U.S. patent application number 14/834177 was filed with the patent office on 2016-02-25 for shelving brace.
The applicant listed for this patent is Pro-Mart Industries, Inc.. Invention is credited to Azad Sabounjian.
Application Number | 20160051044 14/834177 |
Document ID | / |
Family ID | 55347175 |
Filed Date | 2016-02-25 |
United States Patent
Application |
20160051044 |
Kind Code |
A1 |
Sabounjian; Azad |
February 25, 2016 |
SHELVING BRACE
Abstract
A rectangular shelf is supported along its sides by opposing
deck beams and supported on its ends by opposing end frame members,
all joined to corner posts. A hook on each opposing end of a
cross-brace engages a different latch affixed to each deck beam to
keep the deck beams from splaying under heavy load. The latches are
formed from a threaded nut or a washer having a flat side that is
affixed to the deck beam by heat or an adhesive.
Inventors: |
Sabounjian; Azad; (Irvine,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pro-Mart Industries, Inc. |
Irvine |
CA |
US |
|
|
Family ID: |
55347175 |
Appl. No.: |
14/834177 |
Filed: |
August 24, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62041404 |
Aug 25, 2014 |
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Current U.S.
Class: |
211/186 ; 156/60;
211/183 |
Current CPC
Class: |
A47B 47/021 20130101;
A47B 96/06 20130101; A47B 47/0083 20130101; A47B 57/50 20130101;
A47B 96/1441 20130101 |
International
Class: |
A47B 47/02 20060101
A47B047/02 |
Claims
1. A deck beam and cross-brace for use with a support frame for a
shelf in a shelving assembly, said shelf assembly including a pair
of rear posts extending upward and an opposed pair of front posts
extending upward with elongated front and rear deck beams extending
between and connected to respective pairs of rear posts and front
posts in the same plane and parallel to each other to define a
support for a shelf, each of the deck beams having an upper side
and a lower side, the deck beam and cross-brace comprising: a first
deck beam having a first shelf support surface extending along a
length of the first deck beam adjacent an upper side of the first
deck beam, and a threaded nut or a washer each having solidified
metal or an adhesive affixing a flat side of the nut or washer to
an inward facing surface of first deck beam to form a first latch
located adjacent the lower side of the first deck beam, the nut or
washer being orientated relative to the first deck beam so an
opening through the nut or washer faces upward during use; a second
deck beam having a second shelf support surface extending along a
length of the second deck beam adjacent an upper side of the second
deck beam, and a threaded nut or a washer having solidified metal
or an adhesive affixing a flat side of the nut or washer to an
inward facing surface of second deck beam to form a second latch
located adjacent the lower side of the first deck beam, the nut or
washer being orientated relative to the second deck beam so an
opening through the nut or washer faces upward during use, the
first and second latches located at corresponding locations on
their respective deck beams so the first and second latches are
directly opposite each other during use; a cross-brace having an
elongated body with two opposing ends, each end having a hook
extending in the same direction during use, each hook sized to fit
through the opening in one of the first or second latches during
use, the cross-brace having a length selected so the each hook can
pass through the upward facing opening of a different latch during
use when the latches are directly opposite each other, and the
hooks being configured to pass through the openings during use.
2. The deck beam and cross-brace of claim 1, wherein melted metal
affixes the latch to the deck beam.
3. The deck beam and cross-brace of claim 2, wherein at least one
latch is a threaded nut.
4. The deck beam and cross-brace of claim 2, wherein at least one
latch is a threaded nut and the opening is elongated with a long
axis perpendicular to the deck beam at the location of the
latch.
5. The deck beam and cross-brace of claim 2, wherein at least one
latch is a square nut.
6. The deck beam and cross-brace of claim 2, wherein at least one
latch is a hexagonal nut.
7. The deck beam and cross-brace of claim 2, wherein the first
latch is generally parallel to the first shelf support and the
second latch is generally parallel to the second shelf support.
8. The deck beam and cross-brace of claim 2, wherein the first
latch is inclined at an angle of about 30 degrees or less from an
axis perpendicular to the first shelf support.
9. The deck beam and cross-brace of claim 2, wherein the
cross-brace is a rod with a circular cross-section.
10. The deck beam and cross-brace of claim 2, wherein the
cross-brace is one of a braided metal or chain.
11. The deck beam and cross-brace of claim 2, wherein the
cross-brace has one end smaller in cross-section than the other
end.
12. The deck beam and cross-brace of claim 1, wherein an adhesive
affixes at least one of the first and second latches to the deck
beam and said one of the first and second latches comprises a
threaded nut.
13. The deck beam and cross-brace of claim 1, wherein the first and
second latches are located at about the center of a length of the
respective deck beams.
