U.S. patent application number 11/040942 was filed with the patent office on 2005-09-08 for slatwall with hanger securement track.
Invention is credited to Fischer, James R..
Application Number | 20050193641 11/040942 |
Document ID | / |
Family ID | 34915303 |
Filed Date | 2005-09-08 |
United States Patent
Application |
20050193641 |
Kind Code |
A1 |
Fischer, James R. |
September 8, 2005 |
Slatwall with hanger securement track
Abstract
The present invention pertains to a slatwall extrusion and
assembly that supportably secures a hanger, shelf bracket or other
hardware. The slatwall extrusion has a board with a downwardly
facing lip that combines with a lower like-shaped board to form a
uniform longitudinal slot that receives the upper end of a mounting
bracket for the hardware. The lip of each board has a track with
rim to form an upwardly facing groove. The track receives and
supportably secures the lower end of the bracket. The lower end of
lip and the track are spaced apart a predetermined uniform
distance. The bracket snap fits over the rim and into the groove so
that the bracket is securely held by and between the lip and the
track. An embodiment of the invention takes the form of an extruded
slatwall rail having an upper lip and a lower board with the
track.
Inventors: |
Fischer, James R.;
(Sheboygan, WI) |
Correspondence
Address: |
ANDRUS, SCEALES, STARKE & SAWALL, LLP
100 EAST WISCONSIN AVENUE, SUITE 1100
MILWAUKEE
WI
53202
US
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Family ID: |
34915303 |
Appl. No.: |
11/040942 |
Filed: |
January 21, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11040942 |
Jan 21, 2005 |
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29200780 |
Mar 4, 2004 |
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D502778 |
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11040942 |
Jan 21, 2005 |
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29200781 |
Mar 4, 2004 |
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D507355 |
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Current U.S.
Class: |
52/36.5 ;
211/189; 248/220.42 |
Current CPC
Class: |
A47B 96/067 20130101;
A47F 5/0846 20130101 |
Class at
Publication: |
052/036.5 ;
211/189; 248/220.42 |
International
Class: |
E04B 002/74; A47B
047/00; A47B 096/06 |
Claims
I claim:
1. A slatwall assembly comprising: at least one piece of hardware,
said hardware having upper and lower portions, said upper portion
having a ledge and said lower portion having a lower end, said
hardware having an effective hardware height substantially equal to
a distance between its said ledge and lower end; a plurality of
slatwall extrusions, each slatwall extrusion having at least one
longitudinal slat, each said slat having a uniform slat height, and
each said slat having a front surface, a rear surface, a lower lip
and a track, said lip having a lower end and an inside surface,
said inside surface being positioned between its said front and
rear surfaces, and said track extending from said front surface
proximal said lower lip, said track having an upwardly extending
rim that defines a uniform longitudinal groove; said longitudinal
slats forming a set of adjacent slats including upper and lower
slats, said set of adjacent slats being aligned and spaced apart to
form a uniform longitudinal slot, said slot having a narrow portion
proximal said front surface and a wider portion between said lip
and said rear surface, said adjacent slats defining a uniform
lip/track height, said lip/track height being a distance between
said lower end of said lip of said upper slat and said track of
said lower slat, said effective hardware height being between said
slat height and said lip/track height; and, wherein said slot
receives the upper portion of said hardware and said groove of said
lower slat securely receives said lower end of said hardware when
said hardware is in a secure position.
2. The slatwall assembly of claim 1, and wherein said hardware has
a mounting bracket that forms said upper and lower portions of said
hardware, said effective hardware height being an effective bracket
height, and said ledge being formed by an offset of said bracket,
and wherein said rim has a rim height, said effective bracket
height being a predetermined amount less than said lip/track
height, and said rim height is greater than said predetermined
amount, said lower end of said bracket snap-fitting into said
groove.
3. The slatwall assembly of claim 1, and wherein said effective
hardware height is substantially equal to said lip/track height,
and said lower end of said hardware rests on said track of said
lower slat, said hardware supporting the weight of an object and
said track supporting that weight.
4. The slatwall assembly of claim 1, and wherein said slats have a
uniform slat height, said effective hardware height is
substantially equal to said slat height, said ledge of said
hardware rests on said upper end of said lower slat, said hardware
supporting the weight of an object, and said upper end of said
lower slat supporting that weight.
5. The slatwall assembly of claim 1, and wherein each of said
extruded slats has a continuous rear wall.
6. The slatwall assembly of claim 1, and wherein each of said
extruded slats is backless.
7. The slatwall assembly of claim 1, and wherein each of said
slatwall extrusions has upper and lower tabs for joining adjacent
extrusions, said upper and lower tabs having a predetermined height
to align adjacent slatwall extrusions to form one of said uniform
longitudinal slots.
8. The slatwall assembly of claim 1, and wherein said track extends
from said lower end of said lip.
9. The slatwall assembly of claim 1, and wherein said lip has a
stiffening web spaced from said lower end of said lip.
10. The slatwall assembly of claim 9, and wherein said track
extends parallel to said stiffening web.
