U.S. patent application number 10/986979 was filed with the patent office on 2005-05-26 for shelf assembly display jacket.
This patent application is currently assigned to E-Z Shipper Racks, Inc.. Invention is credited to Czerwinski, David J..
Application Number | 20050109723 10/986979 |
Document ID | / |
Family ID | 34594960 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050109723 |
Kind Code |
A1 |
Czerwinski, David J. |
May 26, 2005 |
Shelf assembly display jacket
Abstract
A rack jacket is disclosed. The rack jacket comprises a support
member portion for covering an external surface of at least one of
a plurality of support members, and a cross brace portion, for
covering an external surface of at least one cross brace disposed
between at least two of the vertical support member. The rack
jacket is sized and shaped to conform to an exterior surface of the
rack.
Inventors: |
Czerwinski, David J.;
(Thousand Oaks, CA) |
Correspondence
Address: |
GATES & COOPER LLP
HOWARD HUGHES CENTER
6701 CENTER DRIVE WEST, SUITE 1050
LOS ANGELES
CA
90045
US
|
Assignee: |
E-Z Shipper Racks, Inc.
|
Family ID: |
34594960 |
Appl. No.: |
10/986979 |
Filed: |
November 12, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60519404 |
Nov 12, 2003 |
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Current U.S.
Class: |
211/183 |
Current CPC
Class: |
A47B 47/0083 20130101;
A47F 5/112 20130101; A47F 5/10 20130101; A47B 97/00 20130101 |
Class at
Publication: |
211/183 |
International
Class: |
A47F 005/00 |
Claims
What is claimed is:
1. A jacket for adorning a rack having a plurality of support
members and at least one cross brace disposed between two of the
plurality of support members, the jacket comprising: a support
member portion, for covering an external surface of at least one of
the plurality of vertical support members; and a cross-brace
portion, for covering an external surface of at least one of the
plurality of cross braces; wherein the jacket is sized and shaped
to conform to an exterior surface of the rack system.
2. The jacket of claim 1, further comprising a second support
member portion and a second cross-brace portion.
3. The jacket of claim 1, further comprising a display portion
disposed between the support member portions and the cross-brace
portions.
4. The jacket of claim 3, wherein the display portion is defined by
a punch-out portion formed by a plurality of incisions disposed
between the support member portions and the display portion and
between the cross-brace portions and the display portion.
5. The jacket of claim 4, wherein the display portion, the support
member portions and the cross-brace portions ate formed from a
single sheet of material.
6. The jacket of claim 1, wherein the plurality of incisions are
disposed along less than a perimeter of the display portion,
thereby defining a door having a hinge where the incisions are not
disposed.
7. The jacket of claim 1, wherein: the rack system accepts a pallet
disposed between the plurality of vertical support members, the
pallet having a slot; and wherein the apparatus further comprises a
slot portion disposed adjacent the slot, to permit insertion of
tangs therethrough.
8. The jacket of claim 7, wherein the slot portion is defined by a
slot punch out portion formed by a second plurality of
incisions.
9. The jacket of claim 8, wherein the slot portion forms a slot
door.
10. The jacket of claim 1, wherein an exterior surface of the rack
jacket includes display information.
11. The jacket of claim 1, wherein at least one of the support
member portions comprises an extension.
12. The jacket of claim 11, wherein the at least one extension
comprises a plurality of sections, disposed about an exterior
surface of at least one of the support members.
13. The jacket of claim 12, wherein at least one of the sections
comprises a surface feature interlocking with a surface feature of
at least one of the other sections, thereby affixing the at least
one extension to the at least one of the support members.
14. The jacket of claim 13, wherein the at least one extension is
removably affixed to the at least one of the support members.
15. A cap for adorning a rack having a plurality of support members
and at least one cross brace disposed between two support members,
the jacket comprising: a perimeter surface, sized and shaped for
insertion over the plurality of support members, the perimeter
surface having a horizontal surface disposed adjacent a top of one
of the support members; and a display surface, coupled to the
perimeter surface.
16. A method of packaging items for transportation, comprising the
steps of: assembling a rack comprising a plurality of support
members, a pallet disposed between the plurality of support
members, at least one cross brace disposed between two of the
plurality of support members; placing the items between the
plurality of support members; and placing a jacket around the
rack.
17. The method of claim 16, wherein the items are placed on a
surface disposed between the plurality of support members.
18. The method of claim 16, wherein the step of placing the jacket
around the rack comprises the step of assembling the jacket and
sliding the assembled jacket over the rack.
19. The method of claim 16, wherein the step of placing the jacket
around the rack comprises the step of assembling the jacket around
the rack.
20. The method of claim 16, further comprising the step of placing
a cap on a top of the rack.
21. The method of claim 16, wherein the jacket comprises a
plurality of support member portions and a plurality of cross brace
portions, and a plurality of display portions disposed between the
plurality of support member portions and cross brace portions.
22. The method of claim 21, wherein: the display portions are
defined by punched out portions formed by a plurality of incisions
disposed between the support member portions and the display
portions; and the method further comprises the steps of receiving
the rack; moving the rack to a display location; and punching out
at least one of the defined punch out portions to expose the
items.
23. A rack jacket comprising: a support member portion for covering
an external surface of at least one of a plurality of support
members; and a cross brace portion, for covering an external
surface of at least one cross brace disposed between at least two
of the vertical support member; wherein the jacket is sized and
shaped to conform to an exterior surface of the rack.
24. The rack jacket of claim 23, wherein an exterior surface of the
rack jacket includes display information.
25. The rack jacket of claim 23, wherein at least one of the
support member portions comprises an extension.
26. The rack jacket of claim 25, wherein the at least one extension
comprises a plurality of sections, disposed about an exterior
surface of at least one of the support members.
27. The rack jacket of claim 26, wherein at least one of the
sections comprises a surface feature interlocking with a surface
feature of at least one of the other sections, thereby affixing the
at least one extension to the at least one of the support
members.
28. The rack jacket of claim 27, wherein the at least one extension
is removably affixed to the at least one of the support
members.