14. The deck beam and cross-brace of claim 2, wherein at least one
of the first and second latches is a washer with a flat side.
15. The deck beam and cross-brace of claim 14, wherein the opening
in at least one of the first and second latches is elongated with a
long axis perpendicular to the deck beam at the location of the at
least one latch.
16. The cross-brace and latch of claim 14, wherein the first latch
is generally parallel to the first shelf support and the second
latch is generally parallel to the second shelf support.
17. The deck beam and cross-brace of claim 14, wherein the first
latch is inclined at an angle of about 30.degree. or less from an
axis perpendicular to the first shelf support.
18. The deck beam and cross-brace of claim 14, wherein the
cross-brace is a rod with a circular cross-section.
19. The deck beam and cross-brace of claim 14, wherein the
cross-brace is one of a braided metal or chain.
20. The deck beam and cross-brace of claim 14, wherein the
cross-brace has one end smaller in cross-section than the other
end.
21. The deck beam and cross-brace of claim 1, wherein the first and
second latches are located at about the center of a length of the
respective deck beams.
22. A kit for a shelving assembly having a pair of rear posts
configured to extend upward during use and a pair of front posts
configured to extend upward during use, at least one pair of
elongated front and rear deck beams configured to extend between
and connected to respective pairs of rear posts and front posts in
the same plane and parallel to each other to define a support for a
shelf during use, the kit comprising: a plurality of first deck
beams having a first shelf support surface extending along a length
of the respective first deck beam adjacent an upper side of the
respective first deck beam, the plurality of first deck beam having
a threaded nut or a washer each having solidified metal or an
adhesive affixing a flat side of the nut or washer to an inward
facing surface of respective first deck beam to form a first latch
located adjacent the lower side of the respective first deck beam,
the nut or washer being orientated relative to the respective first
deck beam so an opening through the nut or washer faces upward
during use; a plurality of second deck beams having a second shelf
support surface extending along a length of the respective second
deck beam adjacent an upper side of the respective second deck
beam, and a threaded nut or a washer having solidified metal or an
adhesive affixing a flat side of the nut or washer to an inward
facing surface of respective second deck beam to form a second
latch located adjacent the lower side of the respective second deck
beam, the nut or washer being orientated relative to the respective
second deck beam so an opening through the nut or washer faces
upward during use, the first and second latches located at
corresponding locations on their respective deck beams so the first
and second latches are directly opposite each other during use; a
plurality of cross-braces each having an elongated body with two
opposing ends, each end having a hook extending in the same
direction during use, each hook sized to fit through the opening in
one of the first or second, directly opposing latches during use,
the cross-braces each having a length selected so the each hook can
pass through the upward facing opening of a different latch during
use when the latches are directly opposite each other, and the
hooks being configured to pass through the openings during use.
23. A shelving unit having a pair of rear posts extending upward
and a pair of front posts extending upward with two pairs of
elongated front and rear deck beams extending between and
releasably connected to respective pairs of rear posts and front
posts in the same plane and parallel to each other to define a
support for a shelf during use, the shelf comprising: a first shelf
having two opposing first deck beams each having a first shelf
support surface extending along a length of the respective first
deck beam adjacent an upper side of the respective first deck beam,
each of first deck beams having a threaded nut or a washer each
with a solidified metal or an adhesive affixing a flat side of the
nut or washer to an inward facing surface of each respective first
deck beam to form a first latch located adjacent the lower side of
the respective first deck beam, the first latches being orientated
relative to the respective first deck beam so an opening through
the nut or washer faces upward, the first latches being directly
opposite each other; a plurality of second deck beams having a
second shelf support surface extending along a length of the
respective second deck beam adjacent an upper side of the
respective second deck beam, and a threaded nut or a washer having
solidified metal or an adhesive affixing a flat side of the nut or
washer to an inward facing surface of respective second deck beam
to form a second latch located adjacent the lower side of the
respective second deck beam, the nut or washer being orientated
relative to the respective second deck beam so an opening through
the nut or washer faces upward, the first and second latches
located at corresponding locations on their respective deck beams
so the first and second latches are directly opposite each other; a
first cross-brace having an elongated body with two opposing ends,
each end having a hook extending in the same direction, each hook
fitting through the opening in a different one of the first latches
to help the first deck beams resist splaying under a heavy load; a
second shelf and second cross-brace constructed as the first shelf
and first cross-brace, but spaced apart therefrom.
24. The shelving unit of claim 23, wherein the latches comprise
threaded fasteners affixed to the deck beams by solidified
metal.