11. A slatwall extrusion for supportably securing a piece of
hardware, the hardware having upper and lower portions, the upper
portion having a ledge and the lower portion having a lower end,
the hardware having an effective hardware height substantially
equal to a distance between its said ledge and lower end, said
slatwall extrusion comprising: a plurality of slats, each said slat
having a uniform slat height, and each said slat having a front
surface, a rear surface and a lower lip, each lip having a lower
end and an inside surface, said inside surface being spaced between
its said front and rear surfaces, and a track extending from said
front surface proximal said lower lip, said track having an
upwardly extending rim that defines a uniform, longitudinal groove;
said plurality of slats forming a set of adjacent slats including
upper and lower slats, said set of adjacent slats being aligned and
spaced apart to form a uniform longitudinal slot, said slot having
a narrow portion proximal said front surface and a wider portion
between said lip and said rear surface, said set of adjacent slats
having a lip/track height, said lip/track height being
substantially equal to a distance between said lower end of said
lip of said upper slat and said track of said lower slat, the
effective hardware height being between said slat height and said
lip/track height; and, wherein said slot is adapted to receive the
upper portion of the hardware and said groove of said lower slat is
adapted to receive the lower end of the hardware when said hardware
is in a secure position.
12. The slatwall assembly of claim 11, and wherein the hardware has
a mounting bracket that forms said upper and lower portions of the
hardware, the effective hardware height being an effective bracket
height, and the ledge being formed by an offset of the bracket, and
wherein said rim has a rim height, the effective bracket height
being a predetermined amount less than said lip/track height, and
said rim height is greater than said predetermined amount, said
lower end of said bracket snap-fitting into said groove.
13. The slatwall assembly of claim 11, and wherein the effective
hardware height is substantially equal to said lip/track height,
and said lower end of the hardware rests on said track of said
lower slat, the hardware supporting the weight of an object and
said track supporting that weight.
14. The slatwall assembly of claim 11, and wherein said slats have
a uniform slat height, the effective hardware height is
substantially equal to said slat height, said ledge of the hardware
rests on said upper end of said lower slat, the hardware supporting
the weight of an object, and said upper end of said lower slat
supporting that weight.
15. The slatwall extrusion of claim 11, and wherein each of said
extruded slats has a continuous rear wall.
16. The slatwall extrusion of claim 11, and wherein each of said
extruded slats is backless.
17. The slatwall extrusion of claim 11, and wherein each of said
slatwall extrusions has upper and lower tabs for joining adjacent
slatwall extrusions, said upper and lower tabs having a
predetermined length, said upper and lower tabs having a
predetermined height to align adjacent slatwall extrusions to form
one of said uniform longitudinal slots.
18. The slatwall extrusion of claim 11, and wherein said track
extends from said lower end of said lip.
19. The slatwall extrusion of claim 11, and wherein said lip has a
stiffening web spaced from said lower end of said lip.
20. The slatwall extrusion of claim 19, and wherein said track
extends parallel to said stiffening web.
21. An extruded slatwall rail for supportably securing a piece of
hardware, said hardware having upper and lower portions, said upper
portion having a ledge and said lower portion having a lower end,
said hardware having an effective hardware height substantially
equal to a distance between its ledge and lower end, said extruded
slatwall rail comprising: a continuous rear wall having front and
rear surfaces, and including a slot forming portion with a forward
extending spacer wall; an upper lip having a front surface, said
lip being joined to and spaced from said rear wall via a slot
forming portion, said lip having a lower end and an inside surface,
said inside surface being positioned between said front surface of
said lip and said front surface of said rear wall; a lower slat
having a front wall with a front surface, said front wall being
joined to said rear wall via upper and lower wall portions of said
slat; a track extending from said front surface of said slat, and
said track having an upwardly extending rim that defines a uniform,
longitudinal groove, said rail having a lip/track height
substantially equal to a distance from said track to said lower end
of said lip, said hardware height being substantially equal to said
lip/track height; a slot formed between said upper lip and said
lower slat, said slot having a narrow portion proximal said front
surfaces of said lip and slat and a wider portion between said
inside surface of said lip and said rear wall; and, wherein said
slot is adapted to receive the upper portion of the hardware and
said groove is adapted to receive the lower end of the
hardware.
22. The slatwall assembly of claim 21, and wherein said hardware
has a mounting bracket that forms said upper and lower portions of
said hardware, said effective hardware height being an effective
bracket height, and said ledge being formed by an offset of said
bracket, and wherein said rim has a rim height, said effective
bracket height being a predetermined amount less than said
lip/track height, and said rim height is greater than said
predetermined amount, said lower end of said bracket snap-fitting
into said groove.
23. The slatwall assembly of claim 21, and wherein said effective
hardware height is substantially equal to said lip/track height,
and said lower end of said hardware rests on said track of said
lower slat, said hardware supporting the weight of an object and
said track supporting that weight.
24. The slatwall assembly of claim 21, and wherein said slats have
a uniform slat height, said effective hardware height is
substantially equal to said slat height, said ledge of said
hardware rests on said upper end of said lower slat, said hardware
supporting the weight of an object, and said upper end of said
lower slat supporting that weight.
25. The extruded slatwall rail of claim 21, and wherein said track
extends from said lower wall of said slat.
26. The extruded slatwall rail of claim 21, and wherein said slat
has a stiffening web spaced from said lower wall of said slat.