29. A rack jacket, comprising: a peripheral portion sized and
shaped to fit around and atop a plurality of rack support members;
and a horizontal surface coupled to the peripheral portion, for
preventing the peripheral portion from sliding down the plurality
of rack support members.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent
Application Ser. No. 60/519,404, for "SHELF ASSEMBLY DISPLAY
JACKET," by David J. Czerwinski, filed Nov. 12, 2003.
[0002] This application is also related to the following U.S.
Patent Applications, each of which applications are hereby
incorporated by reference herein:
[0003] U.S. patent application Ser. No. 10/388,860, filed Mar. 14,
2003, for "MODULAR LOW COST PALLET AND SHELF ASSEMBLY," by Jeffrey
Salmanson and Jon R. Dickey, which is a continuation of U.S. patent
application Ser. No. 09/829,589, filed Apr. 9, 2001, for "MODULAR
LOW COST PALLET AND SHELF ASSEMBLY," by Jeffrey Salmanson and Jon
R. Dickey, now U.S. Pat. No. 6,609,466, issued Aug. 26, 2003, which
is a continuation of U.S. patent application Ser. No. 09/358,285,
filed Jul. 21, 1999, for "MODULAR LOW COST PALLET AND SHELF
ASSEMBLY," by Jeffrey Salmanson and Jon R. Dickey, now issued as
U.S. Pat. No. 6,244,194, which is a continuation of application
Ser. No. 09/081,411, filed May 19, 1998, for "MODULAR LOW COST
PALLET AND SHELF ASSEMBLY," by Jeffrey Salmanson and Jon R. Dickey,
now U.S. Pat. No. 5,979,338, issued Nov. 9, 1999, which claim
benefit of U.S. Provisional Application No. 60/046,883, filed May
23, 1997 by Jeffrey Salmanson and Jon R. Dickey, and entitled
"MODULAR PALLET AND SHELF ASSEMBLY USING CONVENTIONAL HARDWARE,"
and U.S. Provisional Application No. 60/062,754, filed Oct. 23,
1997 by Jeffrey Salmanson and Jon R. Dickey, and entitled "MODULAR
LOW COST SHELF ASSEMBLY," all of which applications are hereby
incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0004] 1. Field of Invention
[0005] The present invention relates generally to shipping and
retail display devices and more particularly to a display jacket
that is usable with rack systems.
[0006] 2. Description of Related Art
[0007] Products shipped from the manufacturer or producer are often
shipped to the retailers in corrugated boxes. Typically, these
boxes are loaded onto wooden pallets, lifted with a forklift onto a
shipping container, and unloaded into the container for
transportation to the retail outlet. When the goods arrive at the
retail outlet, the corrugated boxes are removed from the shipping
container, loaded onto pallets, moved to the retail display
location or storage using a forklift or similar device. The
products are then removed from the corrugated boxes, and placed on
retail display.
[0008] There are several problems associated with the
aforementioned procedures. Unloading and loading the corrugated
boxes is a labor-intensive procedure, often resulting in damage to
the products and/or the corrugated boxes. It is also common for the
products to be damaged when the corrugated boxes (which are
typically stacked during storage and transportation) collapse.
[0009] Another problem with these procedures is that the corrugated
boxes are not generally reusable, and must be broken down and
disposed of by the retail outlets. Alternative wood racking
systems, such as those employed in nurseries, do not solve this
problem. These racking systems are also difficult to transport,
require labor intensive procedures to unload transported products
and display them at a retail level, and cannot be broken down
easily at the retail outlet. These devices are also typically held
together with nails, which further complicate their disassembly and
storage, and make any return to the manufacturer generally
unprofitable.
[0010] Modular rack systems, such as those described herein and in
the related patent applications described above, have shown
themselves to solve the foregoing problems. Such rack systems can
be used for both transport and display of the products. However,
the appearance of the rack systems may be unsuitable for some
applications. Further, since the rack system is designed to be
easily broken down and used for a wide variety of applications,
such rack systems typically do not include provisions for making an
attractive retail-level display.
[0011] What is needed is an apparatus and method for modifying the
appearance of rack systems and other transport and/or product
display systems to make them more attractive for retail-level
marketing and sales. The present invention satisfies this need.
SUMMARY OF THE INVENTION
[0012] As the foregoing indicates, there is a need for efficient
transportation of products from the manufacturer or producer to
retail display. The present invention satisfies that need.
[0013] The present invention discloses a "jacket" or sleeve that
configured to be applied over transport and/or display systems such
as rack/shelving systems, converting the rack to esthetically
impactful point-of-purchase displays that that rival or exceed the
appearance of traditional corrugate displays currently used in
retail establishments. This system has advantages over such prior
art systems, including superior strength, rigidity, durability,
volume capacity (for heavy products, the majority of the corrugate
used in a point of purchase display consists of hidden structural
pieces), mobility, stackability, and recoverability (the disclosed
system uses up to 80% less corrugate thus reducing disposal
cost).
[0014] The rack jacket can be cut to fit any size rack and shelf
configuration, preferably using die-cutting techniques. Storage
areas, useful for storing restock items can be created inside the
jacket and rack system by blocking out (not die-cutting) selected
sides adjacent the lower shelf area of the rack or, if the sides
are die-cut, by leaving the sides in place (not punching them out).
The rack jacket need not cover the entire rack. The rack jacket is
designed to attach to just the top of the rack unit or to other
portions.
[0015] Assembly of the rack jacket is simple. It can be
accomplished by simply sliding the jacket directly over an
assembled rack. Die cut tabs fold over the corner posts securing
the unit to the rack without need for any additional mechanical
devices. Alternatively, the jacket can be assembled by wrapping it
around the jacket, and thereafter securing it using tabs or
external devices such as staples. Also, the bottom sections can be
die cut to provide forklift and pallet jack access. This makes the
loaded display easy to move while at the same time hiding the
pallet itself.
