U.S. patent application number 11/088485 was filed with the patent office on 2005-10-13 for wall storage system.
Invention is credited to Heneveld, William R. SR..
Application Number | 20050224433 11/088485 |
Document ID | / |
Family ID | 35059473 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050224433 |
Kind Code |
A1 |
Heneveld, William R. SR. |
October 13, 2005 |
Wall storage system
Abstract
A wall storage system is provided that is surprisingly
versatile, durable, simple, and low cost. It includes perforated
panels and rails, and multiple accessories, many of which can be
used on standard peg board. Various perforated rail configurations
are shown, including a preferred C-shaped rail with flat front and
perpendicular top and bottom flanges. The versatility of the rail
allows it to be wall-hung horizontally or vertically, or to be used
in a floor-supported free-standing unit. Numerous accessories, many
being one-piece formed wire, are configured to stably engage the
rail and panel apertures, including an outwardly extending peg with
swaged or notched end, and a second bent wire handle holder that
rotatably engages the rail. A variety of bracket, shelving, and
basket accessories can also be attached to the present rail and
panel system, many being mountable without additional components.
Anchoring and stabilizing clips are provided for heavy-duty
brackets.
Inventors: |
Heneveld, William R. SR.;
(Grand Rapids, MI) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON, LLP
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
35059473 |
Appl. No.: |
11/088485 |
Filed: |
March 24, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60556263 |
Mar 25, 2004 |
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Current U.S.
Class: |
211/70.6 |
Current CPC
Class: |
A47F 5/0815
20130101 |
Class at
Publication: |
211/070.6 |
International
Class: |
A47F 007/00 |
Claims
The exclusive property or privilege claimed includes:
1. A storage system comprising: a rail having a flat front wall,
and top and bottom flanges extending rearwardly from the front
wall, at least the front wall having a plurality of apertures
therein; a plurality of spacers configured to stably engage a rear
surface of the rail and adapted to space the rail forwardly from a
wall structure; the spacers having a length longer than a depth
dimension of the top and bottom flanges; and accessories each with
at least one leg for stably engaging at least one of the
apertures.
2. The storage system defined in claim 1, wherein the rail includes
a down flange extending from a rear edge of the top flange.
3. The storage system defined in claim 1, wherein the top flange
includes several of the plurality of apertures.
4. The storage system defined in claim 3, wherein the bottom flange
includes several of the plurality of apertures.
5. The storage system defined in claim 1, wherein the plurality of
spacers include a particularly shaped spacer that is shaped and
adapted to fit through at least one of the apertures.
6. The storage system defined in claim 5, wherein the shaped spacer
includes a body defining a screw-receiving hole and further
includes a protrusion offset from the screw-receiving hole and
configured to abut marginal material on the rail forming a selected
one of the apertures to stop rotation of the shaped spacer when the
body of the spacer is offset from the selected one aperture.
7. The storage system defined in claim 1, wherein at least some of
the spacers include at least a first hole for receiving a first
screw for attaching the spacer to a wall structure, and further
include a second hole for receiving a second screw to attach the
rail to the spacers.
8. The storage system defined in claim 1, wherein the accessories
include a peg with an attachment end formed to wedgingly engage a
selected one of the apertures.
9. The storage system defined in claim 8, wherein the attachment
end includes a swaged section.
10. The storage system defined in claim 9, wherein the attachment
end comprises a bent wire section, and the swaged section is formed
at a free end of the bent wire section.
11. The storage system defined in claim 1, wherein at least one of
the accessories is heavy-duty and adapted to support a product of
significant weight, and including an anchor for engaging the rail
to assist the one accessory in transferring stress and loads from
the one accessory to the rail for supporting the product.
12. The storage system defined in claim 1, wherein the plurality of
apertures of the rail includes at least one aperture that is
non-circular in shape, and wherein one of the accessories includes
a configured clip shaped to fit into the non-circular aperture and
then rotate to an interlocked non-removable position.
13. The storage system defined in claim 1, wherein the accessories
includes at least one accessory having an attachment end configured
to fit through at least one selected from the plurality of
apertures and rotatingly engage the rail, the one accessory further
having a product-supporting end that includes material defining
front and rear sections spaced from the attachment end, the front
and rear arms being positioned to receive a handle of a tool
therebetween and adapted to frictionally engage opposing sides of
the handle when the attachment end is rotated due to gravity of the
handle and tool.
14. The storage system defined in claim 1, wherein one of the
accessories includes an attachment end having a wire section, and
including a clip with a first end and an attachment section, the
first end including opposing sides configured to engage opposing
sides of the wire section to stably hold and support the one
accessory, and further the attachment section including mating
protrusions extending from the opposing sides and that when the
opposing sides are positioned together the mating protrusions are
adjacent and are configured to fit through one of the apertures in
the rail and to frictionally engage marginal material forming the
one aperture.
15. A storage system comprising: a first rail having a plurality of
apertures therein and configured for attachment vertically and
horizontally to a building wall; a second rail configured to
matably engage the first rail; a plurality of brackets configured
to engage selected apertures to hold items on the rails; the
brackets being configured to engage the rails when the rails are
positioned vertically and when the rails are positioned
horizontally; and legs configured for attachment to the first and
second rails to hold the first and second rails in a free-standing
upright position on a floor surface; whereby the storage system can
be arranged in a horizontal building-attached position, a vertical
building-attached position and a vertical free-standing
position.
16. A storage system comprising: a rail having front, top, and
bottom walls, and having a plurality of apertures therein; a
storage device having a useful section configured to hold product
when in a use position, and having an attachment section made from
a configured rod to hold the useful section in the use position;
and a stabilizing structure adapted to engage the rail and the
attachment section for securing the storage device stably on the
rail, the stabilizing structure being selected from a group
consisting of: 1) the configured rod shaped to fit into a selected
one of the apertures and including notches in the configured rod
that are shaped to engage front and rear surfaces of the rail
adjacent the selected one aperture; 2) a swaged portion of the
configured rod configured to wedgingly engage a selected one of the
apertures; 3) a separate holder having a recess shaped to receive
the attachment section and having a tab supported on a living hinge
that engages a back surface of the rail when the configured rod is
engaged with the separate holder; 4) a clip with a first end shaped
to encompass and engage the configured rod and a second end shaped
to snap through a selected one of the apertures; and 5) a shaped
portion on the configured rod shaped to fit through a selected one
of the apertures when in a first orientation but shaped to
interlock with the selected aperture when rotated to a vertical
second orientation.