27. The extruded slatwall rail of claim 21, and wherein said track
extends parallel to said stiffening web.
28. The extruded slatwall rail of claim 21, and wherein said lip
has front, rear and side walls that define a hollow interior, and
wherein said walls of said slat define a hollow interior.
Description
[0001] This is a Continuation-In-Part of Design Patent Application
Nos. 29/200,780 and 29/200,781 filed Mar. 4, 2004.
BACKGROUND OF THE INVENTION
[0002] Slatwall is used to support or display a wide variety of
products in an organized manner. The slatwall is typically mounted
flush against a wall, and is particularly useful in retail stores,
garages and the like where goods or items need to be displayed or
stored, and a more finished look is desired but bulky cabinets or
conventional shelving are inappropriate due to lack of space.
Slatwall includes a number of horizontal boards or slats. Adjacent
slats are spaced apart a given distance to form a number of
uniform, horizontal slots. The slots are evenly spaced, one above
the other, through the height of the slatwall. A number of hangers
or supporting hardware are secured to the slatwall by inserting
them into the slots. The hangers are generally cantilevered from
the slatwall so that items can be hung from or supported by the
hangers. The hangers or hardware can also be used to support a
platform for displaying or storing smaller items such as shoes,
packaged fasteners or the like.
[0003] A problem with conventional slatwall is that the supporting
hardware can be dislodged. When people walk by slatwall or quickly
reach for an item on the slatwall, they can inadvertently bump one
or more of the hangers with enough force to rotate and dislodge the
hanger and cause it and the item it supports to fall to the ground.
This can be particularly frustrating and embarrassing to customers
and storekeepers in a retail store setting, and can damage the
goods being displayed. When the slatwall is supporting heavy or
sharp objects such as shovels, racks, saws, and the like as in a
garage setting, the falling objects can cause injury. When many
items are hung or supported by the slatwall at different heights
and a person bumps one of the upper hangers, a cascading effect can
result with several pieces of hardware and objects falling to the
ground.
[0004] Another problem with conventional slatwall hangers is the
unreliable nature with which they grip the slatwall. Only a small
portion of the hanger typically engages the slatwall to keep it
from falling to the ground. Frequently, only one eighth (1/8) inch
of the rim of the hanger engages the slatwall to prevent the hanger
from rotating forward and falling to the ground. This small contact
area produces concentrated stresses on the hanger and slatwall.
These stresses can bend the rim of the metal or plastic hanger and
cause the hanger to rotate forward or otherwise pop out of its
supporting slot and fall to the ground. Similarly, these
concentrated stresses can bend, chip or break the slatwall and
cause the hanger to rotate forward and out of its slot. Normal wear
and tear on the slatwall and the hangers can cause the assembly to
function unreliably because the hangers are more easily dislodged
and knocked from place during use. Hangers with slightly bent or
worn rims will no longer grip the portions of some or all of the
slots, particularly if the lip is worn or chipped. Wood slatwall is
particularly problematic because the edges of the lips of the board
forming the slot can chip under stress or through normal wear and
tear, which permanently damages the slatwall so that hangers will
continue to pop out at the damaged location. Slight variations in
the uniformity of the slots due to manufacturing tolerances and
installation error also cause the hangers to grip the slatwall less
reliably in certain areas of the assembly.
[0005] A further problem with conventional slatwall is that it can
be difficult to rearrange the hangers and the items being displayed
or stored on the slatwall. More permanent type fasteners such as
nails or screws that secure the hangers to the slatwall need to be
removed. This is a cumbersome process that damages the slatwall.
Adding or removing even one hanger and item to the slatwall can
require the removal and reattachment of several hangers. Repeated
rearrangements of the hangers ultimately causes physical and
aesthetic damage to the slatwall. Replacing or repairing the
slatwall results in extra expenses and down time.
[0006] The present invention is intended to solve these and other
problems.
BRIEF DESCRIPTION OF THE INVENTION
[0007] The present invention pertains to a slatwall extrusion and
assembly that supportably secures a hanger, shelf bracket or other
hardware. The slatwall extrusion has a board with a downwardly
facing lip that combines with a lower like-shaped board to form a
uniform longitudinal slot that receives the upper end of a mounting
bracket for the hardware. The lip of each board has a track with
rim to form an upwardly facing groove. The track receives and
supportably secures the lower end of the bracket. The lower end of
lip and the track are spaced apart a predetermined uniform
distance. The bracket snap fits over the rim and into the groove so
that the bracket is securely held by and between the lip and the
track. A stiffening web is used to strengthen the lip. An
embodiment of the invention takes the form of an extruded slatwall
rail having an upper lip and a lower board with the track. The
hardware is easily positioned along the slatwall by sliding it
along the track.
[0008] One advantage of the present slatwall extrusion is that it
reliably secures the hardware or hanger to the slatwall. The track
and groove secure the lower end of the hardware, and prevent the
lower end from rotating forward into a release position. By
securing the lower end, the track helps prevent inadvertent
dislodgement of the hardware, as well as any shelving or goods
being supported by that hardware. The hardware remains in place
even if inadvertently bumped by a person walking by the slatwall
display assembly or a person reaching to grab an item hanging or
otherwise supported by the slatwall. The track significantly
improves the overall performance and satisfaction of the slatwall
assembly. Displayed and stored goods are kept in place and are less
likely to be damaged. Customers and storekeepers do not need to
keep picking up slatwall hardware and display items, and heavy or
sharp items are less likely to fall and injure people.
