that tends not to deform under expected loads, with the joint of each of the holder 404 and tab 408 the strap 406 also being rigid to maintain right angles with respect to the side surface 112 when the closet rod hanger is installed. The strap may also be made of rigid material or permitted to flex to some degree. The rigid materials may be made of metal or plastic. The hanger is, in one embodiment, integrally formed using an injected plastic molding process.
Referring now briefly just to
Referring now to
The leg portions 702a and 714a of each of the panel brackets 702 and 714 position the bracket and its attachment portion 702c and 714c, respectively, a predetermined distance from the wall so that it has a predetermined alignment with the vertical standards 310. In this example, the panel's front surface is aligned with the front of the vertical standards once attached to the panel brackets. The legs also orient the attachment portion 702c and 714c of each so that a flat part of a surface of the attachment portions 702 and 714c, to which a back side of panel 314 will be adhered—an attachment surface—is parallel to the surface of the wall. For example, on the attachment surface of attachment portion 702c and 714c is an adhesive 710, with which a back side of panel 314 is adhered to the bracket once a sufficient number of brackets are positioned and the panel 314 is pressed against the brackets. Non-limiting representative examples of adhesives include double-sided adhesive tape, glue or any other adhesive that will bond the back of the panel to the bracket. Fasteners such as hook-and-loop fasteners could also be used to adhere the panel to the brackets.
Panel brackets 714 further include a shallow ledge 714d that extends below the attachment portion 714c, on which a lower or bottom edge of a panel may rest. For panel bracket 714, the adhesive 710 does not extend the full length of the attachment surface of attachment portion 714c in order to allow a bottom edge of the back panel to rest on ledge 714d without with adhering to the bracket in order to allow it to be properly positioned before being pressed against the brackets. For panel bracket 702, the adhesive may extend the full length of the surface of the attachment portion 702c, though in alternative embodiments it does not have to extend the full length. One or more brackets 714 are used instead of brackets 702 on a lower horizontal rail or clip, where a bottom edge of a panel will be located. Use of the brackets 714 is optional.
In an alternate embodiment, the back panel may be held in place by inserting the ends of the panels in grooves formed on the side of the vertical standard 310. An example is shown in PCT Application No. PCT/US2018/050781.
Referring now to
The drawer in this example is comprised of a box-shaped enclosure. A drawer is mounted within the enclosure so that it can be slide in and out of it. The enclosure is comprised of two side panels 802a and 802b, each of which is joined to a top panel 804 and a bottom panel. The drawer front 808 overlaps the ends of the side panels 802a and 802, with its end surface flush with the surfaces of the side panels, to hide the ends of the side panels when the drawer is closed. The bottom of the drawer front 808 also overlaps the bottom panel 806 to hide the end of the bottom panel when the drawer is closed. Only the front facing edge of the top panel 808 is exposed, with the top edge of the drawer front 808 fitting tightly under the top panel and the surface of the drawer front flush with the front edge of the top panel 804.
A pair of cantilevered brackets 900a and 900b (which are mirror images of each other) are used to hang the enclosure on the vertical standards 310. Each side panel 802a and 802b is connected to support member 902 that projects out from the bracket using fasteners. In the illustrated embodiment, the support member 902 includes screw holes 904 for receiving wood screws (not shown) for attaching the support to an inside surface of each side panel 802a and 802b. A lower tab 906 may also be used to attach the side panel to the bracket at a lower position to prevent or reduce application of torsional forces on the fasteners connecting the side panels to the support member 906. The support projection 902 is coupled to a connection interface 908 by an offset 910 so that the support is offset inwardly with respect to a center plane defined by the connection interface 908 and its rearward projections 914, the center plane being parallel with a center axis of the standard and extending through a column of slots formed on the front the vertical standard into which the rearward projections are inserted. The offset of the support projection at least partially accommodates the thickness of the panel. If desired, it allows for the outer surface 810 of each side panel to be aligned with or inside the plane of the connection interface 908. In a preferred embodiment, the amount of the offset is therefore equal or greater than the thickness of the side panel, though in alternative embodiments it could be less than this thickness. Furthermore, the offset portion begins close to the vertical standard and allows at least the outermost portion of the side panels to reach close to the vertical standard.
The offset portion 910 includes a step 911 that results the offset portion 910 having stairstep cross-section. When connected with bracing 912, the step 911 forms a box-shaped structure that strengthens and reinforces the bracket to help to prevent the bracket from bending at the offset portion under the load of the drawer 800.