[0016] Used with an appropriate rack, the rack jacket can take the
place of a wide variety of retail displays. The rack jacket could
be used with any rack, regardless of it's structural material (e.g.
steel, aluminum, plastic, or wood), and with or without a pallet.
The rack jacket is also especially well suited to permanent
displays, because the outward appearance of the rack can be changed
dramatically, simply by removing one rack jacket and attaching
another. The rack jacket can also be made from a wide variety of
materials, including cardboard, corrugated box material,
fiberglass, compressed particle board, Formica, plastic, (or) foam
board, or light weight plastic poly film or TYVEC type materials.
The material used need not be structural in nature as the
underlying rack assembly supports 100% of the weight of the product
shipped and or displayed on the unit.
[0017] One embodiment of the invention can therefore be described
by a jacket for adorning a rack having a plurality of support
members and at least one cross brace disposed between two of the
plurality of support members. The jacket comprises a support member
portion, for covering an external surface of at least one of the
plurality of vertical support members and a cross-brace portion,
for covering an external surface of at least one of the plurality
of cross braces. The jacket is sized and shaped to conform to an
exterior surface of the rack system. In another embodiment, the
invention can be described as a method of packaging items for
transportation. The method comprises the steps of assembling a rack
comprising a plurality of support members, a pallet disposed
between the plurality of support members, at least one cross brace
disposed between two of the plurality of support members; placing
the items between the plurality of support members; and placing a
jacket around the rack.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Referring now to the drawings in which like reference
numbers represent corresponding parts throughout:
[0019] Referring now to the drawings in which like reference
numbers represent corresponding parts throughout:
[0020] FIG. 1 presents a perspective view of the one embodiment of
the present invention;
[0021] FIG. 2A presents a view of one embodiment of the present
invention, illustrating a coupling between the pallet and the
shelving;
[0022] FIG. 2B presents a close up view of the relationship between
the tabs and the keyhole apertures in one embodiment of the present
invention;
[0023] FIG. 3 presents a side view of one embodiment of the present
invention, illustrating the pallet and vertical support
members;
[0024] FIG. 4 presents a perspective view of an embodiment of the
present invention using cleats;
[0025] FIG. 5 presents a close up view of one embodiment of the
present invention, illustrating a coupling between the pallet and
vertical support members;
[0026] FIG. 6 presents a side view of one embodiment of the present
invention, illustrating the use of cleats to couple the pallet and
the vertical support members;
[0027] FIG. 7 presents a diagram of the cleats used in one
embodiment of the present invention;
[0028] FIG. 8A presents a perspective view of another embodiment of
the present invention illustrating a segmented design suitable for
smaller merchandising units-.;
[0029] FIG. 8B presents a section view of the coupling between the
segments shown in FIG. 8A;
[0030] FIG. 9A presents a side view illustrating the use of an
inverted keyhole aperture configuration;
[0031] FIG. 9B presents a top view illustrating the use of an
inverted keyhole aperture configuration;
[0032] FIG. 10 presents a perspective view of an embodiment using
the inverted keyhole aperture configuration;
[0033] FIG. 11 presents a top view of another embodiment of the
present invention using the inverted keyhole apertures;
[0034] FIG. 12A presents a top view of another embodiment of the
present invention showing an alternative arrangement for the pallet
securing members;
[0035] FIG. 12B presents a side view of another embodiment of the
present invention showing an alternative arrangement for the pallet
securing members;
[0036] FIG. 13 presents a perspective view of another embodiment of
the present invention showing an alternative arrangement for the
pallet securing members;
[0037] FIG. 14 presents a side view of another embodiment of the
present invention showing the use of double-sided keyhole
apertures;
[0038] FIG. 15 presents a side view of another embodiment of the
present invention showing the use of a strengthening segment in the
vertical support member;
[0039] FIG. 16 presents a side view of another embodiment of the
present invention showing the use of fewer keyhole apertures;
[0040] FIG. 17 is a flow chart depicting the assembly of one
embodiment of the present invention;
[0041] FIG. 18A presents a representation of a rack and a rack
jacket, side by side;
[0042] FIG. 18B is a diagram showing one embodiment of the rack
jacket;
[0043] FIG. 18C is a diagram showing a second embodiment of the
rack jacket;
[0044] FIG. 18D is a diagram showing a third embodiment of the rack
jacket;
[0045] FIG. 18E is a diagram showing a fourth embodiment of the
rack jacket;
[0046] FIG. 19 presents a representation of a rack jacket being
affixed to the rack from above;
[0047] FIG. 20 presents a representation of a rack and a rack
jacket, illustrating details of the attachment of the rack jacket
to the vertical posts;
[0048] FIG. 21 presents a representation of a rack jacket installed
on a rack;
[0049] FIG. 22 presents a representation of the rack jacket using a
die-cut cutout to provide a surface for additional advertising;
[0050] FIG. 23 presents a representation of a rack jacket installed
on a rack, illustrating cutouts to allow insertion of the tangs of
a forklift or a pallet jack to transport or lift the rack and rack
jacket;
[0051] FIG. 24 presents a representation showing a perspective view
of the rack and rack jacket illustrated in FIG. 23; and
[0052] FIG. 25 presents a representation showing a rack jacket
mounted to a top portion of a rack.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] In the following description of the preferred embodiment,
reference is made to the accompanying drawings which form a part
hereof, and in which is shown by way of illustration a specific
embodiment in which the invention may be practiced. It is
understood that other embodiments may be utilized and structural
changes may be made without departing from the scope of the present
invention.
[0054] FIG. 1 presents a perspective view of one embodiment of the
present invention. The invention comprises a plurality of vertical
support members 100 (which may be "corner posts" having an "L"
shaped cross section), which are arranged so as to accept a pallet
102 therebetween. In one embodiment, the pallet 102 is a common
two-way wood pallet, which accepts forklift tongues in slots on the
front and rear of the pallet 102. In an alternative embodiment, a
four-way pallet may be used. The four-way pallet comprises
additional slots on opposite sides of the pallet to accept forklift
tongues, thus allowing the pallet to be lifted by a forklift from
any side. The design of the pallet 102 can be changed to
accommodate different loads, with heavier-duty construction pallets
102 employed for maximum strength applications. Each vertical
support member 100 comprises a plurality of keyhole shaped
apertures 108 disposed on the right angle portions of the vertical
support members 100. In one embodiment, the vertical support
members 100 are commonly available angle posts that are 84 inches
in length.