25. A method of making a latch for a deck beam for use with a
shelving unit having opposing deck beams each connected to
different pairs of posts to form a support for a rectangular shelf,
where the latch has an opening extending therethrough which is
configured to receive a hook on the end of a cross-brace, the
method comprising: placing one of a washer with a flat side or a
threaded nut having a flat side against a side of a deck beam, the
deck beam having a shelf support extending along an upper side of
the deck beam and configured to support a side of a shelf during
use, the deck beam having one of a connector or a recess at
opposing distal ends of the deck beam to releasably connect the
deck beam to a post during use; and positioning the one of the
washer or threaded nut adjacent a lower side of the deck beam with
a face of the one of the washer or threaded nut facing toward the
shelf support; and applying heat or an adhesive to the one of the
washer or threaded nut to affix the one of the washer or threaded
nut to the deck beam and form a latch for a cross-brace.
26. The method of claim 28, wherein the positioning step positions
a threaded nut generally parallel to the shelf support and the
applying step uses heat to melt at least one of the deck beam and
the threaded nut.
27. The method of claim 28, wherein the positioning step positions
a washer generally parallel to the shelf support and the applying
step uses heat to melt at least one of the deck beam and the
threaded nut.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The application claims the benefit under 35 U.S.C.
.sctn.119(e) to Provisional Patent Application No. 62/041,404 filed
Aug. 25, 2014, the entire contents of which are incorporated herein
by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] Shelves typically include four corner posts in a rectangular
arrangement with deck beams extending along the long sides of the
shelves and fastened to different pairs of four corner posts to
form a support for each shelf. Shelving units may have several such
shelves and may have end frame members extending between posts to
cooperate with the deck beams to form a rectangular support for the
shelves. In order to keep the shelving units light the deck beams
and end frame members are often formed with an open section and
typically have a flange or shoulder extending from a vertical web
of the deck beam or end frame member, with the shelf resting on the
shoulder or flange. The flange or shoulder extends along the length
of the deck beam and end frame members.
[0004] As the loads placed on the shelves increase the force on the
shoulders or flanges begins to twist the deck beams. To better
accommodate higher loading on the shelves, the deck beams may be
made with a closed sections or made of thicker material. But both
of those approaches increase the weight of the deck beams and
increase the cost. There is thus a need for a deck brace that is
light weight but can accommodate high loads on the shelves.
[0005] Cross-braces are sometimes used to support the shelves and
increase the load carrying capability. Cross-braces typically
extend between the shoulders or flanges that support the shelf and
help keep the shoulder and flanges from bending and twisting the
deck beams as well as supporting the bottom of the shelves. But
that approach requires a connection with the shoulder that does not
interfere with the shelf, thus complicating manufacturing and
assembly.
[0006] Some cross-braces bolt to opposing sides of the deck beams.
But forming the holes and fasteners for the cross-braces requires
multiple manufacturing steps and multiple assembly steps, both of
which can increase cost and reduce ease of assembly. There is thus
a need for a cross-brace that is inexpensive to manufacture and
easy to assemble.
BRIEF SUMMARY
[0007] A rectangular shelf is supported along its sides by opposing
deck beams and supported on its ends by opposing end frame members,
all joined to corner posts. A hook on each opposing end of a
cross-brace engages a different latch affixed to each deck beam to
keep the deck beams from splaying under heavy load. The latches are
formed from a threaded nut or a washer having a flat side that is
affixed to the deck beam by heat or an adhesive.
[0008] There is advantageously provided a shelving unit having a
pair of rear posts extending upward and a pair of front posts
extending upward with two pairs of elongated front and rear deck
beams extending between and releasably connected to respective
pairs of rear posts and front posts in the same plane and parallel
to each other to define a support for a shelf during use. The
shelving unit further includes a first shelf having two opposing
first deck beams each having a first shelf support surface
extending along a length of the respective first deck beam adjacent
an upper side of the respective first deck beam. Each of the first
deck beams has a threaded nut or a washer each with a solidified
metal or an adhesive affixing a flat side of the nut or washer to
an inward facing surface of each respective first deck beam to form
a first latch located adjacent the lower side of the respective
first deck beam. The first latches are orientated relative to the
respective first deck beam so an opening through the nut or washer
faces upward during use. The first latches are directly opposite
each other. The shelving unit has a plurality of second deck beams
having a second shelf support surface extending along a length of
the respective second deck beam adjacent an upper side of the
respective second deck beam. A threaded nut or a washer having
solidified metal or an adhesive affixes a flat side of the nut or
washer to an inward facing surface of each of the respective second
deck beams to form a second latch also located adjacent the lower
side of the respective second deck beam. The nut or washer is
orientated relative to the respective second deck beam so an
opening through the nut or washer faces upward during use. The
first and second latches are located at corresponding locations on
their respective deck beams so the first and second latches are
directly opposite each other. The first shelf also includes a first
cross-brace having an elongated body with two opposing ends, each
end having a hook extending in the same direction. Each hook fits
through the opening in a different one of the first latches to help
the first deck beams resist splaying under a heavy load. The
shelving unit also includes a second shelf and second cross-brace
constructed as the first shelf and first cross-brace, but spaced
apart therefrom.
