UNIVERSAL SHELF GAP FILLER BRACKET

BACKGROUND

[0001] The present disclosure generally relates to shelving systems that include a plurality of shelves that are supported between upright posts of a support frame. More specifically, the present disclosure relates to a shelving system that includes a plurality of configurable shelves that allow the shelves to be used in either a straight shelf state or a notched shelf state to respond to user demands for the shelving system.

[0002] Presently, two different types of shelves can be used with a support frame that includes a plurality of spaced upright posts. The first type of shelf is referred to as a notched shelf that includes cutouts located at the four corners of the rectangular shelf. The cutouts allow a portion of the top surface of the shelf to extend beyond the support post such that when two shelves are positioned in an end-to-end configuration, only a very small gap will be present between the ends of the adjacent shelves. Although the use of notched shelves minimizes the gap between adjacent shelves located at the same vertical level, when the notched shelves are initially installed or need to be removed from the support frame, the notched shelf cannot be simply pulled straight in or out of the support frame. Instead, each notched shelf must be tilted and/or angled to position the notched shelf between the upright posts. This can be both difficult and cumbersome depending on the length and width of the shelf.

[0003] A second type of shelf that can be used with a support frame is referred to as a straight shelf. Typically, straight shelves have straight side walls that extend between spaced first and second end walls to define the rectangular shelf. When a straight shelf is installed on a support frame including the spaced upright posts, the length of the straight shelf is selected and manufactured such that the shelf length is less than the distance between the inside edges of the spaced upright posts. This allows the straight shelves to be pulled straight out of the support frame without any tilting or rotation of the shelf. Although this allows for easier installation and removal of the straight shelves compared to notched shelves, when straight shelves are positioned adjacent to each other, a gap is created between the ends of the adjacent straight shelves. This gap is located behind the upright posts and is generally the same size as the width of the upright posts. Depending on the size of the upright posts, the gap between adjacent straight shelves could allow items to fall through the gap, which is less than desirable in some uses of the shelving system.

[0004] The inventors have identified a need and desire for a shelving system that can be transitioned between a shelving system with straight shelves to a shelving system that includes notched shelves. Such type of shelving system would allow the owner of the shelving system to reconfigure the shelving system if the needs and uses of the shelving system change over time.

SUMMARY

[0005] The present disclosure generally relates to shelving systems that include a plurality of shelves that are supported between upright posts and lateral supports. More specifically, the present disclosure relates to a shelving system that includes a plurality of configurable shelves that allow the shelves to be used in either a straight shelf state or a notched shelf state to respond to user demands for the shelving system.

[0006] In accordance with one exemplary embodiment, a shelving system is provided that can be configured between a straight shelf state and a notched shelf state. The shelving system includes a support frame that includes at least four spaced upright posts. The upright posts are configured to support at least one shelf. The shelf includes a planar top surface that has a first end, a second end, a first side and a second side. The first and second ends define the length of the shelf while the spaced first and second sides define the width of the shelf.

[0007] The shelf includes a first end wall and a second end wall that each extend perpendicular to the top surface of the shelf. A pair of spaced side walls also extend perpendicular to the top surface of the shelf. The shelving system further includes one or more gap filler brackets that can be attached to the first and/or second end walls of the shelf. The gap filler brackets each include an attachment wall and an extension wall that is perpendicular to the attachment wall. The extension wall includes an top extension surface that is generally coplanar with the top surface of the shelf when the gap filler brackets are attached to the first and/or second end walls of the shelf. When the gap filler brackets are attached to the end walls of the shelf and a pair of shelves are installed on the support frame, the extension surfaces of the adjacent gap filler brackets cover a gap that exists between the adjacent shelves.

[0008] In accordance with an exemplary embodiment, the extension wall of each gap filler bracket has a length that is less than the width of the shelf such the gap filler bracket creates a notch at each corner of the shelf. In this manner, the gap filler brackets convert the shelf from a straight shelf into a notched shelf having a notch formed at each corner of the shelf.