[0009] Another advantage of the present slatwall extrusion
invention is its increased contact area between the upper end of
the hanger bracket and the lip of the slatwall. This increased
contact area improves the strength and reliability of the extruded
slatwall, assembly and rail. The track lifts the mounting bracket
so that its upper end rises in the slot to increase the contact
area between the upper end of the bracket and the lip of the
slatwall. A full half (1/2) inch of the bracket engages the inside
surface of the lip of the upper board. This increased contact area
reduces the stresses on the lip, the surrounding portions of the
slatwall, and the bracket so that they do not bend and allow the
hanger to pop out of the slot during use. As a result, much heavier
objects can be more reliably hung or supported from hardware or
hangers without risk that they will pop out during use, even if
inadvertently bumped.
[0010] A further advantage of the present slatwall extrusion
invention is that hangers can be easily secured in place,
rearranged and removed. The mounting bracket of a piece of hardware
is easily snap-fit in place between the cooperating lip, slot and
track. The uniform spacing of the longitudinally extending lip,
slot and track allow the hangers, shelving brackets and other
hardware to slide horizontally along the length of the slatwall and
assembly so that they can be positioned or repositioned at a
desired location without removing and resecuring them. The mounting
bracket snap fits in place without the need of any tools. The
hangers are easily removed from the slatwall with a screwdriver or
other similar flat headed tool, or they can be slid off the end of
the slatwall or assembly. No nails or screws are required to secure
the hardware to the slatwall, so the slatwall remains physically
sound and aesthetically pleasing even after many rearrangements of
the display items.
[0011] Other aspects and advantages of the invention will become
apparent upon making reference to the specification, claims and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a slatwall assembly formed
by several horizontal sections of slatwall with hangers such as
hocks and shelf brackets that are secured in place to the slatwall
invention.
[0013] FIG. 2 is a perspective view of a slatwall extrusion forming
two adjacent boards, where each board forms a lower lip that
includes a support track.
[0014] FIG. 3 is a side sectional view of the slatwall assembly
with a hanger secured to a slot formed by adjacent boards with the
hanger secured between the lower lip of the upper board and the
track of the lower board.
[0015] FIG. 4 is a side sectional view of the slatwall assembly
formed by a first alternate embodiment of the slatwall extrusion
with a stiffening web in the lip and the track extending from the
web and offset from the lower end of its lip.
[0016] FIG. 5 is a side sectional view of the slatwall assembly
formed by a second alternate embodiment of the slatwall extrusion
with the stiffening web in the lip and the track extending from the
lower end of its lip.
[0017] FIG. 6A is a perspective view of a single board embodiment
of the present slatwall extrusion invention.
[0018] FIG. 6B is a side sectional view of the single board
embodiment shown in FIG. 6A.
[0019] FIG. 6C is a side sectional view of the single board
embodiment of FIG. 6A with a stiffening web in its lower lip and
the track extending from the web.
[0020] FIG. 6D is a side sectional view of the single board
embodiment of FIG. 6A with the stiffening web in its lower lip and
the track extending from the lower end of its lip.
[0021] FIG. 7A is a side sectional view of a three-board embodiment
of the present slatwall extrusion invention.
[0022] FIG. 7B is a side sectional view of the three-board
embodiment with a stiffening web in its lower lip and the track
extending from the web.
[0023] FIG. 7C is a side sectional view of the three-board
embodiment with the stiffening web in its lower lip and the track
extending from the lower end of its lip.
[0024] FIG. 8A is a side sectional view of a four-board embodiment
of the present slatwall extrusion invention.
[0025] FIG. 8B is a side sectional view of the four-board
embodiment with a stiffening web in its lower lip and the track
extending from the web and offset from the lower end of its
lip.
[0026] FIG. 8C is a side sectional view of the four-board
embodiment with the stiffening web in its lower lip and the track
extending from the lower end of its lip.
[0027] FIG. 9A is a perspective view of a backless embodiment of
the present slatwall extrusion invention without a continuous rear
wall spanning from its upper end to its lower end.
[0028] FIG. 9B is a side sectional view of the slatwall assembly
formed by the backless embodiment shown in FIG. 9A.
[0029] FIG. 9C is a side sectional view of the slatwall assembly
formed by the backless embodiment shown in FIG. 9A with a
stiffening web in its lower lip and the track extending from the
web.
[0030] FIG. 9D is a side sectional view of the slatwall assembly
formed by the backless embodiment shown in FIG. 9A with the
stiffening web in its lower lip and the track extending from the
lower end of its lip.
[0031] FIG. 10A is a perspective view of a rail extrusion
incorporating the present invention, where the rail includes an
upper lip and a lower board that are spaced to define the slot, and
where the track extends from the lower end of the board.
[0032] FIG. 10B is a perspective view of a second embodiment of the
rail of FIG. 10A with a stiffening web in its lower board, and
where the track extends from the web and is offset from the lower
end of the board.
