US20070181759A1

US20070181759A1 - Shelving system

Info

Publication number: US20070181759A1
Application number: US11/346,808
Authority: US
Inventors: Bradley Young
Original assignee: OSullivan Industries Holdings Inc
Current assignee: Sauder Woodworking Co
Priority date: 2006-02-03
Filing date: 2006-02-03
Publication date: 2007-08-09

Abstract

A shelving system and method for mounting a shelf are provided. The shelving system includes a plurality of support brackets configured to be secured to a support structure and a plurality of support arms configured to engage at least some of the plurality of support brackets. The shelving system further includes a plurality of mounting components configured to be secured to a shelf, with the plurality of mounting components further configured to engage at least some of the plurality of support brackets and the plurality of support arms.

Description

BACKGROUND OF THE INVENTION

This invention relates generally to shelving systems, and more particularly, to a shelving system having a mounting component that engages different support members of the shelving system.
Shelving systems are used in a variety of applications for storing items thereon, thereunder or attached thereto. For example, user installable shelving systems for mounting within garages are known and may be used for hanging and storing different items thereon, for example, storage containers. As another example, shelving systems with different shelving units may be used and designed for closet installation, such as for hanging and storing clothing thereon. These shelving systems also may provide additional components for particular applications, such, for example, a shoe storage component for storing shoes.
These shelving systems typically include mounting hardware such as wall clips and side mounting brackets along with support arms for mounting the shelving to a support structure, such as a wall. The shelving for these systems may be constructed of different materials, such as, wood or metal, and may provided in different configurations, such as, wire or wood shelving provided in different shapes and sizes. These shelving systems often require much time and effort in preparation for installation. Additionally, the time and effort to install these shelving systems also can be extensive. For example, known shelving systems require much preparation including measuring dimensions for hanging the shelving systems and drilling in order to properly install and support the units. Connection of the various support components to shelving units of the shelving system is often tedious and difficult (e.g., components do not properly align). Additionally, because of the construction and configuration of shelving units (e.g., shelves and supports) of these shelving systems, installation may require more than one person. If one person installs the shelving systems, often special equipment or supports are needed. Further, several tools may be required in order to assemble and mount the shelving units.
Further, known support brackets for these shelving systems will often sag over time as a result of the construction of these support brackets, which become overloaded, for example, when items are hung on the front end of the shelving unit or stacked on top of a deck of the top of the shelving unit. Sagging may occur even faster if heavy items or a large number of items are supported by the shelving system. Additionally, inconsistent positioning and installation of mounting brackets and other support components can result in improper installation and problems with failure over time.
Thus, known shelving systems not only are difficult to install both because of the complexity of the installation and the time required, but also may fail as a result of the design of the support components or the installation thereof. Further, the cost of these shelving system can be high because different mounting components, for example, brackets and supports, are needed for connection to the various portions of the shelving units or for different applications.