[0009] In accordance with an exemplary embodiment of the present disclosure, the gap filler bracket is removably attached to one of the first or second end walls of the shelf by an attachment mechanism. The attachment mechanism includes at least one engagement tab formed on the attachment wall of the gap filler bracket. The engagement tab is sized to be received in at least one attachment opening formed on the end wall of the shelf. In some contemplated embodiments, more than one engagement tab and a corresponding number of attachment openings are part of the attachment mechanism. The engagement tabs and attachment openings are equally spaced such that the engagement tabs and attachment openings can mate with each other to hold the gap filler bracket in place on the shelf. The gap filler brackets can be attached to both of the first and second end walls or can be attached to only one of the first and second end walls depending upon the user requirements for the shelf.

[0010] When the engagement tabs are located in the attachment openings, the gap filler bracket can be moved relative to the end wall to cause the engagement tab to entrap the end wall between the engagement tab and the attachment wall to hold the gap filler bracket in place. If the owner desires to re-configure the shelf, the gap filler brackets can be moved in the opposite direction to allow the engagement tab to disengage from the end wall and be removed through the attachment opening. In this manner, the shelf can transition between a notched shelf and a straight shelf.

[0011] The present disclosure is further directed to a configurable shelf assembly that can be used with a shelving system that includes a support frame that includes at least four spaced upright posts. The configurable shelf assembly allows the shelving system to transition between a notched shelf state and a straight shelf state. The configurable shelf assembly includes a shelf having a first end wall and a second end wall that each extend perpendicular to the top surface of the shelf. A pair of spaced side walls also extend perpendicular to the top surface of the shelf.

[0012] The configurable shelf assembly further includes one or more gap filler brackets that can be attached to the first and/or second end walls of the shelf. The gap filler brackets each include an attachment wall and an extension wall that is perpendicular to the attachment wall. The extension wall includes an extension surface that is generally coplanar with the top surface of the shelf when the gap filler brackets are attached to the first and/or second end walls of the shelf. When the gap filler brackets are attached to the end walls of the shelf and a pair of shelves are installed on the support frame, the extension surfaces of the adjacent gap filler brackets cover a gap that exists between the adjacent shelves.

[0013] In accordance with an exemplary embodiment, the extension wall of each gap filler bracket has a length that is less than the width of the shelf such that a notch is created at each corner of the shelf that includes the gap filler bracket. In this manner, the gap filler brackets convert the shelf from a straight shelf into a notched shelf that includes a notch formed at each corner of the shelf.

[0014] In accordance with an exemplary embodiment of the present disclosure, the gap filler bracket is removably attached to one of the first or second end walls of the shelf by an attachment mechanism. The attachment mechanism includes at least one engagement tab formed on the attachment wall of the gap filler bracket. The engagement tab is sized to be received in at least one attachment opening formed on the end wall of the shelf. In some contemplated embodiments, more than one engagement tab and a corresponding number of attachment openings are part of the attachment mechanism. The engagement tabs and attachment openings are equally spaced such that the engagement tabs and attachment openings can mate with each other to hold the gap filler bracket in place on the shelf. The gap filler brackets can be attached to both of the first and second end walls or can be attached to only one of the first and second end walls depending upon the user requirements for the shelf.

[0015] When the engagement tabs are located in the attachment openings, the gap filler bracket can be moved relative to the end wall to cause the engagement tab to entrap the end wall between the engagement tab and the attachment wall to hold the gap filler bracket in place. If the owner desires to re-configure the shelf, the gap filler brackets can be moved in the opposite direction to allow the engagement tab to disengage from the end wall and be removed through the attachment opening. In this manner, the shelf can transition between a notched shelf and a straight shelf.