17. The storage system defined in claim 16, wherein the stabilizing
structure includes the bent rod shaped to fit into a selected one
of the apertures and includes the notches in the bent rod that are
shaped to engage front and rear surfaces of the rail adjacent the
selected one aperture.
18. The storage system defined in claim 16, wherein the stabilizing
structure includes the swaged portion of the bent rod configured to
wedgingly engage a selected one of the apertures.
19. The storage system defined in claim 16, wherein the stabilizing
structure includes the separate holder having the recess to receive
the attachment section and having the tab supported on the living
hinge that engages the back surface of the rail when the bent rod
is engaged with the separate holder.
20. The storage system defined in claim 16, wherein the stabilizing
structure includes the clip with the first end shaped to encompass
and engage the bent rod and the second end shaped to snap through a
selected one of the apertures.
21. The storage system defined in claim 16, wherein at least some
of the apertures include an irregular shape, and wherein the
stabilizing structure includes the shaped portion on the bent rod
shaped to fit through the irregular shape of the selected one of
the apertures when in the first orientation but shaped to interlock
with the irregular portion when rotated to the vertical second
orientation.
22. The storage system defined in claim 16, wherein the top and
bottom walls of the rail have a thickness that is less than about
1/4 inch thick and that simulates a thickness of a peg board with
holes therein.
Description
[0001] This application claims benefit under 35 USC 119(e) of
provisional application Ser. No. 60/556,263, filed Mar. 25, 2004,
entitled WALL STORAGE SYSTEM, the entire contents of which are
incorporated herein in their entirety.
BACKGROUND
[0002] The present application concerns storage rails and
perforated panels such as peg boards, and further concerns
retainers, brackets, and holders attachable thereto.
[0003] There continues to be a need for a simple, low-cost, durable
storage system with the ability to accommodate a wide range of
items including larger and heavier items that are supported
somewhat away from a wall (such as several inches). Further, there
is a need for a system that includes various accessory brackets
attachable thereto, where the brackets are very easily produced,
are low-cost, and the simplest ones are made from a single piece of
formed stock. Further, it is desirable that the simpler brackets do
not require secondary operations such as welding, riveting, and
other forms of attaching multiple pieces together to form the
accessory bracket. Also, these brackets preferably should stably
engage and lock to the rails and/or perforated panels without the
need for separate or complex components.
[0004] Accordingly, a rail/perforated panel system solving the
above-identified problems and having the aforementioned advantages
is desired.
SUMMARY OF INVENTION
[0005] In one aspect of the present invention, a storage system
includes a rail having a flat front wall and top and bottom flanges
extending rearwardly from the front wall, at least the front wall
having a plurality of apertures therein. A plurality of spacers are
provided that are configured to stably engage a rear surface of the
rail and that are adapted to space the rail forwardly from a wall
structure; the spacers having a length longer than a depth
dimension of the top and bottom flanges. Accessories are also
provided, each with at least one leg for stably engaging at least
one of the apertures.
[0006] In a narrower form, several of the accessories include a
wire section forming an attachment end, with the wire section being
swaged to form a tapered formed shape adapted to wedgingly engage
one or more of the apertures in the rail.
[0007] In another aspect of the present invention, a shaped spacer
is provided for attaching a rail or perforated panel to a wall
structure at a location spaced from the wall structure, where the
rail or perforated panel includes apertures. The spacer includes a
body defining a screw-receiving hole and further includes a
protrusion offset from the screw-receiving hole and extending from
an end thereof. The protrusion is configured to abut marginal
material forming the aperture on the rail. By this arrangement, the
spacer and screw can be extended through the aperture, and then
when the screw is rotated, the protrusion abuts the marginal
material to stop rotation of the shaped spacer when the body of the
spacer is offset from the selected one aperture.
[0008] In another aspect of the present invention, a storage system
includes a rail having front, top and bottom walls and having a
plurality of apertures therein. The storage system further includes
a storage device having a useful section configured to hold product
when in a use position, and having an attachment section made from
a configured rod and configured to hold the useful section in the
use position. Still further, the storage system includes a
stabilizing structure adapted to engage the rail and the attachment
section for securing the storage device stably on the rail, the
stabilizing structure being selected from a group consisting of: 1)
the configured rod shaped to fit into a selected one of the
apertures and including notches in the configured rod that are
shaped to engage front and rear surfaces of the rail adjacent the
selected one aperture, 2) a swaged portion of the configured rod
configured to wedgingly engage a selected one of the apertures, 3)
a separate holder having a recess shaped to receive the attachment
section and having a tab supported on a living hinge that engages a
back surface of the rail when the configured rod is engaged with
the separate holder; 4) a clip with a first end shaped to encompass
and engage the configured rod and a second end shaped to snap
through a selected one of the apertures; and 5) a shape portion on
the configured rod shaped to fit through a selected one of the
apertures when in a first orientation but shaped to interlock with
the selected aperture when rotated to a second orientation.
[0009] In another aspect of the present invention, a storage system
includes a first rail having a plurality of apertures therein and
configured for attachment vertically and horizontally to a vertical
support structure, a second rail configured to matably engage the
first rail, and a plurality of brackets configured to engage
selected apertures to hold items on the rails. The brackets are
configured to engage the rails when the rails are positioned
vertically and when the rails are positioned horizontally. The
system further includes legs configured for attachment to the first
and second rails to hold the first and second rails in a
free-standing upright position on a floor surface; whereby the
storage system can be arranged in a horizontal
support-structure-attached position, a vertical
support-structure-attached position and a vertical free-standing
position.