[0009] There is also provided a deck beam and cross-brace for use
with a support frame for a shelf in a shelving assembly. The shelf
assembly includes a pair of rear posts extending upward and an
opposed pair of front posts extending upward. Elongated front and
rear deck beams extend between and are connected to respective
pairs of rear posts and front posts in the same plane and parallel
to each other to define a support for a shelf. Each of the deck
beams has an upper side and a lower side and at least one shelf
support extending from the beam toward an inside of the shelf
assembly for supporting the shelf during use.
[0010] The deck beam and cross-brace include a first deck beam
having a first shelf support surface extending along a length of
the first deck beam adjacent an upper side of the first deck beam.
A threaded nut or a washer, each having solidified metal or an
adhesive affixing a flat side of the nut or washer to an inward
facing surface of first deck beam, forms a first latch. The first
latch is located adjacent the lower side of the first deck beam.
The nut or washer is orientated relative to the first deck beam so
an opening through the nut or washer faces upward during use. A
second deck beam has a second shelf support surface extending along
a length of the second deck beam adjacent an upper side of the
second deck beam. A threaded nut or a washer having solidified
metal or an adhesive affixing a flat side of the nut or washer to
an inward facing surface of second deck beam forms a second latch.
The second latch is located adjacent the lower side of the first
deck beam. The nut or washer is orientated relative to the second
deck beam so that an opening through the nut or washer faces upward
during use. The first and second latches are located at
corresponding locations on their respective deck beams so the first
and second latches are directly opposite each other during use. A
cross-brace is also provided having an elongated body with two
opposing ends. Each end has a hook extending in the same direction
during use. Each hook is sized to fit through the opening in one of
the first or second latches during use. The cross-brace has a
length selected so the each hook can pass through the upward facing
opening of a different latch during use when the latches are
directly opposite each other. The hooks are configured to pass
through the openings during use.
[0011] In further variations, melted metal affixes the latch to the
deck beam. Further, at least one latch is a threaded nut or a
washer with a flat side. Advantageously, at least one latch is a
threaded nut and the opening in the nut is elongated with a long
axis perpendicular to the deck beam at the location of the latch.
The threaded nut may be a square nut, hexagonal nut, a rhombus
shaped nut. The first latch is advantageously generally parallel to
the first shelf support, as is the second latch. But the first
and/or second latches may be inclined at an angle of about 30
degrees or less from an axis perpendicular to the first shelf
support. The first and second latches are preferably located at
about the center of a length of the respective deck beams when only
one cross-brace is used.
[0012] Additionally, the cross-brace may be a rod with a circular
cross-section, or a braided metal or chain. One end of the cross
brace may be smaller in cross-section than the other end to make it
easier to insert the smaller end into the mating latch when the
other (larger) end is already inserted through its mating
latch.
[0013] Instead of solidified metal the latches may be affixed to
the deck beam using adhesive. The adhesive may be used with
threaded nuts, with washers and with the other variations of
latches described herein. Instead of threaded nuts, at least one of
the first and second latches may be a washer with a flat side. The
washer may have an opening that is elongated with a long axis of
that opening perpendicular to the deck beam at the location of the
at least one latch. When the first latch is a washer it is also
generally parallel to the first shelf support and the second latch
is generally parallel to the second shelf support. Whether the
latches are formed of washers or threaded nuts, it is advantageous
if the first latch is inclined at an angle of about 30 or less from
an axis perpendicular to the first shelf support.
[0014] There is also advantageously provided a kit for a shelving
assembly having a pair of rear posts configured to extend upward
during use and a pair of front posts configured to extend upward
during use, with at least one pair of elongated front and rear deck
beams configured to extend between and connected to respective
pairs of rear posts and front posts in the same plane and parallel
to each other to define a support for a shelf during use. The kit
also includes a plurality of first deck beams having a first shelf
support surface extending along a length of the respective first
deck beam adjacent an upper side of the respective first deck beam,
and a threaded nut or a washer having solidified metal or an
adhesive affixing a flat side of the nut or washer to an inward
facing surface of respective first deck beam to form a first latch
located adjacent the lower side of the respective first deck beam.