[0016] Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:

[0018]FIG. 1 is a top perspective view of a notched shelf according to the prior art;

[0019]FIG. 2 is a top view of a shelving system that includes a plurality of notched shelves of FIG. 1 supported on a support frame having a series of spaced upright posts;

[0020]FIG. 3 is a top perspective view of a straight shelf;

[0021]FIG. 4 is a top view of a shelving system that includes a plurality of straight shelves of FIG. 3 supported on a support frame having a series of spaced upright posts;

[0022]FIG. 5 is a front perspective view of a shelving system including a plurality of straight shelves supported on a support frame having a series of spaced upright posts;

[0023]FIG. 6 is a top perspective view of a configurable shelf constructed in accordance with the present disclosure;

[0024]FIG. 7 is a top view of a shelving system that includes the configurable shelf of FIG. 6 supported on a support frame having a series of spaced upright posts;

[0025]FIG. 8 is a top, end perspective view showing one of the gap filler brackets mounted to a first end of the shelf;

[0026]FIG. 9 is a bottom, end perspective view showing one of the gap filler brackets mounted to a first end of the shelf;

[0027]FIG. 10 is an exploded view of the configurable shelf with the pair of gap filler brackets removed from the shelf;

[0028]FIG. 11 is a view taken along line 11-11 of FIG. 9;

[0029]FIG. 12 is an exploded view showing a first mounting configuration for lateral mounting of one of the gap filler brackets of one of the end walls of the shelf;

[0030]FIG. 13 is an exploded view showing a second mounting configuration for vertical mounting of one of the gap filler brackets of one of the end walls of the shelf; and

[0031]FIG. 14 is an exploded view showing a third mounting configuration for vertical mounting of one of the gap filler brackets of one of the end walls of the shelf.

DETAILED DESCRIPTION

[0032]FIGS. 1 and 2 illustrate a first type of shelving system 10 that is known in the prior art. In the shelving system 10 shown in FIGS. 1 and 2, the shelving system 10 includes a series of individual notched shelves 12 that are arranged as shown in FIG. 2 to create a shelving level for supporting items. The shelving system 10 is shown in the top view of FIG. 2 as including a series of upright posts 14 that are positioned to support the corners of each of the notched shelves 12. The upright posts 14 are part of a complete support frame that is used to support a series of notched shelves 12 at different vertical levels in a known manner. At each vertical level, the combination of the notched shelves 12 create a continuous support surface for supporting objects at the vertical level of the shelving system 10.

[0033]Referring back to FIG. 1, each of the notched shelves 12 includes a planar top surface 16 that has an overall length that extends from a first end 18 to a second end 20. The width of the top surface 16 is defined between a first side 22 and a second side 24. As shown in FIG. 1, the notched shelf 12 includes a notch 26 formed at each of the corners of the notched shelf 12. The notch 26 reduces the overall width of the top surface 16 in the areas defined by the notch 26. Likewise, the notch 26 decreases the length of the first and second sides 22, 24 also in the area of the notch 26.

[0034]When the shelving system 10 is assembled as shown in FIG. 2, the notch 26 formed at the corner of each of the notched shelves 12 receives one of the upright posts 14. As can be understood in FIG. 2, the notched shelf 12 has a length that is greater than the distance between the upright posts 14 such that the notched shelf 12 is unable to be moved toward or away from the support frame in the direction shown by arrow 28. Thus, each of the individual notched shelves 12 must be lifted and/or tilted to be installed on the support frame that includes the series of upright posts 14. Although installation of the individual notched shelves 12 requires lifting and/or tilting, the first end 18 of one notched shelf 12 is positioned immediately adjacent to the second end 20 of the adjacent notched shelf 12. Thus, no gap exists between the pair of notched shelves 12 when the shelves 12 are positioned adjacent to each other. This is one benefit of a notched shelving system 10.

[0035]FIG. 3 illustrates a second type of shelf that can be used with a shelving system, which is referred to as a straight shelf 30. As with the notched shelf shown in FIG. 1, the straight shelf 30 extends from a first end 18 to a second end 20 to define the overall length of the straight shelf 30. The straight shelf 30 includes a top surface 16 having a width that extends between the first side 22 and the second side 24. The straight shelf 30 is typically formed from a metal material that includes a top plate 32 that defines the top surface 16. The top plate 32 is joined to a first end wall 34 and a second end wall 36. A pair of side walls 38 depend from the top plate 32 to define the overall size of the straight shelf 30 and to provide the required structural stability for the straight shelf 30.