[0010] In another aspect of the present invention, a storage system
includes first and second rails each having a front wall with a
plurality of regularly spaced apertures therein, the first and
second rails being configured for attachment horizontally to a
vertical support structure. The first and second rails each have a
first end and a second end, the first end including a first
attachment flange deformed from alignment with the front wall and
the second end having a second attachment flange. The first
attachment flange of the first rail being shaped to overlappingly
engage the second attachment flange on the second rail and being
configured for secure attachment thereto with the apertures on both
the first and second rails lining up to form a continuous and
regular pattern across the first and second rails. A plurality of
brackets is provided that is configured to engage selected
apertures to hold items on the rails.
[0011] In another aspect of the present invention, a storage system
includes a C-shaped channel with its length defining a horizontal
use position, and a peg with at least a partial flat area along its
attachment end. The flat area is inserted through at least two
apertures of a channel with the flat section becoming wedged in one
of the apertures in the channel, thus securing the peg to the
channel in a stabilized position.
[0012] In another aspect of the present invention, a storage system
includes a C-shaped channel including a face wall and top and
bottom perpendicular walls, the walls having a plurality of
apertures therein. A hook retainer is formed from a single section
of wire having a radiused end section configured to engage at least
one of the apertures in the face wall and one of the apertures in
the top or bottom wall. The radiused engagement section rotatably
engages the rail for rotation between a first position for placing
a handle within its operative end and a second position where the
retainer rotationally moves such that the handle is gripped and
retained.
[0013] In another aspect of the present invention, a rail storage
system includes a plurality of rails, each having a face wall, a
top flange, and a rear flange extending perpendicular to the face
wall. An attachment tab extends longitudinally from the face wall
with the top and bottom walls being cut away adjacent the
attachment flange. A plurality of apertures on the face wall
includes a repeating pattern of the apertures on the attachment
flange, the attachment flange being configured to align with
apertures on the face wall so that two of the rails can be attached
together longitudinally and/or can be selectively attached in a
perpendicular direction with the attachment flange overlapping onto
the face flange of the other rail.
[0014] In still another aspect of the present invention, a rail
storage system includes a rail positionable in vertical or
horizontal orientation on a wall-supported surface, and also
includes a plurality of accessories including one-piece pegs,
brackets for supporting heavy yard tools up to one foot outwardly
from the rail, and shelves and other storage components that can be
attached to the rail.
[0015] In one form, the hook with leg maintains a same orientation
at different vertical positions.
[0016] In another form, hook retainers can be added to secure a
particular hook to the rail in a fixed orientation.
[0017] In another form, hooks, pegs and holders can be provided
with a rail, where the hooks, pegs and holders fit within a cross
section of the rail . . . which is very advantageous for shipping
and merchandising.
[0018] In another form, a holder and a rail can be configured so
that a single holder stably engages a single aperture in the rail,
such as by notches on the holder engaging flanges on the rail.
[0019] Another application of the present invention includes
providing the same apertures and storage components on a perforated
panel as were described for a rail, such that the same storage
components can be used on the perforated panel.
[0020] These and other aspects, objects, and features of the
present invention will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIGS. 1-4 disclose a rail storage system including different
brackets selectively attached thereto and showing stored items
thereon;
[0022] FIGS. 5-9 disclose a C-shaped rail of the present
invention;
[0023] FIGS. 10-12 disclose a one-piece bent wire holder with
swaged, tapered locking end;
[0024] FIGS. 12A-12C disclose a second swaged, one-piece bent wire
holder;
[0025] FIGS. 12D-12G disclose a rail storage system with a modified
version of the wire holder with notched areas;
[0026] FIGS. 13-15 disclose a second bent wire holder;
[0027] FIG. 18 disclose a second bent wire component, and FIG. 18A
shows a retaining clip usable therewith, and FIG. 18B shows a
similar clip but with its wire-engaging section rotated 90
degrees;
[0028] FIGS. 19-22 show a one-piece wire hook configured to
rotatably engage the rail;
[0029] FIGS. 23-27 disclose a hoop-shaped bent wire holder;
[0030] FIGS. 28-30 disclose an alternative rail;
[0031] FIGS. 31-33 disclose alternative rails and alternative ways
of supporting an end of a bent wire section holder;
[0032] FIGS. 34-35 disclose a bent wire holder usable with FIGS.
28-30 and FIGS. 31-32;
[0033] FIGS. 36-38 disclose another rail and hexagonally-shaped
bent wire member;
[0034] FIGS. 39-41 disclose details of a hook retainer clip shown
in FIG. 18A;
[0035] FIGS. 42-43 disclose an alternative interlocking arrangement
on a portion of a fastener section for engaging a
particularly-shaped aperture in a rail; and
[0036] FIGS. 44 and 45 disclose a chart having on the left-hand
side, various wall mounting arrangements and/or rails, and along a
top having a variety of different accessories attachable to the
various wall mounting options.