[0055] The present invention also comprises a plurality of cross
braces 104, (which may also be L-shaped) that are affixed to the
vertical support members 100. Each cross brace 104 comprises a
right angle portion and a number of cross brace tabs 109, each of
which is small enough to be inserted into the larger portion of the
keyhole shaped aperture 108, yet large enough to be retained by the
smaller portion of the keyhole shaped aperture 108. When a
plurality of braces 104 are so coupled with the vertical cross
members 100, the right angle portion (which comprises the lower
portion of and "L" when viewed from the side) of the brace 104
forms a horizontal surface, upon which a planar surface 106 is
placed. Planar surface 106 is sized so as to be inserted between
all four vertical support members 100 and larger than the aperture
formed by the braces 104 extending between the vertical support
members. Accordingly, the braces 104 serve to support the planar
surface 106. The planar surface 106 can be comprised of particle
board, oriented strand board (OSB), plastic, metal, or other
material. Planar surface 106 may also be molded to conform to the
product.
[0056] In one embodiment, the braces 104 are commonly available
double rivet beams. The size of the braces 104 is selected in
accordance with the desired dimensions of the finished assembly, as
is the pallet 102 size. In a typical arrangement, two of the braces
104 are 48 inches in length, and two are 42 inches in length. The
number of braces 104 used in the assembly is also determined by the
number of desired shelves of the finished product. For example, a
four-shelf unit would require eight 48 inch braces 104 and eight 42
inch braces, whereas a five-shelf unit wood require ten 48 inch
braces and ten 42 inch braces.
[0057] Since four braces 104 are not required to hold the planar
surfaces 106, it is also possible to use only two braces per shelf
level, in a staggered relationship. For example, the first level
can use two 48 inch braces 104, the next, two 42 inch braces 104,
and so on. This configuration is nominally not as strong, but is
lower in cost, and suitable for many applications.
[0058] FIG. 2A presents a close up view of one embodiment of the
present invention, illustrating the relationship between the pallet
102 and the vertical support members 100. In this embodiment,
pallet securing members 118 are utilized to releasably accept and
secure the pallet 102 in place between the vertical support members
100 and below the pallet securing members 118, and to bear the
weight of the racking system when lifted by a fork lift or pallet
jack. Strength considerations determine the number of pallet
securing members required to secure the pallet 102. Typically,
either two or four pallet-securing members 118 are used.
[0059] FIG. 2B presents a detailed view of the embodiment shown in
FIG. 2. Keyhole apertures 108 each comprise a first aperture
segment 107 and a second aperture segment 109, which is smaller in
cross section than the first aperture segment 107. Tab heads 110A
are smaller than the first aperture segment 107, yet larger than
the second aperture segment 109. Hence, when tab heads 110A are
inserted into the first aperture segment 107 and moved laterally,
the tab 110 is affixed within the aperture 108.
[0060] The pallet 102 comprises a plurality of bottom members 112
and support members 114, both of which are affixed to a pallet
cross member 116. In one embodiment, the vertical support members
100 are affixed to the pallet 102 by inserting one or more wood
screws 124 (such as lag screws) of suitable length and diametric
cross section through the appropriate keyhole apertures 108 and
into the pallet 102.
[0061] In another embodiment, a number of pallet-securing members
118 are employed. These pallet-securing members 118 comprise one or
more pallet-securing member tabs 110 which are inserted into the
keyhole apertures 108 of the vertical support members 100.
Ordinarily, the pallet-securing member tabs 110 are of the same
design as the cross member tabs 109. However, since the
pallet-securing member tabs 110 must bear greater weight and shear
force, these tabs may be suitably reinforced or made of stronger
material, if necessary.
[0062] In one embodiment, the securing members 118 are cross braces
104, but inverted so that an interior-facing surface 120 is
disposed above the vertical surface 122. This places an
interior-facing securing surface 120 over the top of the pallet
102, and in particular, the pallet support members 114. In this
configuration, the pallet 102 is restrained between the vertical
support members 100 and below the interior-facing surfaces 120.
Pallet securing member tabs 110 on the support members 118 are
inserted into the larger opening of the keyhole tabs 108. The
support members 118 transfer the weight of the assembly to the
metal structure, rather than the pallet 102.
[0063] The pallet support members 118 and vertical support members
100 may optionally be affixed to the pallet 102 with a suitably
sized fastening device 124 such as a wood screw or lag bolt. The
fastening device 124 should comprise a head larger than any
dimension of the keyhole aperture 108. This assures that the
components are securely fastened together. One-quarter inch lag
bolts of 1-1/4 inch length are suitable for this purpose. If
necessary, a suitably placed hole or aperture may be drilled
through the pallet 102 before the bolt is inserted and thereafter
secured with a nut or other means.
[0064] The tabs 110 comprise a head portion 110A and a shank
portion 110B. The head 110A is a smaller diameter than the larger
portion of the keyhole apertures 108, to allow insertion therein.
In one embodiment, the upper portion of the inner surface of the
keyhole aperture 108 and the tab shank 110B are in contact, thus
causing the tab head 110A to extend beyond the keyhole aperture
108. This provides additional strength to prevent the vertical
support members 100 from extending away from the support brace 118.
In another embodiment, the head size of the fastening device 124 is
selected to be close to or contact the tab to minimize this
possibility. In still another embodiment, the support brace 118
comprises two or more tabs 110, and each tab is inserted into its
corresponding keyhole aperture 108. For additional strength, all of
these couplings may be further secured by additional fastening
devices 124, if desired.
[0065] FIG. 3 presents a front view of one embodiment of the
invention showing another view of the coupling between the pallet
and vertical support members.