[0036]FIG. 4 illustrates a shelving system 10 that includes the spaced upright posts 14 that are designed to support the corners of each of the straight shelves 30. As can be seen in FIG. 3, the length of each of the straight shelves 30 between the first end 18 and the second end 20 is designed to be slightly less or approximately equal to the distance between the innermost edges of each of the upright posts 14. The length of each of the straight shelves 30 thus allows the straight shelves 30 to slide into and out of the support frame as shown by arrow 41. Although the use of straight shelves 30 allows for an easier installation and removal process, when the straight shelves 30 are installed as shown in FIG. 4, a gap 40 is formed between the first end 18 of one of the straight shelves 30 and the second end 20 of the adjacent straight shelf 30. The gap 40 that exists between the adjacent straight shelves 30 allows smaller products to fall between the individual straight shelves 30 or to become stuck when slid along the length of the shelving level.

[0037] As can be understood in the description of the notched shelf 12 and the straight shelf 30, each of the two different types of shelves have advantages/disadvantages when compared to the other type of shelf. It is common for a purchaser of a shelving system to request either the notched shelf or the straight shelf when ordering the shelving system. If the use requirements change, the owner often needs to purchase a complete new set of shelves to accommodate the new requirements.

[0038]FIG. 5 illustrates the configurable shelving system 42 constructed in accordance with one embodiment of the present disclosure. The configurable shelving system 42 shown in FIG. 5 includes a support frame 44 that includes a series of spaced upright posts 14 that are joined to each other by cross supports 46 to provide structural stability for the support frame 44. In the embodiment shown in FIG. 5, a series of shelves 48 are shown supported by the support frame 44 at three separate levels 50A, 50B and 50C. Although three levels 50A-50C are illustrated, it should be understood that the support frame 44 could be either taller or shorter to support a different number of support levels 50. In the embodiment shown, each level 50 includes four shelves 48 that combine to define an overall support platform for holding items at each of the individual levels 50.

[0039]In the embodiment shown in FIG. 5, the shelving system 42 is configured in a straight shelf state in which each of the individual shelves 48 can be moved toward and away from the support frame 44 in the direction shown by arrow 52. The straight shelf state shown in FIG. 5 thus allows the owner of the shelving system 42 to more easily remove and install the individual shelves 48 along the support frame 44 in a similar manner as the shelving system 10 shown in FIG. 4. As with the embodiment shown in FIG. 4, an open gap 40 is created between the spaced ends of each of the shelves 48. Thus, in the straight shelf state, the shelving system 42 emulates the embodiment shown in FIGS. 1 and 2. However, unlike the embodiment of FIGS. 1 and 2, the shelving system 42 is configurable to transition from the straight shelf state of FIG. 5 to a notched shelf state without requiring a series of replacement shelves.

[0040]FIGS. 6 and 7 illustrate a configurable shelf assembly 54 of the present disclosure that allows the shelving system 42 to transition between the straight shelf state of FIG. 5 and a notched shelf state of FIG. 7. The configurable shelf assembly 54 includes the shelf 48 and a pair of gap filler brackets 56 that can be selectively installed and removed from one or both of the ends of the shelf 48. As shown in FIG. 6, the shelf 48 includes a first end 58 and a second end 60 that define the overall length of the top surface 62. The width of the shelf 48 is defined by the first side 64 and the second side 66. The first and second sides 64, 66 are spaced from each other to define the overall width of the shelf 48, as shown by reference character W. As can be understood in FIGS. 5 and 6, when the gap filler brackets 56 are not installed on the shelf 48, the overall length of the shelf generally corresponds to the distance between the inside edges 68 of the upright posts 14. When the gap filler brackets 56 are not installed, the shelves 48 can be slid into and out of the support frame 44 as shown by arrow 52 in FIG. 5.