The nut or washer is orientated relative to the respective first
deck beam so an opening through the nut or washer faces toward the
shelf support surface.
[0015] The kit also includes a plurality of second deck beams
having a second shelf support surface extending along a length of
the respective second deck beam adjacent an upper side of the
respective second deck beam, and a threaded nut or a washer having
solidified metal or an adhesive affixing a flat side of the nut or
washer to an inward facing surface of respective second deck beam
to form a second latch located adjacent the lower side of the
respective second deck beam. The nut or washer is orientated
relative to the respective second deck beam so an opening through
the nut or washer faces the second shelf support. The first and
second latches are located at corresponding locations on their
respective deck beams so the first and second latches are directly
opposite each other during use when the ends of the beams are
connected to the posts.
[0016] The kit also includes a plurality of cross-braces each
having an elongated body with two opposing ends. Each cross-brace
has a hook extending in the same direction during use. Each hook is
sized to fit through the opening in one of the first or second,
directly opposing latches during use. The cross-braces each having
a length selected so the each hook can pass through the upward
facing opening of a different latch during use when the latches are
directly opposite each other. The hooks are configured to pass
through the openings during use.
[0017] There is also provided a method of making a latch for a deck
beam for use with a shelving unit having opposing deck beams each
connected to different pairs of posts to form a support for a
rectangular shelf. The latch has an opening extending therethrough
which is configured to receive a hook on the end of a cross-brace.
The method includes the step of placing one of a washer with a flat
side or a threaded nut having a flat side against a side of a deck
beam. The deck beam has a shelf support extending along an upper
side of the deck beam and configured to support a side of a shelf
during use. The deck beam also has one of a connector or a recess
at opposing distal ends of the deck beam to releasably connect the
deck beam to a post during use. The method further includes
positioning the one of the washer or threaded nut adjacent a lower
side of the deck beam with a face of the one of the washer or
threaded nut facing toward the shelf support. The method further
includes applying heat or an adhesive to the one of the washer or
threaded nut to affix the one of the washer or threaded nut to the
deck beam and form a latch for a cross-brace.
[0018] In further variations, the positioning step positions a
threaded nut generally parallel to the shelf support and the
applying step uses heat to melt at least one of the deck beam and
the threaded nut. In further variations, the positioning step
positions a washer generally parallel to the shelf support and the
applying step uses heat to melt at least one of the deck beam and
the threaded nut.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above, and other features and advantages of the present
invention are further described in the following drawings and
description in which like numbers refer to like parts throughout,
and in which:
[0020] FIG. 1 is a perspective view of a shelving unit having two
shelves removed to show a cross-brace;
[0021] FIG. 2 is a lower perspective view of a shelf brace
connected to a shelf beam of FIG. 1 with a cross-brace;
[0022] FIG. 3 is a left side perspective view of the a portion of
the shelf beam connected to the cross-brace of FIG. 2 with the
shelf removed;
[0023] FIG. 4 is an exploded perspective view of the cross-brace
and shelf beam of FIG. 3;
[0024] FIG. 5 is an alternative embodiment of the cross-brace and
shelf beam of FIG. 4;
[0025] FIG. 6 is a perspective view of a hook and a square nut for
a latch;
[0026] FIG. 7 is a perspective view of a hook and a rectangular nut
for latch;
[0027] FIG. 8 is a perspective view of a hook and rhombus nut for a
latch;
[0028] FIG. 9 is a perspective view of a hook and a washer having a
flat used for a latch;
[0029] FIG. 10 is a perspective view of a hook and square washer
used for a latch;
[0030] FIG. 11 is a perspective view of a hook and D-washer used
for a latch;
[0031] FIG. 12 is a deck beam with a Z shaped cross-section with a
nut for a latch;
[0032] FIG. 13 is a deck beam with a step shaped cross-section with
a nut for a latch;
[0033] FIG. 14 is a deck beam with an inverted L shaped
cross-section with a nut for a latch;
[0034] FIG. 15 is a deck beam with a C shaped cross-section with a
nut for a latch;
[0035] FIG. 16 is a perspective view of a portion of the shelving
unit of FIG. 1 showing two cross-members;
[0036] FIG. 17 is a perspective view of a portion of the shelving
unit of FIG. 1 showing three cross-members; and
[0037] FIG. 18 is a top view of an annular connector formed so its
opening is an oval shape.
DETAILED DESCRIPTION
[0038] Referring to FIGS. 1-3, a storage rack 10 includes at least
two and preferably at least four vertical supports or posts 12
which are typically vertical or substantially vertical, with a
bottom of each post having an optional base configured to rest
against a support surface, such as a floor. The base typically has
a flat surface that abuts and is parallel to the support surface.