[0033] FIG. 10C is a perspective view of a third embodiment of the
rail of FIG. 10A with a stiffening web in its lower board, and
where the track extends from the lower end of the board.
[0034] FIG. 11A is a side sectional view of FIG. 10A showing the
rail extrusion secured to a supporting wall and with a hanger
positioned for insertion into its slot.
[0035] FIG. 11B is a side sectional view of the rail of FIG. 11A
showing the hanger rotated so that its upper end is inserted into
the slot of the rail.
[0036] FIG. 11C is a side sectional view of the rail of FIG. 11B
showing the hanger just prior to being snap fit into the track of
the rail.
[0037] FIG. 11D is a side sectional view of the rail of FIG. 11C
showing the hanger after being snap fit to rail.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] While this invention is susceptible of embodiments in many
different forms, the drawings show and the specification describes
in detail the preferred embodiments of the invention. It should be
understood that the drawings and specification are to be considered
an exemplification of the principles of the invention. They are not
intended to limit the broad aspects of the invention to the
embodiments illustrated.
[0039] Residential, commercial and industrial buildings typically
have walls 5 with a number of uniformly spaced vertical studs 6.
The studs 6 are usually covered by an outer drywall layer 7 or
other covering. The present invention pertains to a slatwall
extrusion 10 used to form a slatwall assembly 12 having a number of
like-shaped slats or boards 15 as generally shown in FIGS. 1-3.
Each extrusion 10 has a uniform cross-sectional shape that extends
along its length form one side 10a to the other 10b. Each board 15
has a generally hollow interior or core 15a. Each extrusion 10 can
have a single board 15 as in FIG. 6A or two or more boards 15 as in
FIGS. 2, 7A and 8A. In other words, each board 15 can be a separate
piece that is individually secured to the wall 5, or a number of
integrally joined boards can be included in a single extrusion 10.
The boards 15 of a multi-board extrusion 10 are uniformly spaced
and parallel.
[0040] The slatwall assembly 12 is formed by a number of
like-shaped extrusions 10. The extrusions 10 are horizontally
aligned so that each board 15 is uniformly spaced from and is
parallel to its adjacent boards. Two adjacent boards 15 form a
working set 16 that includes an upper board 17 and a lower board
18. Fasteners 8 or an adhesive coating are used to secure the
slatwall extrusions 10 to the studs 6 or wall covering 7. Screws 8
are preferred for strength and removability. The slatwall assembly
12 and its individual extrusions 10 are used to mount or display a
variety of objects off the floor of the building in an organized
manner. The objects can be similar, such as in a display for a
number of shoes, or they can vary in size, shape, weight and type,
such as in a garage to mount shovels, racks, saws, garden tools,
etc. The slatwall extrusions 10 are preferably extruded plastic
having a desired combination of rigidity, strength, durability, and
aesthetic appearance.
[0041] Each slatwall extrusion 10 has a rear wall 21 with front and
rear surfaces 21a and 21b that span the height of the extrusion. In
one embodiment, the rear wall 21 extends continuously from the top
of the extrusion to its bottom as in FIGS. 2 and 3. The continuous
rear wall 21 includes a segment 22 that forms the rear wall of each
board 15 in that extrusion 10. The rear wall 21 also includes upper
and lower tabs 23 and 24 that position separate adjacent extrusions
10 into abutting engagement and horizontal alignment as in FIGS. 1
and 3. The upper tab 23 includes an offset 23a at its upper end to
snuggly receive the lower tab 24 of an adjacent extrusion 10. The
upper end of tab 23 and the lower end of tab 24 are parallel to the
boards 15 of the extrusion. When separate extrusions 10 are
properly aligned and secured to a wall 5, the boards 15 of the
separate extrusions forming the assembly 12 are in substantially
parallel and horizontal alignment. The tabs 23 and 24 of separate
adjacent extrusions 10 also combine to form a slot segment between
the adjacent boards of separate extrusions as shown in FIG. 3. The
rear wall 21 of the multi-board extrusions 10 shown in FIGS. 2, 7A
and 8A 10 have one or more slot forming segments 25 that integrally
join adjacent boards 15 of that extrusion. The single-board 15
extrusion 10 shown in FIG. 6A does not include this segment. The
extrusions 10 in the assembly 12 are secured to the wall 5 so that
the rear surface 21b of each extrusion 10 and board 15 lays flush
against the vertical wall studs 6 or wall covering 7.
[0042] Each board 15 in the extrusion 10 and assembly 12 has a
substantially similar shape. Each like-shaped board has a front
wall 27 with a front surface 27a that is generally parallel to the
rear wall 21. The front wall 27 defines the height or width of the
board 15, which is preferably about three (3) inches. The front
wall 27 also defines the depth or thickness of the board 15, which
is preferably about one-half (1/2) inch. Each like-shaped board 15
also includes opposed upper and lower sidewalls 28 and 29. These
walls 21, 27, 28 and 29 combine to define the hollow interior 15a
of the board 15. The upper wall 28 is generally perpendicular to
the front and rear walls 21 and 27. The lower side wall 29 extends
perpendicularly from the front and rear walls 21 and 27, but
includes an offset to form a lip 30.