[0037] FIGS. 46-48 are side, front, and top views of a molded
plastic bracket having top and bottom protrusions shaped to fit
through apertures;
[0038] FIGS. 49-50 are side views of the bracket of FIG. 46 showing
attachment to a perforated panel, the FIG. 50 showing deflection
and pivoting of the lower protrusion to stably engage a rear
surface of the perforated panel when a bent wire hook is positioned
in a recess in the bracket;
[0039] FIG. 51 shows a bracket similar to FIG. 49 but with an
alternative body construction;
[0040] FIG. 52 is a front view of the bracket of FIG. 51;
[0041] FIGS. 53-54 are top and side views of an alternative bracket
having a wire-engaging tubular portion closing with a clam shell
motion, and a leg shaped to engage an aperture in a perforated
panel;
[0042] FIG. 55 is a front view of a bracket engaging a peg
board;
[0043] FIGS. 56-57 are vertical and horizontal cross sections
through the bracket in FIG. 55;
[0044] FIGS. 58-59 are rear and side views of a sheet metal stamped
anchor bracket;
[0045] FIG. 60 is a side view showing use of the anchor bracket of
FIG. 58 to support a shelf or laterally extending bracket;
[0046] FIG. 61 is a perspective view of a first laterally extending
bracket of FIG. 60;
[0047] FIG. 62 is a side view of the anchor bracket of FIG. 58
supporting the laterally extending tool-holder bracket of FIG. 61
on a rail, the rail being spaced from a wall-supporting structure,
FIG. 62A showing the rail, spacer, and anchor without the
tool-holder bracket, and FIG. 62B showing the rail and spacer while
also supporting a hook retainer on the rail;
[0048] FIG. 63 is an exploded perspective view of a rail with
shaped apertures and an accessory with a top pin shaped to slip
into an aperture and then rotate into locking engagement, and a
second protrusion shaped to snap into a bottom aperture upon the 45
degree rotation;
[0049] FIG. 64 is a perspective view of a free-standing arrangement
including a post made from a pair of the rails in FIG. 63 secured
together and supported by legs, and FIG. 64A is a similar view with
the legs exploded away from the post;
[0050] FIG. 65 is a cross-sectional view taken horizontally through
the post of FIG. 64;
[0051] FIG. 66 is a view similar to FIG. 65 but using four of the
rails;
[0052] FIG. 67 is a perspective exploded view of a spacer used on a
finished vertical surface to space a perforated panel away from the
vertical surface and to facilitate installation of the perforated
panel on the surface;
[0053] FIG. 68 is a view of the spacer of FIG. 67 used on a stud
for mounting the peg board on the stud;
[0054] FIG. 69 is a side view illustrating use of the spacer to
facilitate installation of the peg board on a wall, the view
illustrating pre-attachment of the spacer to the wall prior to
mounting the perforated panel (or peg board) to the wall-mounted
spacer, and also illustrating a screw extending through the peg
board and into a spacer prior to attachment to the wall;
[0055] FIG. 70 is a side view showing a spacer used to mount a rail
on a wall board or stud surface;
[0056] FIGS. 71-72 are top and front views of a rail having a
configured end shaped to allow overlap and interconnection of the
end of the rail with an identical rail to form a continuous
extended arrangement of the pattern of holes in the rail; and
[0057] FIGS. 73-74 are side and top views of a unique spacer with
an offset screw-receiving hole and an offset upward protrusion, and
FIGS. 75-76 are cross sections taken along lines A-A and B-B,
respectively, in FIG. 73; and
[0058] FIGS. 77-78 are front fragmentary views of a section of a
rail or perforated panel, the section showing one round aperture,
FIG. 77 showing that the spacer and screw can be extended through
the aperture, and FIG. 78 showing that, when the screw is rotated,
the spacer rotates until the protrusion abuts marginal material
around the aperture to stop rotation, such that the spacer
effectively moves to a position where it spaces the perforated
panel forward of the wall structure to which it is being
attached.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0059] FIGS. 1-4 show the extremely broad versatility of the
present invention. For example, FIG. 1 shows a storage system 20
including a horizontal rail 21 with a plurality of apertures,
various pegs, hooks, retainers, holders, fasteners, and brackets
attached thereto for supporting various items, including heavy
items such as the three spade shovels, up to 12 inches outward from
the rail and for supporting other heavy outdoor yard tools such as
the post digger and line trimmer shown. FIG. 2 is similar to FIG. 1
but includes even more items, and further shows the density,
customization, and strong support of the present system. For the
purpose of this disclosure, the terms pegs, hooks, retainers, and
holders are intended to be broadly construed.
[0060] FIG. 3 discloses an arrangement for supporting items in a
household utility area such as for storing cleaning supplies and
ironing supplies in a dense arrangement. The arrangement of FIG. 3
including a shelf 22 as well as a rotating hook 23, a drop hook 24
that is non-rotatable (on a left side) and a higher located hook 25
(supporting the electrical wire for the iron) in a raised
position.
[0061] FIG. 4 discloses multiple shelves 26, a basket 27, and a
ball hoop support 28 attached to the rail 21 in a vertical
orientation.
[0062] FIGS. 5-9 disclose the present rail, which in one of its
simplest forms is illustrated by FIG. 7 as being a "C" shape. The
illustrated rail 21 is one-piece and in its strongest form is made
from sheet metal.
[0063] Preferably the rail 21 is treated for aesthetics to provide
an optimal color and corrosion resistance, such as may be provided
by a durable finish. The holes 30 are sized, shaped, and configured
for optimal supporting of various hooks, retainers, fasteners, and
brackets, as discussed hereafter. The illustrated channel has
particularly shaped apertures 31, 32 in the top (FIG. 6) and bottom
(FIG. 8). In particular, the repeated apertures 31 in the top
flange (FIG. 6) include a round center portion configured to
receive a wire having a round cross section, and further include
right and left extended narrow portions configured to allow a
swaged end of a bent wire bracket to pass therethrough. The
apertures 32 in the bottom flange have a T-shaped configuration,
and are configured to interlockingly non-rotatably engage the
swaged end of a bent wire holder to stabilize the bent wire when
the wire is supported on the rail 21. (See, for example, FIG. 12.)
The front face of the channel (FIG. 7) includes different
apertures, some of which are shaped to receive a first
diameter-sized wire and others of which are shaped to receive a
second diameter-sized wire or retainer. Further, some of the
apertures are of particular size so that they can receive a
threaded fastener such as a No. 14 sheet metal screw, to
screw-attach brackets (for example, see FIG. 1 heavy-duty
tool-supporting bracket 29). Also, an end of the rail includes a
tab 35 that extends from the front face with the top and rear
flanges being cut away so that the rail can be attached in line
(see FIG. 5) or perpendicularly (see FIG. 5), such as by running
screws through the holes to secure the rails in longitudinal
alignment or a perpendicular arrangement. The overlapping end
flange can be (but does not need to be) bent offset so that a face
of the three rails of FIG. 5 is coplanar. Notably, in FIG. 7, some
of the apertures are not circular but instead have a slightly
rounded rectangular shape. This permits a fastener having a similar
shape to be extended through the "square" aperture and rotated
45.degree. to cause it to be frictionally retained within the
aperture. (For example, see FIGS. 42-43, which illustrate a similar
concept of a twist-lock arrangement.)