The posts 12 are generally arranged at the corners of a rectangle
with a front and rear post at each end of the rectangle. The posts
12 may be referred to herein as corner posts.
[0039] As used herein the relative directions front and rear are
with respect to an aisle along which the storage rack 10 is placed
with two, spaced apart front posts adjacent the aisle and two rear
posts further away from the aisle. The relative directions of
inward and outward refer to the relative direction toward an inside
of the storage rack 10 from that aisle. The relative directions up
and down, upwards or downwards, or above and below, are with
respect to the direction of gravity when the storage rack 10 is in
its vertical, use position.
[0040] Each of the pair of front posts 12a, 12c and rear posts 12b
and 12d are preferably, but optionally, rigidly interconnected to
one another by a plurality of deck beams 14 and end frame members
16. A diagonal brace (not shown) may be optionally provided. The
end frame members 16 are located at or adjacent to the top and
bottom of the posts 12a, 12b and the posts 12c and 12d, and
preferably offset from the ends so that posts 12 can be bolted
end-to-end to increase the length of the post. The depicted end
frame members 16 and deck beams are horizontal and aligned with one
another to form a planar support for a shelf 18. The depicted posts
12 are shown as angled members having two legs at right angles to
each other in cross-section. The cross-sectional shape of the posts
12, frame members 16 and braces 18 will vary with the design
strength of the storage rack 10, as will the thickness or gauge of
the material used. Posts 12 with C-sections, or square sections may
be sued. The posts 12, frame members 16 and the optional diagonal
brace may be optionally be bolted together or fastened by any known
means. For heavier strength units those parts are preferably of
metal and may be welded together to form an end frame assembly. For
lighter units the parts are bolted together or are held together by
the end frame members 16 and deck members 14. The number, location
and shape of end frame members 16, deck beams 14 and any optional
diagonal braces may vary.
[0041] The posts 12 have a plurality of aligned post openings 22
(FIGS. 1-2). The post openings 22 may be on various sides of the
posts and may have various shapes. The depicted post openings 22
are on both sides of the posts 12a-12d. The post openings 22
preferably have a tear drop shape known in the art with a generally
circular top portion (FIGS. 1 and 2) and a narrower bottom portion
so that an enlarged head of a connector attached to an end of end
member 16 or deck beam 14 can fit in the larger top portion and be
restrained by the smaller bottom portion which receives the smaller
sized shaft to which the enlarged connector head is fastened.
Exemplary openings 22 are described in U.S. Pat. Nos. 4,074,812 and
5,624,045, the complete contents of which are incorporated herein
by reference. The post openings are preferably formed in pairs so
two openings 22 are adjacent each other. The post openings 22 are
configured to receive connectors 26 on deck beams and end frames.
By placing the connectors 26 on opposing pairs of deck beams 14 and
end frame members 16 into corresponding sets of openings 22, a
level, rectangular support for shelf 18 may be formed.
[0042] Extending horizontally between the adjacent posts 12 are the
horizontal deck beams 14, with front deck beams 14a extending
between adjacent front posts 12a, 12c and rear deck beams 14b
extending between adjacent rear posts 12b, 12d. The front and rear
deck beams 14a, 14b extend between and are supported by each of the
front (12a, 12c) and rear posts 12c, 12d, respectively. A plurality
of deck beams extend between the posts 12 at the location of each
desired shelf. Five rows of deck beams are shown in FIG. 1 along
with five rows of end frame members 16 for a five shelf shelving
unit 10. The number of shelves 18 can be varied by adding or
removing the supporting deck beams 14 and end frame members 16 and
cross-braces 28.
[0043] The deck beams 14 have a shaped cross-section which forms a
horizontal ledge or shelf support 20 extending inward toward a
center of the shelving unit 10 and located below an upper edge or
side of the deck beam a distance that is preferably about the same
as the thickness of shelf 18. Various open cross-sections for such
beams 14 are shown in FIGS. 12-15, and these are known in the art.
A bottom flange 24 (FIG. 3) extends along the length of the deck
beam at the bottom edge or side of the deck beam 14. The flange 24
is shown as inclined slightly outward at an angle of a few degrees
from the vertical portion of the deck beam, but the flange 24 may
be inclined inward, or may form a short flange extending
perpendicular to the face of beam 14 and preferably extending
inward. The bottom flange 24 is a stiffening flange to strengthen
the deck beam 14.
[0044] The deck beams 14 and end frame members 16 have connectors
26 (FIGS. 1-2) extending from the beams 14 and members 16 and
configured to engage the post openings 22. Alternatively, the ends
of the deck beams 14 and end frame members 16 could be configured
to engage post openings 22, with the openings configured to mate
with the configured ends of the beams 14 and members 16.