[0066] FIG. 4 presents another embodiment of the present invention,
where pallet securing members 118 comprise one or more cleats 126,
including a left cleat 126A and a right cleat 126B.
[0067] FIG. 5 presents a close-up view of the employment of the
cleats 126 in the present invention. Nominally, each cleat 126 is
L-shaped in cross-section, and comprises one or more cleat tabs 111
on one outer surface, and one or more keyhole-shaped apertures 108
on the other outer surface. In one embodiment, the cleat 126 is
affixed to the pallet 102 by one or more fastening devices 128
inserted through the keyhole aperture 108 in the cleat. The
fastening device 128 can be a wood screw of suitable dimension or
other fastening means. Optionally, vertical support member 100 can
be further secured to the pallet by one or more additional
fastening devices 130. Cleat tab 111 extends within a keyhole
aperture 108, and may be secured with an additional fastening
device as described herein.
[0068] FIG. 6 presents a side view of the embodiment shown in FIGS.
4 and 5.
[0069] FIG. 7 is an illustration showing the two types of cleats
employed in the embodiments shown in FIGS. 4 and 5. Left cleats
126A (depicted in FIG. 5), and right cleats 126B are employed.
Nominally, a total of four cleats 126 (two left cleats 126A, and
two right cleats 126B) are used.
[0070] Nominally, four vertical support members 100 are employed in
the present invention, one at each corner of the pallet 102. In
alternative embodiments, the present invention can comprise
additional vertical support members 100 for additional bracing.
Nominally, these additional vertical support members 100 will be
flat, and not L-shaped, so as to be easily affixed to the cross
members 104, but the present invention can accommodate a wide
variety of vertical support member shapes with modification. These
additional vertical support members 100 may be affixed to the
pallet, but need not be so. Further, if exceptional rigidity is
required, the additional cross bracing may be employed in either
the pallet 102 structure, the metal between vertical support
members 100, or both.
[0071] FIG. 8A presents perspective view of another embodiment of
the present invention illustrating a segmented design in which the
assembly comprises two rigid, yet easily separable sections which
can be separated to form smaller shelving units for separate
transport or for display and merchandising of products. In this
embodiment, the vertical support members 100 comprise bottom
vertical support members 100A and top vertical support members
100B, both of which are of generally shorter length than the
vertical support members 100 previously described herein. The lower
portion of the bottom vertical support members 100A are secured to
a first pallet 102A using the techniques and structures described
earlier in this disclosure.
[0072] A plurality of cross braces 104 are coupled to the vertical
support members 100. Cross braces 104A are coupled to the vertical
support members 100 to form an aperture for inserting planar
surfaces 106 a right angle shelf portion on which supports the
planar surfaces 106, as previously described and illustrated.
Pallet support members 105 are inserted between the lower vertical
support members 100A at the topmost position in an inverted "L"
configuration, with the right angle portion disposed above or below
the vertical portion. So disposed, the right angle portions of the
pallet support members 104B form a shelf or cavity which supports a
second pallet 102B, which, if desired, may be secured to the
assembly using lag screws 130 or similar fastening devices inserted
through apertures in the right angle portions of the cross braces
104B. Upper vertical support members 100B and second pallet
securing members such as the cleats 126 described earlier are then
secured to the upper pallet 102B using the structures and methods
previously described to secure the shelving to the pallet 102,
using either cleats 126, pallet securing members 118, or inverted
cross braces 104.
[0073] FIG. 8B presents a side view of the structures shown in FIG.
8A.
[0074] FIG. 9A presents a side view of another embodiment of the
present invention illustrating the use of a unique keyhole aperture
108 configuration. In this embodiment, the vertical support member
100 comprises two sets of keyhole apertures 108, a first set 121
comprising one or more keyhole apertures 108A facing in a first
direction, and a second set 123 comprising one or more keyhole
apertures 108B facing in a second direction substantially inverted
from that of the first set of keyhole apertures 108A. For purposes
of clarity, keyhole apertures 108A will be referred to henceforth
as downward facing keyhole apertures, and keyhole apertures 108B
will be referred to as upward facing keyhole apertures. This
embodiment also shows another alternative for the pallet securing
members 118. Here, one or more right angle support members 140,
having one or more right angle support member tabs 113 of suitable
size for insertion into the upward facing keyhole apertures 108B
are utilized. The right angle support members 140 are disposed
adjacent to the vertical support members 100 in a fitting
relationship and affixed to the vertical support members by
inserting tabs 113 in the upward facing keyhole apertures 108B, and
applying suitable force in a direction towards the upward facing
keyhole aperture 108B smaller portion.
[0075] When the foregoing elements are arranged as described above,
a pallet 102 can be inserted in the space formed by the vertical
support members 100 to allow the entire assembly to be lifted and
moved with a forklift or other similar device. Lifting forces from
the pallet 102 are then borne by the right angle support members
140, right angle support member tabs 113, and upward facing keyhole
aperture 118B smaller portions, structural elements which are well
suited to support considerable weight. This embodiment may also be
practiced with the use of pallet securing members 118 or cleats 126
in the place of right angle support member 140. This embodiment
also obviates the need for the insertion or removal of pallet
securing devices 124, speeding assembly and disassembly.
[0076] FIG. 9B presents a top view of the embodiments shown in FIG.
9A.
[0077] FIG. 10 shows a perspective view of the foregoing embodiment
of the present invention. Safety devices, such as clips or right
angle bolts 142 can be inserted into keyhole apertures 108. In the
event of a tab 110 failure, these safety devices serve to restrict
excessive motion of structures that were supported by the failed
tab 110. In the illustrated embodiment, right angle bolt 142 is
inserted into keyhole aperture 108A. The right angle bolt 142
comprises a head structure 144 which prevents passage through the
keyhole aperture 108, and preferably, a shank structure 146 that is
smaller in cross section than the smaller portion of the keyhole
aperture 108. In one embodiment, shank structure 146 is of
sufficient length and/or mass to assure that the right angle bolt
142 is balanced so as to remain in the keyhole aperture 108 after
insertion. If necessary, the safety device may be locked or secured
into the keyhole apertures by bolts, clips, pins, or other
means.