[0064] FIGS. 10-12 disclose a first bent wire peg 40 (also called a
"holder"). The peg 40 is made from a single piece of wire bent to a
particular configuration and is swaged on one end 41. The swaging
causes a flat end section that is longitudinally tapered with its
root area being slightly larger and its free end being slightly
smaller. Thus, when the bent wire is extended through the top and
bottom flanges as shown in FIG. 12, the swaged end 41 wedges into
position within the aperture 32 in the lower flange. This makes
this wire very stable on the rail, which has tremendous advantages.
Further, the one-piece wire holder is very low-cost to manufacture
and can be quickly and efficiently manufactured. Also, it is
contemplated that, by lifting the hook retainer to disengage the
flat end section, the hook retainer can be rotated 90.degree. to a
storage position flush against the rail where it is positioned out
of the way.
[0065] FIGS. 12A-12C disclose a variation of the bent wire peg,
where the location of a notch 41A (formed by swaging or machining)
is positioned to engage bottom flanges of an aperture in a rail
(FIGS. 12D-12G) while the "tail" end of the peg 40A engaging a back
surface of the rail (FIG. 12A) above the apertures for stability.
An advantage of this modified system of FIGS. 12A-12G is that the
pegs, hooks, holders and accessories can be stored within the cross
section of the rail during shipment (i.e., prior to installation
and use). This is considered to be a tremendous advantage in
merchandising and shipment. Also, it provides a lower cost due to
less material being required and also a stronger upper leg of the
rail without the larger apertures.
[0066] FIGS. 13-15 show a second bent hook 50. This second bent
wire hook 50 has a first end that forms an S-shaped engagement end
51 that engages an aperture in the rail 21 (FIG. 15) and includes a
leg 52 that extends downwardly from the engagement end and then
outwardly. In a first form, the present arrangement can be left to
hang, which permits the lower end of the hook to swing a short
amount back and forth in a direction parallel the rail. As shown in
FIG. 15A, the engagement end of the wire hook 50 can be further
extended at location 52' such that it engages a back side of the
rail 21 when in an intermediate or lower position on the rail (FIG.
15A). This multi-adjustability insures the retainer portion of the
wire hook can be adjusted vertically to maintain an adequate
storage position in any vertical position. This is of particular
benefit in the lowest position where the wire hook, not having the
face of the rail to contact, could swing down and back toward the
mounting surface, thus lowering the angle of the retainer portion
and possibly losing its storage (retention) ability. Also, in the
highest position, the upper end extends through an aperture in the
top flange and again stabilizes the bent wire hook on a face of the
rail. The stabilization can be important for supporting product in
a stable manner.
[0067] FIG. 18 discloses a retainer clip 60 that can be attached to
the hook shown in FIGS. 13-17 to very securely stabilize the wire
on a face of the rail. The retainer clip shown in FIG. 18 is also
shown in more detail in FIGS. 39-41. The clip 60 includes a body
configured to snap around a wire section with a clam shell type
motion, and includes legs that extend from each of the opposing
halves of the clam shell like body. When the legs are positioned
together and extended through an aperture in a rail (or perforated
panel), they frictionally engage the marginal material around the
aperture, which holds them together around the wire and also which
holds them to the rail (or perforated panel). A second retainer
clip 60' (FIG. 18B) is similar to retainer clip 60 in that it
includes a first end forming a pocket for receiving a section of a
round wire, and a second end configured to frictionally fit through
and engage marginal material forming an apertures in a rail or
perforated panel.
[0068] FIGS. 19-22 disclose the hanger 23 (also called a "rotation
hook" or "handle-holder") and which as illustrated includes a vinyl
sleeve 65 such as for stably engaging the handle of a broom, mop,
rake, shovel, hammer, trowel, or other tools with handles. (See
FIG. 1.) The bent wire handle holder 23 (FIG. 21) includes a top
end 66 bent to a radius so that it is adapted to rotatably engage a
lowermost hole on a face of the rail 21 and simultaneously
rotatably engages and extends through an aperture in the lower
flange of the rail 21. This allows the handle holder 23 to rotate
as shown by the arrows (FIG. 21). Thus, the lower end of the holder
which has back and forth sections can be rotated to an outward
position, a handle position therein, and when released, the handle
holder rotates on its upper end such that the middle and lower
transverse sections of wire pinch and engage the handle of a tool.
The vinyl sleeve helps frictional engagement to retain the handle.
For example, see the broom retained in a handle as shown in FIG. 3
in a middle of the drawing. It should be noted that the same
principle would work for an upper face hole and upper flange
aperture.
[0069] FIGS. 23-27 disclose the hoop bracket 28 that can be
attached to a rail 21 using a butterfly clip 70 and pair of No. 14
sheet metal screws (FIG. 27). The hoop 28 can also attach to the
rail 21 with a bracket having fingers which engage apertures in the
rail 21. The illustrated hoop bracket includes an attachment end
with vertically-downwardly extending sections of wire that engage a
front of the rail 21. The ball-supporting hoop bracket 28 is shown
in FIG. 4 (at a top of the photo). It is contemplated that the hoop
bracket 28 can be formed to include bent-wire attachment ends
configured to fit through apertures in a rail (or perforated panel)
and engage the rail (or perforated panel) in a manner similar to
the hook shown in FIGS. 15, 15A, and/or 18.
[0070] FIGS. 28-30 show an alternative rail 80 with a curvilinear
cross-sectional shape similar to an upside down question mark. The
rail 80 as shown in FIG. 28 includes a top flange 81 that abuts the
wall-supporting surface and further includes an angled wall 82 and
rearwardly extending perpendicular lower wall 83 that abuts the
wall surface. Advantageously, the rail 80 of FIG. 28 can be
attached using screws only along its top flange. Alternatively, a
flange can be extended downwardly from the lower wall for
attachment to the wall, if needed. However, gravity tends to cause
the lower wall to engage the wall-supporting surface as items
stored on the rail cause a downward force, such that a lower
attachment is most likely not needed. As shown in FIGS. 29 and 30,
various holes and apertures can be placed in the angled wall and
lower wall of the rail to receive various pegs, hooks, and other
components to support storage.