[0045] Referring still to FIGS. 1-3, a cross-brace 28 extends
between two opposing and generally parallel deck beams 14a, 14b.
The cross-brace 28 is preferably an elongated rod or other member
having a hooked end 30 configured to engage an annular latch 32
fastened to and extending inward from the deck beam 14. The
cross-brace is preferably at least 100 times longer than its
largest cross-sectional dimension. The cross-brace 28 helps keep
the deck beams 14 from spreading apart or splaying when the load on
the shelves becomes large enough to bow or deform the deck
beams.
[0046] The hooked end 30 is preferably bent or otherwise formed to
extend at an acute angle from the longitudinal axis of the
cross-brace 28. An acute angle of about 80-89 degrees is believed
suitable, and an angle of about 85-89 degrees being more preferably
and an angle of about 87-89 degrees being preferred. The angle on
the hooked end 30 depends on the opening 34 in the annular latch 32
as the hooked end 30 passes through the opening 34 and preferably
passes through vertically.
[0047] The latch 32 is preferably formed by the female portion of a
threaded fastener which has flat sides that are joined by heat to
the deck beam, such as being welded, glued, soldered,
ultrasonically welded, frictionally welded, or otherwise fastened
to the inner side of the deck beam 14. This melted and solidified
material 33 forms a connecting material affixing the latch to the
deck beam.
[0048] Preferably portion of the deck beam 14 or the latch 32 is
melted and more preferably melted material from both the deck beam
and latch are melted and intermixed to connect the parts together.
A square nut (FIG. 6) or a hexagonal nut (FIG. 5) is preferred for
use as latch 32. Rectangular nuts and rhombus nuts (FIGS. 7 &
8, respectively) may also be used, as may any nut with polygon
sides and an opening 34 suitable for passage of the hook 30. The
flat sides on the nut make it easy to position the flat side of the
nut against the flat side of the deck beam 14 and fasten them
together. Preferably the deck beam 14 is laid flat with its inner
face oriented upward and the nut forming the latch 32 is placed
vertically against the deck beam so the parts can be easily welded
or otherwise fastened together. Likewise, the deck beam 14 may have
its opposing edges vertically oriented and the nut forming the
latch 32 may be positioned horizontally against the vertical deck
beam 14 so the two parts may be fastened together.
[0049] The latch 32 is preferably fastened to the deck beam 34 so
that the opening 34 is oriented generally vertically and encircles
a generally vertical axis during use. While the latch 32 is
generally horizontal during use, it may vary off horizontal in
either direction by up to about 45 degrees, and preferably less
than about 30 degrees, and more preferably by about 5 degrees. If
inclined more than about 45 degrees the possibility that gravity
may assist unintended disengagement of the hook 30 from the latch
32 increases greatly. This 45 degree limitation means that the
opening 34 faces upward during use, and it also means that the
opening 34 and the face of the latch faces the shelf support 20
which is located above the latch. Thus, the face of the washer or
threaded nut forming the latch faces the shelf support 20, at a
relative angle of 0.degree.-45.degree. with the 0.degree. angle
being parallel to the shelf support 20 as shown in the figures. But
the latches 32 on opposing deck beams 14 are preferably within 1-5
degrees of each other if a cross-brace 28 having a continuous,
solid cross-section is used, otherwise the cross-brace will have to
be twisted to bring at least one hook into alignment with the hole
34 in the second-engaged latch 32. A corded cross-brace 28 may
accommodate latches orientated on opposing directions as the cord
allows the hooks 30 to twist. Thus, the latch 32 preferably has its
faces and opening 34 generally parallel to the shelf 18 and shelf
support 20 but may be inclined therefrom. As used herein the term
generally parallel means a variation of about 10.degree. in either
direction.
[0050] The latch 32 is located adjacent the bottom edge or lower
edge of the deck beam 14. The top surface of the latch 32 is offset
from the bottom edge or bottom side of the deck beam 14 by an
amount that is preferably slightly larger than the distance between
the distal end of the hook 30 and the adjacent side of the
cross-member 28. When the lower side of the cross-member 28 abuts
the top of the latch 32 (FIG. 3), the hook 30 extends through the
latch 32 and preferably extends at least slightly below the latch
32. If the hook extends below the lower edge of the deck beam 14
then items being placed on the shelves 18 may hit the bottom of the
hook 30 and urge it out of the latch 32. Thus, the latch 32 is
preferably positioned far enough away from the bottom of the deck
beam 14 so the latch 32 acts as a limit stop and prevents the
distal end of hook 30 from extending below the lower edge or lower
side of the deck beam 14. A little more space is preferred to guard
against engaging items placed on the shelves that are tipped, and
to guard against engaging a user's hands as items are placed on,
removed from, or moved on the shelves 18. But to prevent outward
splaying of the beam members 14, the latch 14 is preferably at or
very near the bottom edge or bottom side of the beam members. Thus
the position is a compromise between the effectiveness of the latch
and cross-brace 28, and the potential contact of the ends of the
hook 32 with items placed on the shelves 18 or with users hands.