BRIEF DESCRIPTION OF THE INVENTION

In an exemplary embodiment, a shelving system is provided that includes a plurality of support brackets configured to be secured to a support structure and a plurality of support arms configured to engage at least some of the plurality of support brackets. The shelving system further includes a plurality of mounting components configured to be secured to a shelf, with the plurality of mounting components further configured to engage at least some of the plurality of support brackets and the plurality of support arms.
In another exemplary embodiment, a mounting component for mounting a shelf is provided that includes a base, a plurality of posts extending from one side of the base and configured to engage a shelf and a tab extending from another side of the base opposite the side having the plurality of posts. The tab is configured to engage a support bracket mounted to a support structure and to engage a support arm configured to support the shelf.
In yet another exemplary embodiment, a shelving system is provided that includes means for securing a shelf to a support structure, means for supporting the shelf and means for engaging both the means for securing and means for supporting.
In still another exemplary embodiment, a method for mounting a shelf is provided. The method includes configuring a mounting component to secure to a shelf and configuring the mounting component to engage a support bracket mounted to a support structure and a support arm for supporting the shelf.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a shelving system constructed in accordance with various embodiments of the invention.
FIG. 2 is a perspective view of a mounting component of the shelving system of FIG. 1.
FIG. 3 is a perspective view of a support bracket of the shelving system of FIG. 1.
FIG. 4 is a perspective view of a support arm of the shelving system of FIG. 1.
FIG. 5 is a perspective view of a portion of a shelf showing a mounting component engaged with a support bracket in accordance with various embodiments of the invention.
FIG. 6 is a perspective view of a shelf constructed in accordance with various embodiments of the invention.
FIG. 7 is a plan view of a template constructed in accordance with various embodiments of the invention.
FIG. 8 is a perspective view of a portion of a shelf showing a mounting component engaged with a support arm in accordance with various embodiments of the invention.
FIG. 9 is a perspective view of a support arm engaged with a support bracket both constructed in accordance with various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Various embodiments of the present invention provide a shelving system having press-in shelf hardware with slip-on connecting arms for mounting a shelf to, for example, a wall or other supporting structure. This shelving system allows one person installation on a variety of different surfaces, such as, for example, brick, masonry, drywall and wood.
In general, and as shown in FIG. 1, the shelving system 20 includes a plurality of mounting components 22, a plurality of support brackets 24, and a plurality of support arms 26 for mounting and supporting a shelf 28 (e.g., wood shelf) to a support member or structure 30, for example, a wall.
More particularly, and as shown in FIG. 2, the mounting component 22 generally includes a base 32 having an edge 33. In an exemplary embodiment, the base 32 is formed as a generally planar surface and includes on a first side 34 a plurality of protrusions generally defining a plurality of posts 36 extending generally perpendicularly from the base 34. For example, a pair or posts 36 may be provided. In the various embodiments, the posts 36 are shaped having a generally circular cross-section with a plurality of ribs 38 extending radially around the circumference of the posts 36 and longitudinally along the posts 36 to define a “saw-shaped” cross-sectional pattern. On a second side 40 of the base 32, a mounting extension 42 extends generally perpendicularly therefrom and is configured and shaped in a complementary manner for engagement with either the support bracket 24 or support arm 26. More particularly, the mounting extension 42, in an exemplary embodiment, is formed as a tab having a generally rectangular cross-section with a curved end 44 to allow insertion of the mounting component 22 for engagement with the support bracket 24 and support arm 26.
Referring now to FIG. 3 and the support bracket 24, in an exemplary embodiment, the support bracket 24 is configured having an offset portion 46 defining a indented region 49, which may be, for example, generally U-shaped and has angled walls 47. For example, the angled walls 47 may be angled at about forty-five degrees from the indented region 49. The offset portion 46 is configured to engage the mounting extension 42 of the mounting component 22 (shown in FIG. 2), and more particularly, the tab shape of the mounting extension 42 of the mounting component 22 is configured to generally abut the indented region 49. The support bracket 24 further includes mounting portions 48 at the ends of the support bracket 24 and extending from the angled walls 47 to define a generally “winged” shape configuration. The mounting portions 48 are generally parallel to the indented region 49. Each of the mounting portions 48 includes an aperture or opening 50 for use in mounting the support bracket 24 to, for example, a wall using a screw, bolt or other wall mounting mechanism as is known.
Referring now to FIG. 4 and the support arm 26, in an exemplary embodiment, the support arm 26 includes a generally planar body 52 extending from a first mounting portion 54 to a second mounting portion 56 on opposite ends of the body 52. Optionally, the body 52 may be configured having a plurality of ridges 53 forming a corrugated configuration. The first mounting portion 54 includes an extension 58 (e.g., a tab) extending at an angle from the body 52 and configured to engage the offset portion 46 of the support bracket 24 (shown in FIG. 3). More particularly, a face 47 of the extension 58 is configured to abut the indented region 49. Additionally, the first mounting portion 54 includes a shoulder 51 formed on each side of the extension 58 and configured to engage a top portion of the mounting portions 48 of the support bracket 24. The second mounting portion 56 includes an engagement portion 60 extending at an angle from the body 52 and having an opening 62 therein for receiving therethrough the mounting extension 42 of the mounting component 22 (shown in FIG. 2). Additionally, the second mounting portion 56 includes a lip 64 configured generally perpendicularly (at about a ninety degree angle) to a face 61 of the engagement portion 60 and configured for engagement against the edge 33 of the base 32 of the mounting component 22 (shown in FIG. 2).