[0071] Also, it is contemplated that modifications can be made to
the C-shaped rail 21 and brackets therefore (see FIGS. 31-33). For
example, FIG. 31 shows that a bent wire holder 81A can include a
short curved end 82A that extends through an aperture on the front
face of the rail and further can include a swaged end 83A that
engages a shaped mating aperture in the top flange to stabilize the
hook retainer on the rail 21. Further, FIG. 32 discloses another
C-shaped rail 21B with a return flange 85 spaced a short distance
below the top flange. The peg 87 includes a swaged end 88 that
engages the two parallel top walls of the rail 21B for stable
support. FIG. 33 shows another arrangement, and notes that the
swaging is located at a bottom of the peg 89. However, it is noted
that the swaged end could also be located at a top end of the
rail-engaging portion of the peg.
[0072] FIGS. 34 and 35 disclose a simplified bent wire peg 90 that
can be engaged with any one of the aforementioned rails.
[0073] FIGS. 36-38 show that the bent wire peg(s) can, in fact, be
made from a hexagonal shape or other non-circular shape. In such
event, the bent wire peg 92 does not need to be swaged but instead
can engage a matingly shaped hole such as a hexagonal hole in the
C-shaped rail 21 (see FIG. 38). It is also contemplated that the
pegs can be made of non-metal materials, such as plastic. Hence,
the terms "wire" and "wire section" as used herein, are intended to
include materials having the slenderness and structure of a metal
wire, but that are not necessarily metal.
[0074] The hook retainer clip 60 is a molded plastic piece as shown
in FIGS. 39-41. FIG. 41 shows the clip engaged with a rail 21 and
supporting a bent wire holder 93. However, it is noted that the
present arrangement can also be used to engage various holes such
as in peg board 94, drywall, or other supporting surface.
[0075] FIGS. 42-43 disclose a non-uniformly shaped hole 100 in a
component such as a rail 21 or perforated panel. They further show
a retainer section 101 having a protrusion with a star-shaped end
similar in shape to the hole 100 but supported by a stem 102 of
reduced area. The stem 102 includes opposing radiused edges 103 and
opposing flat edges 104. When the retainer section is extended into
the hole, the stem 101 is oriented as shown in FIG. 42. When the
retainer section is rotated 45.degree., the stem 101 is positioned
as shown in FIG. 43. In FIG. 43, the flat edges 104 engage
different portions of the hole to restrict the rotation to only
45.degree.. The star-shaped end 105 includes protruding tips 106
forming blind surfaces that are moved under the marginal material
107 forming the hole 100 as the retainer section 101 is rotated
45.degree. from the position shown in FIG. 42 to the position shown
in FIG. 43. Thus, in FIG. 43, the blind surfaces interlockingly
engage the flange areas on the hole to interlockingly retain the
retainer section in place. This not only holds the unit within the
hole, but also can provide friction to stabilize the retainer
section 101 rotationally. Notably, it is contemplated that the
interlocking arrangement (i.e., the 45.degree. rotation) could be
incorporated into a screw-receiving plastic anchor placed in a hole
in the rail, or other mounting surface. It has also been considered
that a similar rotational locking method could be applied to a wire
retainer holder or other such component, along with a surface
having an appropriate aperture.
[0076] FIGS. 44 and 45 are left and right sections of a single
chart showing on a left side margin of FIG. 44 various mounting
options, including a rail that is positioned horizontally or
vertically and attached to a wall or studs. Further, many of the
various components related to the present invention can be
supported directly on a finished wall, on exposed studs, or on a
rail or a perforated panel such as a peg board. Also, various
attachment clips can be used (for example, see the lower left-hand
corner of FIG. 44). Across the top of FIGS. 44-45 are various
attachment accessories. In particular, they disclose a heavy-duty
L-shaped peg (see FIGS. 10-12), a shorter heavy-duty peg, a two and
four inch hook with locking clip (see FIGS. 13-18, 18A), and a
handle holder (see FIGS. 19-22 and FIG. 3). They also show a tool
organizer bracket that extends outwardly up to twelve inches from
the rail (see FIGS. 1, 2 and 61) and shelves (see FIG. 3), and
utility organizer baskets (see FIG. 4). It also shows additional
specialized brackets such as for supporting items including a
hoop-shaped ball rack (see FIGS. 23-27), and bike and utility
supports.
[0077] FIGS. 46-48 are side, front, and top views of a molded
plastic bracket 110 having top and bottom protrusions 111 and 112
shaped to fit through apertures in a perforated panel (e.g., peg
board 94), rail 21, or other perforated surface. The bracket
includes a body 113 with a vertical hole 114 and a horizontal
outwardly-extending upwardly-open recess 115 that forms a
continuous shape adapted to receive an L-shaped end of a bent-wire
peg 116 (see FIG. 50). The L-shaped protrusion 111 extends
rearwardly and upwardly, and the rearwardly extending tab 112 is
attached by a living hinge 117 to the body. Flanges 118 extend from
the body (FIG. 49) and form a flat surface for stably engaging a
wall board 94. As shown in FIG. 49, the bracket 110 fits against a
peg board 94, with the upper protrusion 111 hooked into a top
aperture, and the bottom tab 112 also fit into a lower aperture.
FIGS. 49-50 are side views of the bracket of FIG. 46 showing
attachment to a peg board, the FIG. 50 showing deflection and
pivoting of the lower protrusion/tab 112 to stably engage a rear
surface of the peg board 94 when a bent wire peg 116 is positioned
in a recess in the bracket. Specifically, when the L-shaped end of
the bent-wire peg (FIG. 50) is positioned in the vertical hole, the
bottom of the L-shaped end abuts the tab 112, bending it to an
interlocking position that grips a rear surface of the peg board,
securing the plastic bracket and the bent peg to the peg board.
This same arrangement can be used on any one of the rails disclosed
herein.
