U.S. patent application number 10/366951 was filed with the patent office on 2004-08-19 for modular multi-piece shelf and shelving unit.
Invention is credited to Craft, Charles W., Skov, Erik L..
Application Number | 20040159622 10/366951 |
Document ID | / |
Family ID | 32849847 |
Filed Date | 2004-08-19 |
United States Patent
Application |
20040159622 |
Kind Code |
A1 |
Craft, Charles W. ; et
al. |
August 19, 2004 |
Modular multi-piece shelf and shelving unit
Abstract
A self-locking multi-piece shelf is disclosed wherein the shelf
includes a first and second endcap, and a body having a first and a
second end. The first endcap slidingly engages with the first end
of the body, whereby a first part of a locking mechanism located on
the body engages with a second part of the locking mechanism
located on the first endcap, thereby locking the first endcap to
the body. The second endcap slidingly engages with the second end
of the body, whereby a first part of a locking mechanism located on
the body engages with a second part of the locking mechanism
located on the second endcap, thereby locking the second endcap to
the body.
Inventors: |
Craft, Charles W.; (Apple
Creek, OH) ; Skov, Erik L.; (Akron, OH) |
Correspondence
Address: |
MARSHALL, GERSTEIN & BORUN LLP
6300 SEARS TOWER
233 S. WACKER DRIVE
CHICAGO
IL
60606
US
|
Family ID: |
32849847 |
Appl. No.: |
10/366951 |
Filed: |
February 14, 2003 |
Current U.S.
Class: |
211/153 ;
108/106; 211/188 |
Current CPC
Class: |
A47B 96/021 20130101;
A47B 87/0246 20130101; F16B 12/26 20130101 |
Class at
Publication: |
211/153 ;
211/188; 108/106 |
International
Class: |
A47F 005/00 |
Claims
What is claimed is:
1. A self-locking multi-piece shelf comprising: a shelf body having
a first end, a second end, an upper side, and a lower side; first
and second endcaps each slidingly attached to the first and second
ends, respectively, and providing one or more riser sockets
therein; at least one locking mechanism first part carried on each
of the first and second ends; and at least one locking mechanism
second part carried on each of the first and second end caps;
wherein each locking mechanism first part is engaged with a
corresponding locking mechanism second part.
2. The self-locking multi-piece shelf of claim 1 wherein the shelf
body includes a plurality of support beams.
3. The self-locking multi-piece shelf of claim 2 wherein the
plurality of support beams are located between the upper and lower
sides extending from the first end of the shelf body to the second
end of the shelf body.
4. The self-locking multi-piece shelf of claim 2 wherein the
plurality of support beams are each an inverted T-beam support
beams.
5. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism first parts are apertures.
6. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism second parts are wedge-shaped protrusions located
on an inner surface of the first and the second endcaps.
7. The self-locking multi-piece shelf of claim 1 wherein the
endcaps slidingly telescope over the ends of the shelf body.
8. The self-locking multi-piece shelf of claim 1 wherein the
endcaps slidingly telescope into the ends of the shelf body.
9. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism first parts are wedge-shaped protrusions.
10. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism second parts are apertures.
11. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism first parts are integral to the respective
endcaps.
12. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism first parts are integral to the respective ends
of the shelf body.
13. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism second parts are integral to the respective
endcaps.
14. The self-locking multi-piece shelf of claim 1 wherein the
locking mechanism second parts are integral to the respective ends
of the shelf body.
15. The self-locking multi-piece shelf of claim 1 wherein the shelf
body is constructed from one of extruded or blow molded
polyethylene, polypropylene, and polystyrene material.
16. The self-locking multi-piece shelf of claim 1 wherein the
endcaps are constructed from one of injection molded or blow molded
polyethylene, polypropylene, and polystyrene material.
17. A self-locking multi-piece shelf comprising: a shelf body
having a first end, a second end, an upper side, and a lower side,
wherein one or more apertures are located on the ends of the shelf
body; first and second endcaps each attached to the first and
second ends of the shelf body, respectively, and having one or more
sockets, wherein the endcaps include one or more wedged shaped
tabs; wherein the one or more wedged shaped tabs of the first
endcap engage the one or more apertures located on the first end of
the shelf body, and the one or more wedged shaped tabs of the
second endcap engage the one or more aperture located on the second
end of the shelf body.
18. The self-locking multi-piece shelf of claim 17 wherein the
lower side includes a plurality of slots located between support
beams, thereby creating a plurality of T-beams.