[0043] The lip 30 is an integral part of its respective board 15.
When secured to the wall 5, the lip 30 extends in a downward
direction. Each lip 30 is formed by a lower portion of the front
wall 27 and the bottom wall 29 of the board 15. The bottom wall 29
includes a substantially horizontal lower end wall 32 with surface
32a, and has a substantially vertical inner wall 33 with surface
33a. The lower wall 32 has a width or depth dimension of about
one-quarter (1/4) inch. The inside wall 33 has a width or height
dimension of about one-half (1/2) inch. Each lip 30 has a generally
hollow interior 30a that is part of the hollow interior 15a of the
board 15. For increased rigidity, the lip 30 includes a stiffening
web 35 that is preferably horizontal or perpendicular the rear and
front walls 21 and 27 as shown in FIGS. 4, 5, 6C, 6D, 7B, 7C, 8B
and 8D. Each of the walls 21, 27, 28, 32 and 33 and the web 35 has
a uniform thickness of about one-sixteenth ({fraction (1/16)})
inch.
[0044] Each board 15 includes an outwardly extending track 40 to
support a piece of hardware, as discussed below. The track 40 is an
integral part of each board 15 and each extrusion 10. Each track 40
extends along the length of the extrusion 10. Each track 40 is in
substantially linear alignment with and is parallel to the lower
end 32 of its corresponding lip 30 as shown in FIGS. 3, 5, 6B, 7A
and 8A. The track 40 can also be positioned to extend linearly from
the stiffening web 35 as shown in FIGS. 4, 6C, 7B or 8B. Each track
40 includes a horizontal rail 42 having a forward end 42a and an
upper surface 42b. The forward end 42a of the rail 42 has an
upwardly extending rib 43. The rib 43 has a tip 43a, a curved outer
surface 43b and a flat vertical inner surface 43c. The rail 42
extends from the front surface 21a about one-eighth (1/8) inch. The
height of the rib 43 is about one-sixteenth ({fraction (1/16)})
inch from upper surface 42b to tip 43a. Similar to the walls of the
board 15, the rail 42 has a thickness of about one-sixteenth
({fraction (1/16)}) inch, except at its forward end 42a where the
track and rim have a combined height of about one-eight (1/8) inch.
The surface 21a of the front wall 21 of the board 15 combines with
the upper surface 42b of the rail 42 and the inner surface 43c of
the rib 43 to form a groove 45.
[0045] Each set 16 of adjacent boards 17 and 18 in the assembly 12
has the same lip/track height. The upper surface 42b of the track
40 of each lower board 15, 18 is spaced a uniform distance from the
lower end 32 of the lip 30 of its adjacent upper board 15, 17. The
adjacent boards 15 of a multi-board extrusion 10 are integrally
formed to have this lip/track height. The tabs 23 and 24 of the
extrusions 10 are structured and sized so that when two adjacent
extrusions are properly assembled and fastened to the wall 5, the
lowest board 15, 17 of the upper extrusion and the upper board 15,
18 of the adjacent lower extrusion form a working set 16 with this
lip/track height. In the embodiments shown, the lip/track height is
about two and five-eights (2-5/8) inches. The lip/track height is
uniform along the length of the extrusion 10 and assembly 12.
[0046] Each set 16 of adjacent boards 17 and 18 forms a slot 50
that is generally L-shaped when viewed in cross-section as in FIG.
3. Each slot 50 extends uniformly along the length of the extrusion
10 and assembly 12 from one side 10a, 12a to the other 10b, 12b.
The L-shaped slot 50 has a narrow portion 52 and a wide or tall
portion 54. The narrow portion 52 forms an opening through the
front of the extrusion 10 or assembly 12 between the adjacent
boards 15. The narrow portion 52 is located between the lip 30 of
the upper board 17 and the upper sidewall 28 of the lower board 18,
and more particularly between the plains formed by the front
surface 21a of the front wall 21 and the inside surface 33a of the
lip 30. The narrow portion 52 has a width or height dimension of
about three-eighths (3/8) of an inch, and a depth dimension
extending into the slatwall 10 of about one-quarter (1/4) inch. The
wider portion 54 is located between the inside surface 33a of the
lip 30 and the rear wall 24. The wider portion 54 has a width
dimension of about seven-eighths (7/8) inch, and a depth dimension
of about one-eighth (1/8) inch. The total depth of the slot 50 is
about three-eighths (3/8) inch. Although the slats 15 are shown and
described to have only a lower lip 30 so as to form an L-shaped
slot 50, it should be understood that the upper sidewall 28 of the
slat 15 could also have an upwardly extending lip so as to form a
T-shaped slot without departing from the broad aspects of the
invention. When the track 40 extends from the lower end 32 of the
lip 30 as in FIG. 3, the lip/track height is roughly the height of
one board 15 and the narrow portion 52 of one slot 50.
[0047] Another embodiment of the slatwall extrusion 90 is shown in
FIGS. 9A and 9B. In this embodiment, the rear wall 21 does not
extend continuously from the top of the extrusion 90 to its bottom.