Except for the bracing 912, the bracket—the support projection 902, the offset 910, the connection interface 908, and rearward projections 914—is, in one embodiment, formed from a single piece of material, such as steel, that is cut and then folded. The bracket is thus able to maintain a narrow profile.
The bottom panel and top panel are attached to the side panels using 804 and 806 using fasteners or other means for joining them to from a rigid, box like enclosure that will support the drawer. In this example, posts 810 that are screwed into the bottom and top panels are inserted into holes 811 formed along the top and bottom edges of the side panels and then locked using cam locking nuts 812 are inserted prior to the posts are inserted and rotated from the inside the enclosure. Openings 814 are formed in the support members 902 to allow for access to the cam locking nut. Optional dowels 816 can also be used to help to hold the panels together. The entire enclosure can be assembled with a screw driver.
The connection interface 908 comprises rearward projections 914, each of which is inserted a separate slot in a column of slots (not visible due to raised portions extending from the front wall that obscures from side angle the column of slots) in the front of the vertical standards. Each of the rear projections 914 has cut or formed in it a slot 912 that fits over a lower, transverse edge of one of the slots in the column of slots on the vertical standard 310. The rearward projections 914 thus form hooks with which the bracket is hung on the vertical standard. The connection interface also comprises another rearward extension in the form of a tab 918 falls into a slot once the rearward projections are inserted and pushed down over the lower edges of the slots, as described above, thus helping to ensure that the hooks are and remain properly seated.
In this example, the drawer frame includes, in addition to drawer front 808, a bottom 818, rear 820 and sides 822. The drawer is, for example, supported within the enclosure by slides, drawer extensions, or similar mechanism 824 that is connected between the drawer frame and the bottom panel 806. However, many types of drawer slides, extensions, push-to-open and soft close mechanisms could be substituted.
The structure of the bracket enables the side panels to hide most of the bracket while also centering the outer surface of the sides of the enclosure on the vertical standard in a manner that allows single, shared vertical standard to be used to support two drawers side-by-side. Furthermore, because of the thin connection interface 904 and wider slots, the brackets 900a and 900b of adjacent drawers are able to share the same the same slots on the vertical standard. Thus, the two drawers can be hung on the vertical standers very close to each other, with side panels of the two drawers abutting each other. The close fitting gives the storage system an appearance similar to custom drawers and allows for more pleasing aesthetics.
Although described in reference to a drawer, in alternate embodiments the drawer could be omitted, or another type of organizational or storage component could be substituted for the drawer, without substantially altering the enclosure or how it is constructed and supported by the cantilevered brackets.
Non-limiting representative examples of verticals standards that can be used with the components described above are disclosed or described in PCT Application No. PCT/US2018/050781. However, these standards can be adapted to be connected or otherwise supported on a wall using fasteners, clips, and brackets, and in other ways. Additionally, the vertical standards may, optionally, include raised portions extending from the front of the vertical standard that visually obscures from side angles one or more columns of slots to which the cantilevered brackets are connected.
Unless otherwise expressly stated, the foregoing description of exemplary and preferred embodiments, and accompanying drawings, are intended to be representative, non-limiting examples of the invention that is claimed, and may describe multiple inventions in addition to the one set forth in the claims. The invention, as defined by the appended claims, is therefore not intended to be limited to the details of the described examples and embodiments, or to any preferred embodiment. Furthermore, the subject matter of a claim is not intended to be limited by statements made in reference to aspects of any of the embodiments or examples other than those particular aspects that are expressly set forth in a claim. Rather, the invention, as claimed, is intended to encompass equivalents of the examples and embodiments, as well as alterations and modifications to them that come within the ordinary and customary meaning of the claim terms, unless such terms have been expressly defined in this specification or otherwise subject to construction, such as under 35 U.S.C. § 112(f), that are required by statute.
Number | Date | Country | Kind |
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PCT/US2018/050781 | Sep 2018 | US | national |
This application is related to U.S. provisional application No. 62/730,524, filed Sep. 12, 2018, and is also related to PCT application number PCT/US2018/050781 filed Sep. 12, 2018, each of which is incorporated herein for all purposes.
Filing Document | Filing Date | Country | Kind |
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PCT/US2018/058598 | 10/31/2018 | WO | 00 |