19. The self-locking multi-piece shelf of claim 17 wherein the
endcaps slidingly telescope over the ends of the shelf body.
20. The self-locking multi-piece shelf of claim 17 wherein the
endcaps slidingly telescope into the ends of the shelf body.
21. The self-locking multi-piece shelf of claim 17 wherein the
shelf body is constructed from one of polyethylene, polypropylene,
and polystyrene material.
22. The self-locking multi-piece shelf of claim 17 wherein the
endcaps are constructed from one of polyethylene, polypropylene,
and polystyrene material.
23. The self-locking multi-piece shelf of claim 17 further
including at least one stop located in each of the endcaps adapted
to position the shelf body relative to the endcaps.
24. The self-locking multi-piece shelf of claim 17 wherein the one
or more apertures include an inner edge and an outer edge.
25. The self-locking multi-piece shelf of claim 17 wherein the one
or more wedge shaped tabs include an inner portion and a stop
surface.
26. A modular shelving system comprising: a plurality of shelf
bodies having a first end, a second end, an upper side, and a lower
side; a plurality of first and second endcaps each able to
slidingly attach to the first and second ends of the plurality of
shelf bodies, the plurality of first and second endcaps providing
one or more riser sockets therein; at least one locking mechanism
first part carried on each of the first and second ends of the
plurality of shelf bodies; and at least one locking mechanism
second part carried on each of the plurality of first and second
endcaps; and a plurality of risers, wherein the plurality of risers
engage with the one or more riser sockets on the plurality of
endcaps.
27. A method of creating a shelf comprising: providing a
self-locking multi-piece shelf consisting of a shelf body having a
first end, a second end, an upper side, and a lower side, and a
first and second endcap adapted to slidingly engage with the shelf
body ends, a first part of a locking mechanism, and a second part
of the locking mechanism; aligning the first endcap with the first
end of the shelf body, and the second endcap with the second end of
the shelf body; and sliding the first endcap relative to the first
end of the shelf body, and the second endcap relative to the second
end of the shelf body until the first part and the second part of
the locking mechanisms engage.
Description
FIELD OF THE DISCLOSURE
[0001] The present invention generally relates to plastic shelves
and, more particularly, to a plastic shelf having a shelf body and
endcaps and to a shelving unit incorporating same.
BACKGROUND OF THE DISCLOSURE
[0002] It is known in the art to provide modular shelving systems
or units. One type of modular unit includes a plurality of
rectangular panels or shelves, wherein each shelf has four sockets,
one provided in each corner of the shelf. Successive shelves may be
stacked and interconnected to adjacent shelves by inserting posts
or risers into each of the sockets. The modular construction
provides flexibility for the consumer to assemble a shelf system or
unit with a desired number of shelves and/or to a desired
height.
[0003] Manufacturing cost, cost component, ease of assembly, and
product versatility are all variables that are considered in the
development and production of these shelving systems. In previous
designs, the shelf components and, more specifically, the shelves
were manufactured as an integral unit consisting of a one-piece
shelf having a plurality of sockets, or as a multi-piece unit
consisting of a shelf body, end units having sockets, and fasteners
connecting the end units and body together. There are several
problems that exist with these designs, including, but not limited
to, the difficulty and cost associated with the design and
manufacture of integral units, and the complexity and tedious
assembly associated with multi-piece shelving units requiring
fasteners.
[0004] In other previous designs, material and component cost was
reduced by decreasing the amount of material used in the shelves,
and more specifically, by reducing the thickness of the shelf
material and/or by eliminating structural components of the shelf.
These cost reducing designs, however, result in shelving units that
are weak and that twist or bend more easily. Similarly, the shelves
may be less durable and/or stable, thereby reducing the life of the
shelving unit and perhaps limiting the shelving unit to use in
storing only lighter objects.