[0078] FIG. 51 shows a bracket 120 similar to FIG. 49 but with an
alternative body construction. The body includes a boss 121 that
forms a forwardly/horizontally extending hole for receiving a
linear end of a peg 122. The body includes a rib 123 that extends
downwardly from the boss. A top hooking-type L-shaped protrusion
125 and a lower fixed leg-like protrusion 124 extend rearwardly
from the body for engaging holes in the peg board. It is
contemplated that the lower leg can be large enough to frictionally
engage the aperture that it fits into. Alternatively, it can be
formed slightly upward, so that it deflects upon installation into
its hole, thus increasing a frictional retention in the aperture.
FIG. 52 is a front view of the bracket of FIG. 51, and shows a
shape of the apertured boss and the down rib, and also laterally
extending ribs 126 shaped to stably engage the peg board 94.
[0079] FIGS. 53-54 are top and side views of an alternative bracket
130 having a wire-engaging tubular portion 131 formed by top and
bottom members 132 and 133 that close with a clam shell motion to
grip a wire bracket 134, and a leg 135 shaped to engage an aperture
136 (FIG. 55) in a peg board 94. FIG. 55 is a front view of a
bracket engaging a peg board, and FIGS. 56-57 are vertical and
horizontal cross sections through the bracket in FIG. 55. FIG. 56
shows a section of the wire within the tubular portion of the
bracket. It is contemplated that the wire bracket can be
substantially any shape as long as it includes a horizontal section
extendable through the tubular portion of the bracket. Preferably,
the wire bracket is symmetrical for balanced loading on the
alternative bracket of FIGS. 53-54, but this is not required per
se.
[0080] FIGS. 58-59 are rear and side views of an anchor bracket
140. Anchor bracket 140 is preferably stamped from sheet metal for
strength and low cost, but it is contemplated that it could be made
from other materials. This bracket 140 is used to help support
larger brackets adapted to sustain and support large loading,
particularly when the brackets extend forwardly such a distance
from the rail (or perforated panel or peg board) that additional
strong support may be required. The anchor bracket 140 of FIGS.
58-59 includes a body 141 and an L-shaped leg 142 extending from a
middle of the bracket rearwardly and then upwardly. As shown in
FIG. 60, when installed, a lower portion of the anchor bracket 140
engages a front surface of the perforated panel 94 (or rail 21),
but an upper portion of the anchor bracket 140 is spaced slightly
from the front surface of the perforated panel 94 (or rail 21).
This provides room for a section 143 of a rear section 144 of a
sheet metal bracket, such as bracket or shelf 29 shown in FIGS. 60
and 61. The innermost flat attachment flange 143 fits between the
upper portion of the anchor bracket 140 and the perforated panel 94
(or rail 21). This also draws the L-shaped leg against a rear side
of the peg board, increasing stability of the arrangement on the
perforated panel 94 (or rail 21). Sheet metal brackets such as
shown in FIG. 61 are known in the art, and are publicly
available.
[0081] FIG. 62 is a side view of the anchor bracket 140 of FIG. 58
supporting the laterally extending shelf, such as shelf 22 (see
FIG. 3) on a rail 21. The rail 21 is attached to a wall using top
and bottom screws 150 through spacers 152. When inserted, the
L-shaped leg 142 of the anchor bracket 140 contacts the back
surface of the rail 21. The spacers 152 can be used to provide
clearance between the upper flange of the rail 21 and the wall
board 151. After the anchor bracket 140 is in place, the shelf 22
is mounted on the anchor bracket 140 with its back surface against
the rail 21. A flexible force-fitting fastener 140' is then
inserted through the lower holes of the shelf 22 and rail 21,
securing the shelf 22 on the rail. It should be noted that the
anchor bracket 140 can be used with various other storage
components, such as bracket 29 shown in FIGS. 1 and 61. It should
be further noted that the anchor bracket also works with perforated
panels, such as peg board. Notably, by providing spacers 152 at top
and bottom locations, a thickness of the rail 21 can be reduced.
This allows material savings and also provides space savings when
shipping and storing product prior to installation (which can be a
very advantageous and desirable feature in competitive retail store
environments). It should be noted that the shape of the formed rail
reduces the necessary thickness of material, thus further
increasing material savings. It is contemplated that a thickness of
the rail 21 can in some circumstances be reduced to a thickness
equivalent to the thickness of a peg board, such that accessories
intended for use on standard peg boards can also be used on the
rail 21. (See FIG. 62B, for example.) Where brackets and
accessories adapted for higher loads are to be mounted to the rail
21, an anchoring bracket 140 can be used at locations relatively
close to the top spacer 152 as shown in FIGS. 62 and 62A.
[0082] FIG. 63 is an exploded perspective view of a rail 21 with
shaped apertures 160 and an accessory 161 with an attachment flange
162 having a top pin 163 shaped to slip into the aperture 160. The
top pin 163 is similar in shape to the star-shaped apertures, and
has corners 164 that engage marginal material on the back surface
of the face wall of the rail when the accessory is rotated
45.degree. into locking engagement with the top aperture. A second
protrusion 165 is provided on the accessory and is shaped to snap
into a bottom aperture upon the 45.degree. rotation. Thus, the
accessory is self-attaching and self-locking without the need for
secondary attachment fasteners and anchors. Nonetheless, such
additional fasteners can be used, if desired.
[0083] FIG. 64 is a perspective view of a free-standing apparatus
including a post 170 made from a pair of the rails 21 in FIG. 63
secured together and supported by legs 171. The legs 171 can be
stamped or tubular or otherwise formed. FIG. 65 is a
cross-sectional view taken horizontally through the post of FIG.
64, and shows bolts 172 with washers and nuts 173 securing the
rails together back to back, with the top and bottom flanges
inter-engaging to form a stable box-shaped beam. The leg component
171 can be a stamped sheet metal part having a center section 175
that abuts a rear of the box-shaped rail arrangement, and is held
there by the bolts and nuts. The leg portions 176 of the leg
component 171 extends forwardly and at an angle a sufficient
distance and angle to stably support the post 170 in a
free-standing arrangement. It is contemplated that a top of the
post 170 could be anchored to a wall structure. For example, a
second component identical to leg component 171 could be provided.