[0078] Friction between the tabs 110 and the upward facing keyhole
apertures 108B as well as friction between the right angle support
members 140 and the vertical support members 100 are generally
sufficient to retain the tabs 113 in the smaller portion of the
keyhole aperture 108B. However, if desired, vertical support member
100 and right angle support member 140 may also comprise
interconnecting fastening means. Such fastening means can feature,
for example, one or more shear apertures 150 in each structure
adjacently disposed on assembly, thus allowing the insertion of a
pin, nail, or other device 152 after assembly to restrict the
apertures from sliding relative to one another. Similarly, if
desired, the right angle support member 140 and pallet 102 can be
affirmatively secured to the vertical support member 100 by means
of a wood screw, nail, bolt or other securing device 144 inserted
through the upward facing keyhole aperture 108B larger portion.
[0079] FIG. 11 presents a diagram illustrating another embodiment
of the present invention. In this embodiment, a simple cleat 126 is
used in place of the right angle support member 126. If additional
strength is desired, a second cleat can be disposed at a right
angle to and lapped on top of the illustrated cleat so that the
cleat tabs 111 from the second cleat are disposed through the
upward facing keyhole apertures 108A in the vertical support member
100. If necessary, the location of the upward facing keyhole
apertures 108A presented to the cleat tabs 111 of the second cleat
can be adjusted vertically in an amount sufficient to account for
the vertical displacement of the second cleat, or the location of
the tabs on the second cleat can be so adjusted to achieve the same
effect. Also, if desired, a nail, bolt, or wood screw may be
inserted into the cleat 126 keyhole aperture 118 and into the
pallet 102 to secure the pallet 102 to the assembly.
[0080] Upward facing keyhole apertures 108B are generally disposed
near the lower portion of the vertical support members 100.
However, that need not be the case. Upward facing keyhole apertures
108B can be disposed on any portion of the vertical support members
100, and when used in conjunction with other structures herein
described, provide an exceptionally strong means for lifting and
transporting any assembly constructed using the vertical support
members 100.
[0081] FIGS. 12A and 12B present another embodiment of the present
invention, in which the pallet securing members (here, inverted
cross braces 104) are affixed so that the securing surface is
disposed at the bottom of the securing member. This configuration
can be advantageously used to accommodate different pallet 102
thicknesses.
[0082] FIG. 13 presents a perspective view of the alternative
embodiment shown in FIGS. 12A and 12B.
[0083] FIG. 14 presents a side view of another embodiment of the
present invention in which keyhole apertures are replaced with
double-sided keyhole apertures 200. Each double-sided keyhole
aperture 200 has an upward oriented aperture segment 202 and a
downward oriented aperture segment 204. This design is simpler to
produce because the keyhole apertures 200 have a symmetrical
orientation and can be easily punched from the vertical support
members 100 without reorientation.
[0084] FIG. 15 illustrates another embodiment of the present
invention using double-sided keyhole apertures 200. In this
embodiment, a strengthening segment 220 is placed between the
double-sided keyhole apertures 200 to increase the strength of the
modular shelving. This configuration is particularly well suited to
heavy loads. Strengthening segment 220 can be implemented by a
greater distance between double-sided keyhole apertures 222 and
224, a greater distance between the double-sided keyhole apertures
224 and 226, or a greater distance between both. Alternatively, a
vertical support member can be reinforced in this area as required
with additional thickness material, molding or stamping a stronger
shape, or by heat treatment.
[0085] FIG. 16 illustrates another embodiment of the present
invention in which only a limited number of double-sided keyhole
apertures 200 are utilized. This configuration is useful in
situations where higher vertical support member 100 rigidity is
required, or when less flexibility in shelf location is
required.
[0086] In addition to the aforementioned advantages, the present
invention is also easily constructed and broken down. Construction
is accomplished by placing pallet securing members 118 or cleats
128 about the periphery of the pallet 102 so that the pallet
securing tabs 110 (or, in embodiments using cleats 126, the cleat
tabs 111) face outward from the center of the pallet. Next,
vertical support members 100 are placed at each corner of the
pallet 102. Then, downward force is applied to the vertical support
members to lock them to the pallet securing members 118 (or cleats
126). Then, the desired number and location of shelves is
determined. At the aforementioned locations, four cross braces 104
are inserted into the structure with the tabs 110 on the braces
fitting into the keyhole apertures 108 in the vertical support
members 100. Downward force is then applied to the cross braces
104, affixing them in position. When so inserted, these cross
braces 104 form a shelf upon which the planar surface 106 is
placed, completing the construction. Disassembly follows the
reverse procedure.
[0087] FIG. 17 presents a flowchart illustrating the foregoing
operations. The process begins by placing 302 a pallet securing
member 118 having a pallet securing tab 110 about the periphery of
a pallet so that the pallet securing tab faces outward from the
center of the pallet 102. Then, vertical support members 100 are
placed 304 at each corner of the pallet 102, and the pallet
securing tabs 110 are inserted 306 through the keyhole apertures
108. Pressure is then applied 308 to each vertical support member
100 so as to affix the keyhole apertures 108 to the pallet securing
tabs 110. A plurality of cross braces 104 having cross brace tabs
109 are then disposed 310 between the vertical support members 100.
These cross braces 104 are then coupled and secured to the vertical
support members 100 by inserting the cross member tabs 109 in the
vertical support member apertures 108 and applying suitable force
on the cross member braces 104. Finally, the process is completed
by placing 316 shelving between the vertical support members 100
and upon the cross member braces 104.