[0041]Referring back to FIGS. 6 and 7, each of the gap filler brackets 56 is an angled bracket that includes an extension wall 70 that defines a top extension surface 72. The top extension surface 72 is generally coplanar with the top surface 62 when the gap filler bracket 56 is installed on the shelf 48 as shown in FIG. 6. The extension surface 72 thus extends the top surface 62 past the first and/or second end 58, 60 of the shelf 48. It is contemplated that the gap filler brackets 56 could be installed on both of the first and second ends 58, 60 of the shelf in some embodiments but that only one of the gap filler brackets 56 could be used in other embodiment, depending on user requirements for the shelf. As an example, in the embodiment shown in FIG. 7, the gap filler brackets 56 could be removed from the outer ends of the adjacent shelves 48 while the installed gap filler brackets 56 at the inner ends of the adjacent shelves 48 would cover the interior gap between the adjacent shelves 48.

[0042]As illustrated in FIG. 6, the extension surface 72 formed on the extension wall 70 has a width E. The width E of the extension surface 72 is less than the width W of the top surface 62 of the shelf 48 defined between the spaced first and second sides 64, 66. The difference between the widths W and E creates a notch on each of the corners of the configurable shelf 54 when the gap filler bracket 56 is installed on the shelf 48. In this manner, the configurable shelf 54 can emulate the look and function of the notched shelf 12 shown in FIG. 1.

[0043] Referring now to FIG. 7, when the gap filler brackets 56 are installed on both the first end 58 and the second end 60 of each of the shelves 48, the extension surface 72 extends behind one of the upright posts 14. When the gap filler brackets 56 are installed and the shelves 48 are installed on the support frame, the extension surfaces 72 on the adjacent gap filler brackets 56 fill the internal gap 40 that was present between the adjacent shelves 48 in the straight shelf state, as was best illustrated in FIG. 5. Thus, when the gap filler brackets 56 are installed on each of the shelves 48, the gap filler brackets 56 both cover the gap between adjacent shelves and extend behind the upright posts 14. In this manner, the shelf 48 can be transformed from functioning as a straight shelf to a notched shelf.

[0044] In the configuration shown in FIG. 7, the shelving system 42 is transformed from the straight shelf state shown in FIG. 5 to a notched shelf state shown in FIG. 7. When in the notched shelf state shown in FIG. 7, the gap filler brackets 56 fill the internal gaps between adjacent shelves. In the notched shelf state, the individual shelves 48 can no longer be slid in the direction shown by arrow 52. However, in the notched shelf state, the internal gap that existed between adjacent shelves 48 is covered by the extension surface 72 on each of the adjacent gap filler brackets 56. In this manner, the configurable shelf assembly 54 allows each shelf 48 to transition between a straight shelf and a notched shelf without having to utilized different shelves.

[0045] Referring now to FIGS. 8 and 9, further details of the attachment of the gap filler bracket 56 to the shelf 48 will now be further described. As shown in the top exterior view of FIG. 8 and the bottom interior view of FIG. 9, each of the shelves 48 includes a pair of spaced side walls 74 that extend perpendicular to and below the top plate 76 that defines the top surface 62 of the shelf 48. The side walls 74 are joined to both a first end wall 78 and a second end wall 80 that are best shown in FIG. 10. The first and second end walls 78, 80 also extend perpendicular to the top plate 76 and perpendicular to the side walls 74. The first and second end walls 78, 80 provide points of attachment for the individual gap filler brackets 56. As was discussed previously, the gap filler brackets 56 can be selectively installed upon and removed from either one or both of the first and second end walls 78, 80 to configure the shelf assembly 54 as either a straight shelf or a notched shelf.

[0046] As can best be seen in FIGS. 8 and 10, each of the gap filler brackets 56 includes an attachment wall 82 and the extension wall 70. The extension wall 70 is joined to the attachment wall 82 at a corner bend 83 such that the extension wall 70 extends perpendicular to the attachment wall 82 to form a generally right angle. In the embodiment shown, the attachment wall 82 and the extension wall 70 are formed from a unitary metal plate bent at the corner bend 83 and stamped into the configuration shown. As shown in FIG. 8, the attachment wall 82 is designed to be installed upon and supported by one of the end walls, such as the second end wall 80 shown in the embodiments of FIGS. 8 and 9. As was described previously, the length E of the extension surface 72 is less than the width W of the top surface 62 such that the a space exists between the ends 84 of the extension surface 72 and the outer surface of the side walls 74. This space creates a notch at each corner of the configurable shelf assembly 54 when the shelf assembly is configured in the notched shelf configuration.