SUMMARY OF THE DISCLOSURE
[0005] In accordance with one aspect of the disclosure among
others, a self-locking multi-piece shelf is disclosed. In one
exemplary embodiment, the shelf includes a body and a pair of
endcaps. The body has a first and a second end, wherein each of the
first and second ends includes a first part of a locking mechanism
that is integral to the body. The pair of endcaps each include one
or more sockets, and a second part of the locking mechanism that is
integral to the endcap. In one example, the first endcap is sized
to slidingly engage with the first end of the body and the second
endcap is sized to slidingly engage with the second end of the
body. The first part of the locking mechanism in the first end of
the body engages with the second part of the locking mechanism in
the first endcap, and the first part of the locking mechanism in
the second end of the body engages with the second part of the
locking mechanism in the second endcap.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of one embodiment of a
self-locking multi-piece shelf as constructed in accordance with
the teachings of the disclosure;
[0007] FIG. 2 is a cross-sectional view of a snap-mechanism of the
self-locking multi-piece shelf of FIG. 4;
[0008] FIG. 3 is a cross-sectional view of the self-locking
multi-piece shelf of FIG. 1;
[0009] FIG. 4 a perspective view of another embodiment of a
self-locking multi-piece shelf as constructed in accordance with
the teachings of the disclosure;
[0010] FIG. 5 is a cross-sectional view of the self-locking
multi-piece shelf of FIG. 4;
[0011] FIG. 6 is a perspective view of a modular shelving unit,
including risers and shelves as constructed in accordance with the
teachings of the disclosure; and
[0012] FIG. 7 is a perspective view of one embodiment of a tab as
constructed in accordance with the teachings of the disclosure.
[0013] While the method and device described herein are susceptible
to various modifications and alternative constructions, certain
illustrative embodiments thereof have been shown in the drawings
and will be described below in detail. It should be understood,
however, that there is no intention to limit the invention to the
specific forms disclosed. On the contrary, the intention is to
cover all modifications, alternative constructions, and equivalents
falling within the spirit and scope of the invention as defined by
the appended claims.
DETAILED DESCRIPTION
[0014] Referring now to the drawings, and with specific reference
to FIG. 1, a self-locking multi-piece shelf constructed in
accordance with the teachings of the disclosure is generally
depicted by reference numeral 20. As shown therein, the
self-locking multi-piece shelf 20 in one exemplary embodiment
includes a body 22 and one or more endcaps 24, and in this example,
a pair of the endcaps 24.
[0015] In one exemplary embodiment, the body 22 defines the center
portion of the self-locking multi-piece shelf 20, and may have
various shapes and sizes adapted to engage with the corresponding
pair of endcaps 24. Possible body shapes can include, but are not
limited to, round, rectangular, oval, or square. The disclosed body
22 in this example includes a first end 30, a second end 32, a
front side 34, a rear side 36, an upper side 38 and a lower side
40. For ease of illustration and understanding, the body 22 and the
self-locking multi-piece shelf 20 in general, will herein be
described as having a generally rectangular shape, wherein the
upper side 38 and the lower side 40 are rectangular and wherein the
upper side 38 and the lower side 40 and the front side 34 and the
rear side 36, are respectively substantially parallel to each
other. Furthermore, the front side 34 and the rear side 36, and the
upper side 38 and the lower side 40 can be correspondingly spaced
apart giving the body 22 a depth and a thickness.
[0016] In one exemplary embodiment, as best seen in FIGS. 3 and 5,
the body 22 has a plurality of support beams 42 located between the
spaced apart upper side 38 and the lower side 40. In this example,
the beams 42 extend the length of the body 22 interior to the upper
and lower sides. More specifically, the support beams 42 extend
substantially perpendicular to and between the upper and the lower
sides 38, 40, and extend from the first end 30 of the body 22 to
the second end 32 of the body 22.
[0017] The thickness, depth, and number of the support beams 42 may
depend and vary according to several factors, including but not
limited to, the intended use of the self-locking multi-piece shelf
20, the width of the body 22 and/or the length of the body 22. For
example, if the intended purpose of the self-locking multi-piece
shelf 20 is to store large, heavy objects, the number, thickness,
and/or depth of the support beams 42 may be increased. Similarly,
the longer the body 22 (i.e., the distance between the first and
second ends 30, 32 of the body 22) and wider the body 22 (the
distance between the front 34 and the rear 36 of the body 22), the
more support beams 42 may be used. Also, the support beams 42 need
not run the entire length of the body 22. The beams may each be
shorter in length, but arranged and positioned over the body 22 to
achieve desired support and strength characteristics. The
orientation and design of the support beams 42, are also not
limited to the one disclosed above. Possible orientations and
designs can include, support beams 42 that have a criss-cross
pattern, support beams that run diagonal to the length and/or width
of the body 22, support beams that run transverse to the length of
the body, or a combination thereof. Further, other structural
devices can be utilized to add strength and rigidity to the shelf,
in place of the beams 42. For example in-molded ribs, as shown in
FIG. 5, may be square, or may be straight beams that include
support structures on both ends of the beam. Similarly, other
structural devices, such as triangular, slanted or other shaped
structural devices may increase the shelf s structural
performance.