[0088] The present invention may be practiced in a number of
embodiments. For example, while the foregoing has been described
with respect to conventional L-shaped steel shelving with tabs 110
and keyhole shaped apertures 108, the present invention can be
practiced with other means to affix the elements of the invention
together. Similarly, although generally stronger in construction,
L-shaped members are not required to practice the present
invention. Although the present invention is especially suitable
for transport via fork lifts, it is also envisioned that the
foregoing invention can be practiced with the use of wheels (which
may comprise braking or setting means) affixed to the bottom
surface of the pallet 102. Also, while the present invention has
been described with apertures 108 on the vertical support members
100, and tabs on other elements, the invention is not so limited,
and could be practiced in other embodiments. For example, the
present invention could be practiced using tabs on the vertical
support members, and apertures on the other interconnecting
elements. Cross braces can also be affixed with the use of
push-through sections at appropriate locations in the vertical
support members. Such push through sections can be fashioned by
making U-shaped cuts in the vertical support members, and bending
the cut sections inward. The upper portion of the cut sections can
then support cross braces or shelving of medium to light
weight.
Rack Jacket
[0089] FIG. 18A presents a representation of a rack/shelving system
1802 and an embodiment of the jacket 1804. This embodiment of the
rack jacket 1804 is sized to fit snugly around the rack 1802, and
includes two openings 1806, which when installed on the rack 1802,
are disposed adjacent the related slots 1808 of the pallet 1809,
thus permitting the insertion of forklift or pallet-jack tangs, and
allowing the rack 1802 and the rack jacket 1804 to be lifted and
moved about by the pallet 1809. The rack jacket 1804 comprises at
least one support member portion 1818 for covering an external
surface of at least one of the plurality of support members 1821,
and a cross brace portion 1820, for covering an external surface of
at least one of the cross braces 1824, 1816. The support member
portions 1818 and the cross brace portions 1824 define apertures
1828 therebetween.
[0090] The upper portion of the jacket 1804 includes one or more
optional extensions 1812A-1812D which are placed around vertical
support member 100 upper portions 1814A-1814D. Although the
illustrated embodiment includes four extensions 1812A-1812D, fewer
extensions can be used. For example, it may be desirable to include
only two extensions (e.g. 1812A and 1812B), if extensions
1812C-1812D are not visible when the system is on display.
[0091] The jacket 1804 can be attached to the rack 1082 in a
variety of ways. For example, the jacket 104 may be simply slid
over the top (or bottom) of the rack 1802, wrapped around the rack
1802 and closed with glue or interfacing tabs and slots.
[0092] FIG. 18B presents a diagram showing one embodiment of the
jacket 1804. In this embodiment, the jacket 1804 is constructed
from a single contiguous piece of material such as corrugated
cardboard, with a portion 1830 of the material folded over and
glued at location 1832 to form a contiguous ring of material, as
shown in the top view. The flattened condition shown in FIG. 18B
permits storage of a large number of rack jackets in a small space.
The ring of material can then be die-cut with incisions 1821 to
create display portions, which may optionally be defined by punch
out portions formed by a plurality of incisions or perforations. In
the illustrated example, the jacket 1804 includes first punch-out
portions 1834A, 1834B, (and first punch out portions 1834A' and
1834B' on the back side of the ring of material), second punch out
portions 1836A and 1836B (and second punch out portions 1836A' and
1836B' on the back side of the ring material), and slot punch out
portions 1838A and 1838B (and slot punch out portions 1838A' and
1838B' on the back side of the ring material). This allows the user
to remove the punch-out portions 1834, 1836, 1807 and 1806 as
desired to define optional extensions 1812, punch out apertures
1828, punch out slot openings 1806 (and 1807 if 4-way access to a
the pallet 1809 is desired).
[0093] FIG. 18C presents a diagram illustrating an embodiment of
the jacket 1804 wherein punch out portions 1834A, 1834A', 1834B,
1834B', 1836A, 1836A', 1836B, 1836B', 1838A and 1838A' have been
punched out, creating punch out openings 1806, punch out apertures
1834A and 1834B, and extensions 1812. Note that a cavity 1840 has
is formed between the punch out portions that were not punched out
(1834A, 1834A', and 1834B), and an punch out aperture 1828 has been
formed at the rear of the jacket 1804, providing access to the
cavity. If desired, additional or different punch out portions may
be removed, allowing the user to create a variety of different
configurations.
[0094] While the foregoing illustrates an embodiment in which the
punch out portions 1834, 1836 patterns are sized and shaped to
correspond to spaces between the cross braces 1824 and support
members 1821, this need not be the case. For example, punch out
opening 1834A may be only as large as is necessary to provide
sufficient access physical and/or visual) to the area inside the
jacket 1804. Punch out portions 1834, 1836, 1806, and 1838 also be
perforated with incisions disposed along less than a perimeter of
the display portion (e.g. on three sides instead of four sides)
permitting the formation of a door structure. This is especially
useful when used in punch out portions 1838, as it allows the
creation of an aperture for insertion of fork lift tangs for
purposes of transit, and allows the "door" to be folded back over
adjacent to other jacket 1804 structures, to create a more
consistent visual appearance (as if the punch-out portions 1838
were not punched out.
[0095] FIG. 18D presents a diagram showing the jacket 1804 shown in
FIG. 18C when folded out. The resulting jacket 1804 includes an
aperture 1828, two openings 1806, and a plurality of extensions
1812. Further, by virtue of the removal of punch-out portion
1834B', aperture 1828B' is created.
[0096] FIG. 18E presents a diagram showing the jacket when
punch-out portions 1834A, 1834A', 1834B, 1834B', 1836A, 1836A',
1836B, 1836B', and 1838A are removed. This configuration is
analogous to that which is illustrated in FIG. 18A, and forms punch
out apertures 1828A, 1828A', 1828B, and 1828B'.
[0097] If desired, the jacket 1804 can be constructed without any
of the foregoing punch-out openings thus creating a permanently
closed area in the assembled product that can be used to store
extra stock of the displayed product or other items.