The second component would be attached so that its legs extend in
an opposite (rearward) direction, so that ends of the legs could be
attached to a wall structure, with the post 170 being stabilized at
a location spaced several inches in front of the wall structure.
FIG. 66 is a view similar to FIG. 65, but illustrates a four-rail
box-shaped post 180 where two parallel rails 21 are positioned
perpendicularly between two additional parallel rails 21, with the
arrangement being secured by bolts 172 and nuts 173.
[0084] FIG. 67 is a perspective exploded view of a spacer 190 used
on a wall board 151 to space a perforated panel or peg board 94
away from the wall board 151 to provide space for the insertion of
hooks, adapters, fasteners, and brackets into the peg board. The
spacers 190 facilitate mounting of peg board 94 by being able to
locate sufficient points of attachment to the wall board 151
without having to do so through the peg board 94 (such as when the
peg board 94 is a fairly large sheet). It is also a great advantage
to not have to position spacers toward the center of a larger-size
peg board during the mounting process, so that an installer does
not have to reach around the peg board to a center location on a
back of the peg board. The illustrated spacer 190 is a molded
plastic part having flat front and rear surfaces and at least one
aperture 191 extending through the spacer between the flat front
and rear surfaces. The front and rear surfaces are large enough to
stably engage the peg board 94 and the wall board 151, thus
providing a stable arrangement after assembly. The screw(s) 196 for
attaching the peg board 94 to the wall board can be extended
through a hole in the peg board 94 and through a single hole in the
spacer 190 and into the wall board 151. Alternatively, a first
screw can be used to secure the spacer 190 to the wall board 151 or
stud 195 (FIG. 68), and a second screw can be used to attach the
peg board 94 to the spacer 190, for which there can be a second
hole in the spacer (FIG. 69). The first and second screws 196 can
be installed in any order, whichever best facilitates installation,
as illustrated by FIG. 69. By rotating the spacer 190, the relative
location of the alternative holes 191/192 can be varied to
facilitate assembly. It is noted that the spacers 190 can also be
used to support the peg board 94 on a stud 195 or other wall
surface (see FIG. 68) or on a rail 21. The spacers can also be used
at top and bottom locations to support a rail (see FIG. 70).
[0085] FIGS. 71-72 are top and front views of a rail 200 having a
configured end 201 shaped to allow overlap and interconnection of
the end of the rail with an identical rail to form a continuous
extended arrangement of the pattern of holes in the rail 200. The
rail 200 includes top and bottom flanges 202 extending from its
front wall 203 similar to the rails shown previously herein. The
rails 200 include an end flange 204. The end flange 204 may be
offset a distance equal to a thickness of material. Alternatively,
the end flange 204 may not need to be offset at all, depending on
the thickness of the rail material and the functional requirements
of the rail system. The end flange 204 includes a pair of apertures
205 that align with the apertures 205 in the (opposite) end of the
rail, so that when two identical rails 200 are aligned
longitudinally with the end flange of one rail overlapping on the
next rail, the pattern of apertures continue at a regular spacing
without interruption. The top and bottom flanges 202 are eliminated
at the end flange to prevent interference at the region of overlap.
By this arrangement, if fasteners engage the mating holes on the
longitudinally aligned rails, then only a couple of holes are
"lost" for use by storage brackets. If other apertures are provided
for securement of the rails to a wall, then no apertures are lost
to the storage brackets.
[0086] FIGS. 73-78 illustrate a spacer 210 configured to receive a
mounting screw 211 and together fit through an aperture 212 in a
rail 21 (or through an aperture in a perforated panel), the spacer
210 being configured to, when the screw is rotated, rotate out of
alignment with the aperture 212 to a position where it effectively
acts as a spacer to hold the rail 21 (or perforated panel) forward
of the wall structure to which the rail 21 (or perforated panel) is
being attached. This is particularly advantageous since it allows
an installer to attach a spacer at any location along a rail 21 (or
perforated panel) with one hand, while holding the rail 21 (or
perforated panel) with their other hand. It is also advantageous
when installing large perforated panels to make it much easier to
secure spacers away from the edges of the panel. The spacer 210
(FIGS. 73-73) includes an elongated cylindrical body 213 defining a
long direction and a cross-sectional shape (FIG. 76) that is the
same as the hole through which it will be extended. (Notably, the
illustrated cross-sectional shape is circular, but it could be any
cross-sectional shape desired.) A longitudinally-extending hole 214
is formed in the body 213 at a location offset from a center point
215 of the body 213. (FIG. 74). A protrusion 216 extends from an
end of the body 213 at a position offset from the center point 215
and also offset from the hole 214. As shown in FIG. 77, the screw
211 and spacer 210 can be extended through the aperture 212 in the
rail 21. As shown in FIG. 78, when the screw 211 is rotated, the
spacer 210 rotates until the protrusion 216 engages the marginal
material 217 around the aperture 212, at which time the rotation of
the spacer 210 is stopped while the screw 211 continues to rotate.
By this arrangement, a substantial portion of the body 213 is
positioned offset from the aperture 212. As the screw 211 is
further rotated threadingly into the wall structure, the body 213
of the spacer 210 eventually is pinched between a rear surface of
the rail 21 and the front surface of the wall structure.
[0087] The present arrangement can be provided in a variety of
kits. In particular, it is believed that the various one-piece hook
retainers, handle holders, and ball holders are particularly novel
in combination with the present rail in terms of their shape,
stable engagement with the rail, mating array of holes and
configured apertures on the rail.
[0088] It is also believed that the use of the same rail with the
ability to be wall hung horizontally and/or vertically and/or
assembled in a free-standing floor-supported arrangement is very
useful and unique.
[0089] It is to be understood that variations and modifications can
be made on the aforementioned structure without departing from the
concepts of the present invention, and further it is to be
understood that such concepts are intended to be covered.
* * * * *