[0018] In one exemplary embodiment, the lower side 40 of the body
22 may be perforated or segmented. More specifically, as best seen
in FIGS. 3, the lower side 40 of the body 22 may include slots 44
located intermittent the support beams 42. The slots may 44 create
T-shaped beams 42 having a first portion 43 extending
perpendicularly downward from the upper side 38 and a second
portion 45 attached to the end of the first portion and oriented
substantially parallel to the upper side 38. The slots 44 and the
T-beams 42 may extend the entire length of the body 22, and more
specifically from the first end 30 to the second end 32 of the body
22. In this example, the second portions 45 define the lower side
40 of the body 22.
[0019] In one exemplary embodiment, the one or more endcaps 24 can
be similar or identical and may be interchangeably used, whereas in
another embodiment the endcaps 24 can be different and can be
specifically designed to engage with specific parts of the body 22.
In this example, the endcaps 24 are designed to engage with the
first or second end 30, 32 of the body 22. The disclosed endcaps 24
each include an open inner end 48, a closed outer end 50, a front
side 52, a rear side 54, an upper side 56 and a lower side 58. For
ease of illustration and understanding, the endcaps 24 are herein
described as having a generally rectangular shape, wherein the
upper side 56 and the lower side 58 are generally rectangular in
shape, although defining slightly rounded corners 59, and wherein
the upper side 56 and the lower side 58 and the front side 52 and
the rear side 54, are respectively substantially parallel to each
other (FIGS. 1 and 4). In this example, each of the endcaps 24 has
a pair of sockets 60 each adapted to engage with a corresponding
riser 62 of a shelving unit. Furthermore, the front and rear sides
52, 54, and the upper and lower sides 56, 58 can be correspondingly
spaced apart giving the endcaps 24 proper size to accommodate a
particular shelving unit.
[0020] The inner end 48 of the disclosed endcaps 24 are open and
adapted to receive one or either of the first or second end 30, 32
of the body 22. Each endcap 24 telescopes onto one of the ends 30
or 32 in this example. More specifically, the inner surfaces of the
front and rear sides 52, 54 of the endcaps 24 may be spaced to
slidingly engage with the outer surfaces of the front and rear
sides 34, 36 of the body 22, respectively. Similarly, the inner
surfaces of the upper and lower sides 56, 58 of the endcaps 24 may
be spaced to slidingly engage with the outer surfaces of the upper
and lower sides 38, 40 of the body 22, respectively.
[0021] In another exemplary embodiment, the inner end 48 of the
disclosed endcaps 24 are open and are adapted to be receive by one
or either of the first or second end 30, 32 of the body 22. Each
endcap 24 telescopes into one of the ends 30 or 32 in this example.
More specifically, the outer surfaces of the front and rear sides
52, 54 of the endcaps 24 may be spaced to slidingly engage with the
inner surfaces of the front and rear sides 34, 36 of the body 22,
respectively. Similarly, the outer surfaces of the upper and lower
sides 56, 58 of the endcaps 24 may be spaced to slidingly engage
with the inner surfaces of the upper and lower sides 38, 40 of the
body 22, respectively.
[0022] Located toward the closed outer end 50 of the disclosed end
caps 24 are the sockets 60 adapted to engage with risers 62, as
seen in FIGS. 1 and 6. Each socket 60 may be adapted to engage with
a riser 62 both from the lower side 58 of the endcaps 24 and/or
from the upper side 56 of the endcaps 24. For example, the sockets
60 may receive risers 62 on the lower side 58 of the endcaps 24,
and/or the socket 60 may receive risers 62 on the upper side 56 of
the endcaps 24, thereby giving the self-locking multi-piece shelf
20 modular capability. The endcaps 24 may, however, have a solid
upper side 56 or a solid lower side 58 if needed in a particular
application. For example, as best seen in FIG. 6, a unique bottom
self-locking multi-piece shelf 20a in a shelving unit can be only
adapted to receive risers 62 on the upper side 56 of the endcaps
24, and may therefore have a solid lower side 58. Similarly, a top
self-locking multi-piece shelf 20c in a shelving unit can be
adapted only to receive risers 62 on the lower side 58 of the
endcaps 24, and may therefore have a solid upper side 56. To
simplify the description of the self-locking multi-piece shelf 20
and its various components, the self-locking multi-piece shelf 20
is referred to herein as 20a-20c, while retaining all of the
various embodiment and elements of the self-locking multi-piece
shelf 20.