The segment 22 of the rear wall 21 that would otherwise form the
rear wall of its board or boards 15 is missing. This backless
slatwall extrusion 90 is otherwise generally shaped and sized
similar to the extrusion 10 having a continuous rear wall 21. The
backless slatwall extrusion 90 can also include a stiffening web 35
in its lip 30 as in FIGS. 9C and 9D. The track 40 is in parallel
alignment with and extend from the stiffening web 35 as in FIG. 9C,
or is in parallel alignment with and extends from the lower end 32
of the lip 30 as in FIGS. 9B and 9D. Although not shown, the upper
and lower tabs 23 and 24 of the rear wall 21 can have the structure
shown in FIGS. 2 and 3 or the structure shown in FIGS. 9A and
9B.
[0048] A further embodiment of the invention is an extruded slat
rail 100 shown in FIGS. 10A-C. The slat rail 100 has a continuous
rear wall 121, a lower board 126 and an upper lip 130. The rear
wall 121 has front and rear surfaces 121a and 121b. The rear wall
121 spans the height of the extruded rail and extends continuously
from the top of the extrusion to its bottom. The rear wall 121
includes a segment 122 that forms the rear wall of its board 126
and a segment 125 that forms the rear wall of its corresponding
slot 50. The board 126 has a front wall 127 with a front surface
127a that is generally parallel to the rear wall 121. The front
wall 127 defines the height or width of the board 126, which is
preferably about two and three-eighths (2-3/8) inches. The front
wall 127 also defines the depth or thickness of the board 126,
which is preferably about one-half (1/2) inch. The board 126
includes opposed upper and lower sidewalls 128 and 129 that are
generally perpendicular to the front and rear walls 121 and 127.
These walls 121, 127, 128 and 129 combine to define the hollow
interior 126a of the board 126. The rail extrusion 100 is secured
to the wall 5 so that its rear surface 121b and board 126 lay flush
against the vertical wall studs 6 or wall covering 7.
[0049] The lip 130 is integrally joined to the board 15 via the
slot forming segment 125 of the rear wall 121 and a spacer wall 137
that extends forward a distance of about one-eighth (1/8) inch.
When secured to the wall 5, the lip 130 extends in a downward
direction. The lip 130 is formed by a front wall 131 with a front
surface 131a, a lower end wall 132 with a surface 132a, an inside
wall 133 with an inside surface 133a, and an upper sidewall 134.
The bottom wall 132 has a width or depth dimension of about
one-quarter (1/4) inch. The inside wall 133 has a width or height
dimension of about one-half (1/2) inch. Each lip 130 has a
generally hollow interior 130a.
[0050] The track 40 of the rail 100 has the same structure
discussed above. The outwardly extending track 40 is an integral
part of the rail 100 and extends the length of the rail. The track
40 is in substantially linear alignment with and is parallel to the
bottom sidewall 129 of its board 126 as shown in FIG. 10A. The
board 126 can include a horizontal stiffening web 35 as shown in
FIGS. 10B and 10C. The track 40 can be positioned to extend from
the stiffening web 135 as shown in FIG. 10B or the bottom sidewall
129 of the board as in FIG. 10C. The components and dimensions of
the track are similar to those discussed above. Each wall 121, 127,
128, 129, 131, 132, 133 and 134 of the extruded rail 100 as well as
its track rail 42 has a uniform thickness of about one-sixteenth
({fraction (1/16)}) inch. Again, the lip/track height is the
distance between the upper surface 42b of the track 40 and the
lower end 132 of the lip 130. This lip/track height remains
substantially constant along the length of the rail 100.
[0051] Hangers 60 are supportably secured by the cooperating lip
30, 130, track 40 and slot 50 of the slatwall extrusion 10,
assembly 12, backless extrusion 90 or rail 100. As shown in FIGS. 3
and 11A-D, each hanger 60 has a mounting bracket 61 for mounting it
to the slatwall extrusion 10, assembly 12 or rail 100. The mounting
bracket 61 has inside and outside surfaces 62 and 63, an upper
portion 64 with a ledge or offset 65 and an upper most end 66, a
middle portion 67 that is generally flat, and lower portion 68 with
a lower most end 69. The upper portion 64 has a length or height
dimension of slightly less than the length of the lip 30 or about
one-half (1/2) inch. The combined length or height dimensions of
the middle and lower portions 67 and 68 of the hanger is about the
combined height of one board 15 and a narrow portion 52 of slot 50,
or about two and a half (2-1/2) inches. The hanger 60 has an
effective height for the purpose of securing it to the slatwall
extrusion 10, assembly 12, backless extrusion 90 or rail 100. For
the hangers 60 shown, the effective height of the hanger is
determined by the effective height of the bracket 61. Given that
the upper end 66 of the bracket 61 does not engage the wall 29
forming the top of the slot 50, the height of the lower and middle
portions 67 and 68 of the bracket 61, the distance between its
offset 65 and lower end 69, forms the effective height of the
hanger 60 or bracket 61. This effective hardware height is
substantially equal to the lip/track height of the slatwall
extrusion 10, assembly 12, backless extrusion 90 and rail 100. Were
the upper end 66 of the bracket 61 to engage the wall 29 forming
the top of the slot 50, then the effective hanger height would be
the distance between the upper and lower ends 66 and 69 of the
bracket.