In operation, the mounting component 22 is configured to be secured to a shelf 28 and engage the support bracket 24 at a generally rear portion of the shelf 28. Specifically, as shown in FIG. 5, the mounting component 22 is configured to be secured to a lower surface 70 of the shelf 28. In particular, the posts 36 of the mounting component 22 are configured to engage holes or openings 72 (shown in FIG. 6) of the shelf 28. For example, as shown in FIG. 6, a plurality of pre-drilled openings 72 may be provided on the lower surface 70 for engaging a plurality of the mounting components 22. The plurality of pre-drilled openings may be spaced at predetermined distances, for example, based on the size, weight, etc. of the shelf 28. Alternatively, a user can drill holes in the shelf 28 for receiving the mounting components 22. The posts 36 of the mounting component 22 are inserted within the opening 72. Once the posts 36 are inserted within the openings 72, the ribs 38 (shown in FIG. 2) further engage and resist removal of the posts 36 from the openings 72. The openings 72 are generally sized to have a diameter approximately the same as the diameters of the posts 38 of the mounting component 22. However, the openings 72 may be sized slightly smaller or larger depending on the size of the ribs 38, etc.
The mounting component 22 is also configured to engage the support bracket 24 such that the mounting extension 42 of the mounting component 22 engages the offset portion 46. More particularly, the support bracket 24 is secured to a support structure (e.g., a wall) using screws, fasteners, etc. inserted through the openings 50 of the mounting component 22 as is known. The spacing of the mounting components 22 may be defined by, for example, a template 80, such as a Mylar template as shown in FIG. 7. The template 80 may include, for example, indications 82 identifying the mounting locations, for example, drilling locations for drilling holes for securing the mounting components 22 to, for example, a wall. The template 80 also may include a shelf location indicator 84 to properly locate a shelf 28 in a desired or required location and shows the center line 86 for the shelf 28. The template 80 further may include a level line 88 for use in leveling the template 80 to ensure that the shelf 28, once mounted using the mounting components 22, is also level (e.g., generally horizontal).
Referring again to FIG. 5, once the support bracket 24 is secured to, for example, a wall, the indented region 49 generally defines a receiving portion or opening 90 for receiving therethrough the mounting extension 42 of the mounting components 22, usually the mounting components 22 on a rear portion of the shelf 28 with the curved end 44 facing away from the wall. The insertion of the mounting extension 42 into the opening 90 generally includes initially tilting the shelf 28 at a downward angle such that the curved end 44 is parallel to the opening 90, and once inserted therethrough, raising the shelf to a horizontal position. Once the mounting extension 42 is inserted through the opening 90, the curved end 44 resists backward movement of the mounting extension through the opening 90.
Further, as shown in FIG. 8, the mounting component 22 is configured to be secured to the shelf 28 and engage the support arm 26 at a generally front portion of the shelf 28. The mounting component 22 is secured to the shelf 28 as described in more detail above. The support arm 26 is configured to engage the mounting extension 42 of the mounting component 22, and more particularly, the second mounting portion 56 of the support arm 26 is configured to receive through the opening 62 the mounting extension 42. Once inserted therethrough, the lip 64 of the second mounting portion 56 engages and abuts against the edge 33 of the mounting component 22 to resist movement of the support arm 26 (e.g., resist downward and/or rotational forces). Additionally, the face 61 of the engagement portion 60 of the second mounting portion 56 abuts against the base 32 of the mounting component 22 to further resist movement of the support arm 26.
The support arm 26 also engages the support bracket 24 at the first mounting portion 54 as shown in FIG. 9. Specifically, the indented region 49 of the support bracket 24 which is secured to, for example, a wall, generally defines a receiving portion or opening 90 as described in more detail above. The opening 90 is configured for receiving therethrough the extension 58 of the support arm 26. More particularly, the extension 58 extends into the opening 90 until the shoulders 51 of the first mounting portion 54 engage and abut against a top portion of the mounting portions 48 of the support bracket 24. This engagement in combination with the engagement of the support arm 26 to the mounting component 22 at the front of the shelf 28, and the engagement of the mounting component 22 at the rear portion of the shelf 28 to the support bracket 24, supports the shelf 28 in a generally horizontal position.
Thus, in operation, the shelving system 20 provides secure support of a shelf 28 that may be installed by a single individual. For example, using the template 80 or by measuring, a user can secure the support brackets 24 to a wall or other support structure. Additionally, mounting components 22 are secured to the shelf 28, and more particularly, to holes 72 in the shelf 28, which may be predrilled or formed by a user. Thereafter, a user can secure support arms 26 to mounting components 22 at a front portion of the shelf 28 by inserting the mounting extension 42 of the mounting components 22 through the openings 62 of the support arm 26. Thereafter, with the support arms 26 hanging below the shelf 28, the shelf 28 may be mounted to the wall or support structure using the mounting components 22 at a rear portion of the shelf 28. The mounting is provided by tilting the shelf 28 slightly downward from horizontal and inserting the mounting extension 42 into the opening 90 defined by the indented region 49 of the offset portion 46 of the support brackets 24. Thereafter, the shelf 28 is raised to horizontal and at the same time the extension 58 of the support arm 26 extends into the opening 90 of support brackets 24 also secured to the wall, but below the support brackets 24 to which the mounting components 22 at the rear of the shelf 28 are mounted. It should be noted that the curved ends 44 of the mounting components 22 at the front of the shelf 28 and the curved ends 44 of the mounting components 22 at the back of the shelf 28 point in different directions, for example, inward toward the wall and outward from the wall, respectively. It also should be noted that the procedure for mounting a shelf 28 is not limited to the steps and order described above. For example, the support arm 26 may be mounted to the support bracket 24 before being mounted to the mounting component 22 on the shelf 28.
It further should be noted that the number of the various components used in the shelving system 20 may be varied. For example, depending on the size of the shelf 28 to be mounted, the load requirements for the shelf 28, etc. more or less mounting components 22, support brackets 24 and support arms 26 may be used. Additionally, the size and shape of the various components may be modified. For example, the length of the support arm 26 may be varied based on, for example, the dimensions of the shelf 28, the load requirements for the shelf 28, etc.
Thus, various embodiments of the invention provide a shelving system have a universal mounting component allowing easier installation. Further, the connection of the various components may be accomplished without the use of fastening or connection means.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims

1. A shelving system comprising:

a plurality of support brackets configured to be secured to a support structure;

a plurality of support arms configured to engage at least some of the plurality of support brackets; and

a plurality of mounting components configured to be secured to a shelf, the plurality of mounting components further configured to engage at least some of the plurality of support brackets and the plurality of support arms.

2. A shelving system in accordance with claim 1 wherein the plurality of mounting components each comprise a plurality of posts for engaging holes of the shelf.

3. A shelving system in accordance with claim 1 wherein the plurality of mounting components comprise a mounting extension formed as a tab and each of the plurality of support arms comprises an opening at an end, with the tab configured to extend through the opening.

4. A shelving system in accordance with claim 3 wherein the mounting extension comprises a curved end.

5. A shelving system in accordance with claim 3 wherein the end of each of the plurality of support arms comprises a lip configured to engage an edge of a base of the plurality of mounting components.

6. A shelving system in accordance with claim 3 wherein the end of each of the plurality of support arms comprises a face to engage a base of the plurality of mounting components.

7. A shelving system in accordance with claim 1 wherein the plurality of support brackets comprise an offset portion having an indented region configured to form an opening when secured to the support structure and the plurality of support arms each comprise an extension at an end, the extension configured to extend through the opening.

8. A shelving system in accordance with claim 7 wherein the plurality of support arms each comprise a pair of shoulders at the end for engaging the support bracket.

9. A shelving system in accordance with claim 1 wherein the plurality of mounting components comprise a plurality of posts each having a plurality of ribs configured to resist movement of the mounting component when secured to the shelf.

10. A shelving system in accordance with claim 1 wherein the plurality of mounting components are configured to provide user press-in operation to secure the mounting components to the shelf.

11. A shelving system in accordance with claim 1 wherein the plurality of support arms are configured to provide slip-on operation to secure the supports arms to the shelf and the plurality of support brackets.

12. A shelving system in accordance with claim 1 further comprising a template to identify locations for mounting the plurality of support brackets to the support structure.

13. A shelving system in accordance with claim 1 wherein the plurality of mounting components are configured to be secured to a wood shelf.

14. A mounting component for mounting a shelf, the mounting component comprising:

a base;

a plurality of posts extending from one side of the base and configured to engage a shelf; and

a tab extending from another side of the base opposite the side having the plurality of posts, the tab configured to engage a support bracket mounted to a support structure and to engage a support arm configured to support the shelf.

15. A mounting component in accordance with claim 14 wherein the tab comprises a curved end configured to resist movement once engaged to one of the support bracket and support arm.

16. A mounting component in accordance with claim 14 wherein the plurality of posts each comprise a plurality of ribs extending radially around the circumference of the plurality of posts.

17. A mounting component in accordance with claim 14 further comprising a base and an edge configured to engage the support arm.

18. A shelving system comprising:

means for securing a shelf to a support structure;

means for supporting the shelf; and

means for engaging both the means for securing and means for supporting.

19. A method for mounting a shelf, the method comprising:

configuring a mounting component to secure to a shelf; and

configuring the mounting component to engage a support bracket mounted to a support structure and a support arm for supporting the shelf.

20. A method in accordance with claim 19 further comprising configuring the mounting component to resist movement when engaged with at least one of the support bracket and the support arm.