[0023] In one exemplary embodiment, as best seen in FIGS. 1, 2 and
4, the self-locking multi-piece shelf 20 may include one or more
locking mechanisms 64 to secure the endcap to the shelf body 22.
More specifically, the shelf body 22 may include a first portion of
the locking mechanism 64 and the one or more endcaps 24 may include
a second portion of the locking mechanism 64. The first portion of
the disclosed locking mechanism 64 is the receiving portion of the
mechanism, such as an aperture 70, adapted to receive and retain
the second portion of the locking mechanism 64. The second portion
of the disclosed locking mechanism 64 is the engagement portion,
such as a tab 72, adapted to nest in and engage with the aperture
70. Additionally and/or alternatively, the first and second
portions of the locking mechanism 64 can be located and/or placed
in reverse order as described above. For example, the body 22 may
include the second portion of the locking mechanism 64, such as the
tab 72, and the endcaps 24 may include the first portion of the
locking mechanism 64, such as the aperture 70.
[0024] It is further contemplated that the self-locking multi-piece
shelf 20 can include a multitude of the locking mechanisms 64 that
can be located on the body 22 and the endcaps 24. In one example,
the first portion includes one or more rectangular apertures 70
located near the first and second ends 30, 32 of the body 22, and
the second portion includes one or more wedge-shaped tabs 72 having
a triangular profile located near the inner end 48 of the one or
more endcaps 24. The disclosed apertures 70 include an outer edge
74 and an inner edge 76, such that the inner edge 76 is oriented
toward the center of the body 22, and the outer edge 74 is oriented
away from the center of the body 22. The tabs 72 include an inner
portion 78 and an stop surface 80, such that the inner portion 78
is oriented toward the inner side of the endcap 24, and the stop
surface 80 is oriented toward the outer side of the endcap 24.
[0025] In one exemplary embodiment, as shown in FIG. 1, the body 22
includes two apertures 70 located near the upper side 38 of the
first end 30 of the self-locking multi-piece shelf 20 adapted to
engage with two tabs 72 located on an inner surface of the upper
side 56 of the endcaps 24. In an alternate embodiment, as shown in
FIG. 4, the body 22 may include the above described two apertures
70 and two tabs 72 and further include two apertures 70 located
near the lower side 40 of the first end 30 of the self-locking
multi-piece shelf 20 adapted to engage with two tabs 72 located on
an inner surface of the lower side 58 of the endcaps 24.
[0026] The various components of the self-locking multi-piece shelf
20, including the body 22 and the end caps 24, may be fabricated
from relatively light weight, durable, and sturdy plastic materials
such as polyethylene, polypropylene, polystyrene, or other suitable
plastic materials. The process or processes used to form the
various components of the disclosed self-locking multi-piece shelf
20 may also vary considerably as necessary to form each given
component. The components may be injection molded, blow molded,
continuously molded, extruded, vacuum formed, rotation molded, or
the like. The manufacturing process or processes can be selected
based on feasibility, cost, tooling concerns, as well as other
factors for a given application.
[0027] In one embodiment, the self-locking multi-piece shelf 20 can
be constructed in a sturdy yet cost effective manner. More
specifically, the self-locking multi-piece shelf 20 can be
constructed using various methods including blow molding, injection
molding, and/or extrusion. For example, the body 22 of the
self-locking multi-piece shelf 20 can be economically constructed
in various widths and thicknesses using, for example, a continuous
blow molding or a continuous extrusion process. Such continuous
processes permit fabricating the profile of the body 22 in
continuous lengths. For example, manufacturing of the body 22 using
an extrusion process enables the manufacturer to easily and
inexpensively manufacture long strips 23 of the body 22, that can
then be cut into individual bodies 22. The bodies 22 can be cut
into varying lengths, thereby enabling the manufacturer to easily
and cost effectively achieve various length bodies 22 without
changing tooling parameters, and yet form them having structures
providing strength and rigidity to the bodies. The endcaps 24 can
be manufactured, for example, using a blow molded and/or injection
molding process to obtain a sturdy endcap, thereby creating a
sturdy yet cost efficient self-locking multi-piece shelf 20.