[0052] The hanger 60 has a hang rod 71 for supporting the goods or
a shelf. The hang rod 71 has one end 72 that is secured to the
middle portion 67 of the bracket 61, a cantilevered middle portion
73 that extends generally horizontally when the hanger is secured
to the slatwall 10, and an inclined end 74 that is angled up to
keep the goods from sliding off the hanger 60. The cantilevered
support 60 creates a torque that causes the middle and lower
portions 67 and 68 of the bracket 61 to push against the front wall
27 of the lower board 18, and the upper portion 64 to push against
the inside surface 33a of the lip 30 of the upper board 17. When
the hanger is in its secured position as in FIG. 3, the hanger 60
and the weight of the goods it supports rests on the track 40. The
lip 30 and slot 50 formed by a set 16 of boards 17 and 18 combine
with the upper portion 64 of the bracket 61 to prevent the bracket
from rotating forward out of the slot 50 and out of supporting
engagement with the track 40. Although the hanger 60 is shown and
described to have a particular shape, it should be understood that
other hangers or pieces of hardware with other shapes, such as a
hook or shelf bracket, could be used to support the goods, or a
rack, tray or shelf for the goods, without departing from the broad
aspects of the invention. For example, the mounting bracket 61
could be replaced by other components, or the upper portion 64 of
the bracket could be formed by the hang rod 71.
[0053] The hangers are secured to adjacent boards 17 and 18 of the
slatwall extrusion 10, 90 or assembly 12 in a multi-step process.
These same steps are used to secure the hangers 60 to the slatwall
rail 100. First, the hanger 60 is angled backward into a tilted
position 81 as in FIG. 11A. The upper stepped portion 64 is
inserted into the slot 50 until the upper most portion 66 clears
the narrow outer portion 52 and enters the wider inner portion 54.
The hanger 60 is then rotated forward by hand or otherwise into a
generally vertical engaged position 82 as in FIG. 11B. The hanger
60 now engages the slatwall 10 but is not secured to the slatwall.
Although the hanger 60 cannot rotate any further forward, it can be
rotated backward, which could cause it to become dislodged from the
slatwall. Next, the hanger 60 is slid upward until the upper
surface of the stepped portion 64 engages the lower end 32, 132 of
the lip 30, 130. The hanger 60 is now in a pre-snap fit position 83
and is ready to be secured by and between the lip 30, 130 and track
40 of adjacent boards 17 and 18 or the rail 100 as in FIG. 11C. The
lowermost end 69 of the hanger 60 is just below the tip 43a of the
rib 43 of the track 40. As discussed above, the front 43b of the
rim 43 of the track 40 is rounded so that pushing the lower most
end 69 of the hanger towards the lower board 18, 126 causes the
hanger 60 to move a little further up and elastically bends the
track 40' down to allow the lower most end 69 to snap fit into the
groove 45. The weight of the hanger 60 and the object it supports
causes the hanger to slide down onto the rail 42 so that the weight
of the hanger and the object are supported by the track 40. The
hanger is now in its secured position 84 as in FIG. 11D. The
lowermost end 69 of the hanger 60 is in groove 45 and abuttingly
engaging the rail 42, its flat middle and lower portions 67 and 68
flushly engage the front surface 27a of the front wall 27, and its
upper stepped portion 64 is inserted in slot 50 with its flat outer
surface 63 flushly engaging the inside surface 34a of the lip.
[0054] The secure position 84 increases the load carrying capacity
of the hangers 60 and allows for easy positioning and removal of
the hangers. As discussed above, the inside surface 43c edge of the
upper end of the rib 43 is flat and not rounded. The lowermost end
69 cannot be easily knocked out so that the hanger 60 remains in
its secure position 84 even when the hanger or object is bumped. In
addition, when the hanger 60 is in its secured position 84, a
majority of the outer surface 63 of the vertical segment of the
upper stepped portion 64 abuttingly engages the inside surface 33a,
133a of the lip 30, 130 of the upper slat 17 or rail 100. By having
the hanger 60 extend higher up in the slot 50 so that it presses
against an upper portion of the lip 30, 130, less torque is
produced on the upper portion of the lip so that the lip more
effectively resists outward bending and better retains its shape
under load. In addition, the higher contact area requires more
bending of the lip 30, 130 before the uppermost end 66 of the
hanger 60 will clear the lower end 32 of the lip, which would allow
the hanger to rotate forward and out of the slot 50. Thus, the
higher contact increases the holding strength of the slatwall 10,
assembly 12 and rail 100, and their weight carrying capacity.
Although the hanger 60 is held firmly in place by the cooperating
track 40 and slot 50 of the slatwall extrusion 10, assembly 12 and
rail 100, the hanger 60 is free to slide from side to side along
their length. This sliding allows the hangers 60 to be easily
positioned or repositioned at a desired lengthwise location along
the slatwall extrusion 10, assembly 12 or rail 100. In addition,
the hanger 60 can be easily removed from the track 40 and slot 50
by simply sliding the hanger to the end of the slatwall and off on
of the side ends 10a or 10b, or 100a or 100b.
[0055] While the invention has been described with reference to its
preferred embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted without departing from the broad aspects of the
invention.
* * * * *