[0047]FIGS. 11-14 illustrate multiple different embodiments for an attachment mechanism that is used to attach the gap filler bracket 56 to one of the first and second end walls 78, 80. In the embodiment shown in FIG. 12, the attachment wall 82 is shown including a first portion of the attachment mechanism, which is one of a pair of engagement tabs 86 that are formed near the end 88 of the gap filler bracket 56. FIG. 8 shows the two engagement tabs 86 near the two ends 88 of the attachment wall 82. Each of the engagement tabs 86 is a portion of the metallic attachment wall 82 that extends away from an outer surface 90 of the attachment wall 82. The engagement tab 86 is designed to be received within one of a pair of receiving opening 92 formed in the first or second end wall of the shelf 48, such as the second end wall 80 shown in FIGS. 9 and 12. The receiving openings 92 form the second part of the attachment mechanism that is used to attach the gap filler bracket 56 to one of the end walls of the shelf 48. The receiving opening 92 has a shape that allows the engagement tab 86 to enter into the receiving opening 92. When the engagement tab 86 is received in the receiving opening 92, the gap filler bracket 56 can be moved in the direction shown by arrow 94 to initially install the gap filler bracket 56 on the second end wall 80. Later, the gap filler bracket 56 can be moved in the opposite direction to remove the gap filler bracket 56 from the end wall 80.

[0048]FIG. 11 is a cross-section view showing the engagement between the engagement tab 86 and the second end wall 80. The second end wall 80 includes the receiving opening 92 that allows the engagement tab 86 to initially pass behind inner surface 96 of the second end wall 80. As the gap filler bracket is moved in the direction shown by arrow 94 in FIG. 12, the engagement tap 86 flexes outward and holds the engagement wall 82 of the gap filler bracket in the position shown. In a first embodiment shown in FIG. 11, the outer end 98 of the engagement tab 86 extends to the left such that the sliding movement of the entire gap filler bracket 56 in the direction shown by arrow 100 will result in engagement between the engagement tab 86 and the outer surface 96 of the second end wall 80.

[0049] In the second embodiment shown in FIG. 13, the engagement tab 86 is oriented such that the outer end 98 of the engagement tab 86 faces upward. This allows the entire gap filler bracket 56 to be moved upward as shown by arrow 102 into the engaged position.

[0050]FIG. 14 illustrates a third embodiment in which the outer end 98 of the engagement tab 86 faces downward which allows the entire gap filler bracket 56 to be moved downward as shown by arrow 104 into the engaged position. It should be understood that by moving the gap filler bracket 56 in the opposite direction to the direction of initial engagement, the gap filler bracket 56 can be removed from the shelf 48 to change the shelf from the notched shelf configuration to the straight shelf configuration.

[0051] Although the exemplary embodiment shown in the drawing figures includes one or more engagement tabs 86 formed on the attachment wall 82 of the gap filler bracket 56 and the receiving openings 92 formed in the end wall of the shelf, it is contemplated that the location of these components could be reversed while operating within the scope of the present disclosure. In such contemplated embodiment, the engagement tabs 86 would be located on the end wall of the shelf and the receiving openings 92 would be located on the attachment wall 82.

[0052] In additional, although the attachment mechanism is shown in the Figures as including the mating engagement tabs 86 and receiving openings 92, it is contemplated that other mechanisms could be utilized while operating within the scope of the present disclosure. The attachment mechanism should be configured to allow the gap filler brackets to be selectively installed and removed on one or more ends of the shelf. Preferably, such attachment can be carried out without any tooling or connectors, although the use of tooling and connectors is also contemplated.

[0053] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.