[0028] Many benefits can be achieved by manufacturing the
self-locking multi-piece shelf 20 using a plurality of processes
and techniques. For example, by manufacturing the endcaps using a
blow molding or injection molding process, detailed and intricate
structures and/or elements can be incorporated into the endcaps 24.
The ability to create the details and intricacies, will produce a
solid and structurally superior product (then other manufacturing
processes), while utilizing a minimal amount of material to produce
the same product. Furthermore, because the structure of the endcaps
24 requires individual manufactured units, there is no time saving
available when using other manufacturing processes.
[0029] In contrast, when utilizing a continuous blow molding or
extrusion method to manufacture the shelf body 22, the
manufacturing time can be greatly expedited by manufacturing
extended lengths of the body 22 and then cutting them to size.
Similarly the structure, such as the support beams and the profile
of the body 22, as seen in FIGS. 3 and 5, can be easily altered or
changed by adjusting or replacing the dye of the extrusion
device.
[0030] The combination of the two separate processes, in
manufacturing the self-locking multi-piece shelf 20, includes
further benefits to the ones described above. For example, by
creating two separate pieces and by using two separate
manufacturing processes, there is a great reduction in the cost of
the manufacturing process of the self-locking multi-piece shelf 20.
More particularly, if the self-locking multi-piece shelf 20 would
be manufactured as a single piece unit, a large mold(s),
irregardless of the process, would be required, thereby increasing
the cost of manufacturing. By creating two separate pieces, however
(i.e. the endcap 24 and body 22), the size of the mold(s) for the
endcaps 24 and/or body 22 can be reduces, thereby decreasing its
cost. Furthermore, by constructing the self-locking multi-piece
shelf 20, from two separate pieces and two separate processes, a
sturdy and structurally sound shelf is created, while obtaining a
certain amount of modularity. More specifically, because the endcap
24 and body 22 are manufactured separately, various versions of the
body 22 can be created that can all be utilized with the endcap 24.
For instance, the body 22 can be designed and manufactured with
less material, such as thinner support beams, when intended to be
used for storing lighter objects. Similarly, the body 22 can be
designed and manufactured with more material, such as thicker or
additional support beams, when intended to be used for storing
heavy objects. The modularity also extends to the length of the
body 22, whereby the body 22 can be manufactured in various lengths
while still being able to connect with the endcaps 24.
[0031] In operation, as best seen in FIGS. 1, 2 and 4, the user
first connects the various components of the self-locking
multi-piece shelf 20 together prior to use. In the disclosed
embodiment, the user aligns the inner side 48 of the first endcap
26 to the first end 30 of the body 22, and slides the inner surface
of the first endcap 26 onto the outer surface of the first end 30
of the body 22. More specifically, the inner side 48 of the first
endcap 26 and the first end 30 of the body 22 are aligned such that
the upper side 38 of the body 22 slidingly engages with the inner
surface of the upper side 56 of the first endcap 26, the rear side
36 of the body 22 slidingly engages with the inner surface of the
rear side 54 of the first endcap 26, the lower side 40 of the body
22 slidingly engages with the inner surface of the lower side 58 of
the first endcap 26, and the front side 34 of the body 22 slidingly
engages with the inner surface of the front side 52 of the first
endcap 26.
[0032] Once the first end cap 26 and the first end 30 of the body
22 are properly aligned, the user then forces the body 22 and first
endcap 26 together. As the endcap 26 is forced onto the body 22,
the tabs 72 located on the inner surface of the first endcap 26
displace away from one another in this example, thereby allowing
the continued engagement of the first endcap 26 with the body 22.
The number of tabs 72 may vary depending on the design of the shelf
20. However, the disclosed example has two tabs 72 in the inner
surface of the upper side 48, and two tabs 72 on the inner surface
of the lower side 58.
[0033] The tabs 72 may move in a variety of ways depending on the
construction and design of the locking mechanism 64. In one
exemplary embodiment, the tabs 72 may be a rigid protrusion from
the inner surface of the endcaps 24 having a general wedge shape.
The inner portion 78 of such a tab 72 located toward the inner side
48 of the endcap 24 is generally flush with the inner surface and
ramps or inclines away from the inner surface as the tabs 72
approach the outer side of the endcaps 24. In this embodiment, the
inner portion 78 of the tabs 72 (when located on the inside of the
upper side 56 of the endcap 24) may abut the upper side 38 of the
shelf body 22 as the shelf body 22 and the endcaps 24 are engaged.