[0098] In one embodiment, one or more of the extensions 1812
include appropriate structures permitting their detachable
attachment to the upper rack portions vertical support member 100
upper rack portions 1814A-1814D. For example, FIG. 18E shows one of
the extensions 1812C having a flap portions 1850A, 1850B that can
be folded along creases 1852A, 1852B, respectively, after the
perforated portions 1856A, 1856B have been separated. Edges of the
extension 1812C include a first structure 1854B and a second
complimentary structure 1854A that can be mated to affix the flap
portions 1850A, 1850B together, thus affixing the extension 1812C
and thereby the jacket 1804 to an upper portion (e.g. 1814C) of the
vertical support member 100 of the rack system 1802. In the
illustrated embodiment, the first structure 1854A comprises a
trapezoidal tab and the second structure 1854B comprises a
complimentary interlocking slot, however, other analogous
structures can be used. It is also envisioned that adhesive
materials (e.g. tape, glue, hook-and-pile fasteners such as VELCRO)
can be used to achieve the same or similar result.
[0099] Especially if the rack 1802 is similarly constituted, the
rack jacket 1804 can also be implemented without extensions
1812A-1812D, and merely slipped around the rack 1802 and affixed
with tabs around one or more of the cross-posts 1816.
[0100] FIG. 19 presents a representation of the rack jacket 1804
being slid over the top of the rack 1802.
[0101] FIG. 20 presents a representation showing another close up
of extension 1812C and vertical support member upper portion 1814C.
Extension 1812C includes four sections 1850A, 1850B, 1852A, and
1852B. Sections 1852A and 1852B are sized and shaped and sized to
conform to the outside of the upper portion 1814C, and sections
1850A and 1850B, which are sized and shaped to fit to conform to
the inside of the upper portion 1814C. Section 1850A can be
attached to section 1850B, thus wrapping the extension 1812C around
the vertical support member upper portion 1814C using appropriate
interlocking structures 1854A and 1854B. In the illustrated
embodiment, section 1850B includes a tab 1854B, and section 1850A
includes a tab interface 1854A that cooperatively interacts with
tab 1854B, to removably affix section 1850A to section 1850B. Of
course, the upper portion 1814C may be different than the L-shaped
design shown, (square in cross-section, for example) and in such
cases, the extension 1812C and associated sections are shaped to
fit a square cross-sectioned upper portion 1814C. Further, section
1850A can be affixed to section 1850B by use of an additional
structure (e.g. a small section of cardboard inserted into matching
apertures in sections 1850A and 1850B), rather than by the use of
tabs on sections 1850A and 1850B themselves.
[0102] FIG. 21 presents a diagram of the jacket 1804 installed to
the rack 1802. FIG. 22 presents a diagram of jacket 1804 in which
one of the punch-outs is used to provide a surface 2204. The
surface 2204 can be used, for example, for additional advertising
or information about the products carried by the rack jacket. In
this embodiment, an aperture (e.g. 1828A) is created in the jacket
1804 by punching out a die-cut cutout (e.g. 1834A), and affixing
the cutout 1834A to two or more of the extensions 1812A-1812D or
between the extensions 1812A-1812D and their associated upper rack
portions 1814A-1814D. Although FIG. 22 illustrates the cutout 1834A
as affixed to extensions 1812C and 1812D, the cutout 1834A can be
affixed to any of the extensions 1812 as desired. The cutout 1834A
can be affixed between the selected extensions 1812 by use of
interlocking tab structures, fasteners (including staples) by
adhesives (including hook and pile as well as chemical adhesives),
or tape. In one embodiment, the cutout 1834A can also be affixed
between extensions 1812 by sizing the cutout 1834A to slightly
exceed the space between the extensions 1812. In this embodiment,
the cutout 1834A can be slid between the extensions 1812, with
friction keeping the cutout 1834A in place.
[0103] FIG. 23 presents a representation of a rack jacket 2302 that
includes advertising and other marketing information on the outer
surface of the jacket 2302. In this embodiment, a planar surface
2306 includes apertures 2308 therethrough so that the displayed
product can be presented as desired. A different structure,
specially designed to grip or hold the displayed product, can be
substituted for the planar structure 2306 if desired.
[0104] FIG. 24 presents a perspective view of the rack jacket 2302,
showing the aperture 2308.
[0105] FIG. 25 presents a representation of another embodiment of a
rack jacket 2502. In this embodiment, the jacket comprises a cap
2502 that slides down over the top of the upper portions
1814A-1814D of the support members 100. The cap 2502 comprises a
perimeter portion 2508 and a display portion 2510. The perimeter
portion 2508 and the display portion 2510 may be integrated
together and formed of a single sheet of material, if desired. The
perimeter portion is sized and shaped for insertion over the
plurality of support members 100 as shown, and can be held
vertically in place by either frictional contact with the rack
1802, or by one or more horizontal surfaces 2506 that contact the
top of the upper portions 1814A-1814D of the vertical support
members, thus preventing the cap 2502 from sliding down the
vertical support members 100.
[0106] The rack jacket 1804 can be used not only for display, but
also for transporting items stored in the rack 1802. For example,
the user may assemble the rack system, and place items on the
planar surfaces 106. The jacket 1804 can then be placed over (or
around) the rack, thus confining the items to the shelves in the
rack 1802 during transit. A cap 2502 such as that which is
illustrated in FIG. 25 can also be placed at the top of the rack
system 1802 to assure that items disposed on the top shelf are
secured during transit.
[0107] After the rack 1802 and jacket 1804 are delivered, they may
be transported to the display location (e.g. via forklift or pallet
jack). If used for transit, the cap 2502 can be removed, and punch
out openings 1834A-1836D and 1836A-1836D can then be punched out
(and used for display as shown in FIG. 22, if desired). Hence, the
jacket 1084 can be used to serve the dual function of providing
more secure transit as well as enhancing the retail display.
CONCLUSION
[0108] The foregoing description of the preferred embodiments of
the invention has been presented for the purposes of illustration
and description. It is not intended to be exhaustive or to limit
the invention to the precise form disclosed. Many modifications and
variations are possible in light of the above teaching. It is
intended that the scope of the invention be limited not by this
detailed description, but rather by the claims appended hereto. The
above specification, examples and data provide a complete
description of the manufacture and use of the composition of the
invention. Since many embodiments of the invention can be made
without departing from the spirit and scope of the invention, the
invention resides in the claims hereinafter appended.
* * * * *