Upon further engagement, the tabs 72 are may cause the endcap 24
and/or the body 22 to deflect, creating space for the tabs 72
between the endcaps 24 and the body 22. Due to the inherent
qualities of the material used, after the tabs 72 deflect the
endcap 24 and/or the body 22, the original form of the endcap 24
and/or the body 22 will return once the tabs 72 are fully engaged
with the apertures 70.
[0034] In another exemplary embodiment, the tab 72 may be flexible
and may be a portion of the inner surface of the endcap 24, such as
a partially cut out finger that is biased toward the inside of the
endcap 24 away from the inner surface, thereby creating a tab 72
having resilient qualities. A partial cut out finger can be
obtained by removing or cutting enough material out of an area
thereby creating a tab (FIG. 7). The tab 72 may, however obtain its
resilient qualities otherwise. For example, the tab may be a
cantilever beam that is biased through a manufacturing process, or
the like. In this embodiment, when the tabs 72 are flexible and
have resilient qualities, the tabs 72 once engaged with the body
22, may depress to allow further engagement between the body 22 and
the endcap 24. More specifically, the inner portion 78 of the tabs
72 (when located on the inside of the upper side 56 of the endcap
24) may abut the upper side 38 of the shelf body 22 as the shelf
body 22 and the endcaps 24 are engaged. Upon further engagement,
the tabs 72 may deflected against their bias by the ends 30, 32 of
the body 22, thereby allowing the endcap 24 to further engage. Due
to the resilient qualities of the tabs 72, after the tabs 72 are
deflected, the tabs 72 will return to their original position once
the tabs 72 are fully engaged with the apertures 70.
[0035] In one exemplary embodiment, the body 22 is received in the
endcap 24 until the tabs 72 engage and pop into the apertures 70,
thereby locking the endcap 24 to the body 22. More specifically, as
the tabs 72 approach the apertures 70 located on the body 22, the
tabs 72 may have a bias to engage with the aperture 70. As the tabs
72 fully engage with the apertures 70, the tabs 72 protrude into
the apertures 70 thereby preventing the endcaps 24 from disengaging
the body 22. The endcap 24 may be prevented from disengagement from
the body 22 by the stop surface 80 of the wedge-shaped tab 72
acting as a stop against the outer edge 74 of the aperture 70.
[0036] In one exemplary embodiment, the self-locking multi-piece
shelf 20 may be designed to prevent sliding movement of the body 22
relative to the endcaps 24, once the tabs 72 are engaged with the
apertures 70 (FIG. 2). For example, once the body 22 has traversed
far enough into the endcap 24 to engage the tabs 72 with the
apertures 70, the body 22 may continue to traverse further into the
endcap 24 unless it is prevented from doing so. In one exemplary
embodiment, the endcap 24 may include stops 82 adapted to prevent
the body 22 from traversing into the endcap 24 any further than
desired. The stops 82 may, for example, be a post or ledge located
in the endcap 24 to allow the body 22 to traverse into the endcap
24 enough to engage the tabs 72 of the endcap 24 with the aperture
of the body 22, and to prevent any further substantial sliding
movement of the body 22 relative to the endcaps 24 once the tabs 72
and apertures 70 are engaged. In other exemplary embodiments, the
stops 82 may be part of the socket 60, may be part of the outer
side 50 of the endcap 24, or may be the outer side 50 itself.
[0037] Once the various components of the self-locking multi-piece
shelf 20 have been combined, the user may connect other components
such as one or more risers 62 to the self-locking multi-piece shelf
20 to create a shelving system as shown in FIG. 6. More
specifically, the shelving system may be purchased separately, or
may be purchased as components, wherein the user may purchase the
riser and self-locking multi-piece shelf 20 individually. The
shelving system may include 8 risers 62 and 3 self-locking
multi-piece shelves 20 as shown in FIG. 6, but may be comprised of
any number of self-locking multi-piece shelves 20 and risers 62.
Furthermore, the shelving system may include other types of risers
and shelves (not shown). For example, the risers 62 may include
risers of more than one length and the shelves may include, one or
other multi-piece shelves, including but not limited to solid one
piece shelves, shelves having perforation, shelves having a bin or
basket feature, etc.
[0038] The foregoing detailed description has been given for
clearness of understanding only and no unnecessary limitations
should be understood therefrom, as modifications will be obvious to
those skilled in the art.
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