The position is a further compromise because the outward splaying
arises when the shelf 18 is above the cross-brace 28 and the load
on the shelf and supporting shelf support 20 cause the deck beams
14 to twist about a longitudinal axis of the each beam. The closer
the cross-brace 28 and latches 32 are to the bottom edge or bottom
side of the cross-braces, the greater the resisting torque the
cross-brace 28 provides. The closer the cross-brace 28 is to the
bottom edge or bottom side of the deck beam (i.e., to flange 24),
the smaller the cross-sectional area of the cross-brace 28 can
be.
[0051] For a deck beam 14 having a vertical height of about 3-4
inches during use as in FIGS. 1-3, and a cross-brace 28 formed of
metal rod having a diameter of about 0.25 inches and the hook 30
extending about 0.5 inches beyond the bottom side of rod 28, the
top of the latch 32 is preferably located about 0.5 to about 1 inch
from the bottom of the deck beam 14. If the deck beam has a width W
(the vertical height during use), the top of the latch 32 is
preferably about 0.2 W to about 0.3 W from the bottom edge of the
deck beam.
[0052] Depending on the weight to be placed on shelves 18, the
number of cross-braces 28 and latches 32 will vary. For most
shelves a single cross-brace 28 located at or about the center of
the length of the beam member is believed suitable as shown in FIG.
1. For heavier loads on the shelves 18, two equally spaced from the
center of the deck beams and thus at locations of about 1/3 and 2/3
the length of the deck beams are believed suitable as shown in FIG.
17. If three cross-braces 28 are used, they would be located at
about 1/4, 1/2 and 3/4 the length of the deck beams as shown in
FIG. 17. Additional cross-members 28 could be used, preferably
equally spaced along the length of the opposing deck beams 14.
[0053] The internal threads 36 on the annular latch 32 form
engaging ridges which provide high friction contact areas that help
resist moving the hook 30 out of the opening 34 of the latch 32.
That is believed to provide a more secure connection between the
hook 30 and latch 32 and thus maintain the hook 30 of the
cross-member engaged with the latch 32 and the beam member 14 to
which the latch 32 is fastened.
[0054] Because the hook 30 passes through the opening 34 of the
latch 32, and because the opening 34 must be large enough to allow
that passage, threaded fasteners with large openings may be needed.
The longer the length of the hook 30, the larger the opening 34.
Using standard nuts reduces costs. It is thus advantageous to use
thin, commercially available hexagonal nuts and square nuts for the
latches 32. Square nuts come with both faces being flat, or one
face being flat and the other face curved and it is preferred to
use the nut that has both faces flat and parallel. The same applies
to hexagonal nuts. Hexagonal Jam nuts are usually thinner than
other hex nuts and are preferred for hex nuts. Flanged nuts are not
preferred as they are thicker, so flangeless nuts are
preferred.
[0055] Referring to FIGS. 2 and 4, the opposing ends of the
cross-member 28 preferably have the same shaped hook 30. But
optionally, as shown in FIG. 4, one end of cross member 28 may have
a hooked end 30' at an acute angle B that is smaller than the acute
angle A at the other end, and if so the smaller angled end is
preferably installed first. For installation, the cross-member 28
may be angled downward with the more acute angled end 30' above the
latch 32 to pass through the opening 34, with the cross-member 28
being rotated as needed to pass the acute-angled end 30 through the
opening 34 and to bring the less-acute angled hook 30 into position
above the latch 32 on the opposing deck beam 32, for normal
insertion.
[0056] Referring to FIGS. 9-11, instead of threaded nuts, it is
believed suitable to use washers, preferably rectangular or square
washers (FIG. 10) without threads to form the latch 32. The flat
sides on the washer are believed suitable for easy fastening of the
washer to the deck beam 14 to form the desired latch 32. The
washers are also thinner than threaded nuts and that is also
desirable. It is also believed suitable to use flat, round washers
that have a flat formed on one side of the washer either during
manufacture of the washer or afterwards. FIG. 9 shows such a
washer. D-shaped washers as in FIG. 11 are made with flat side and
are believed suitable. Washers with tapered thickness are also
believed suitable as the washers are sufficiently thin that a
change in thickness of even 100-200% does not alter their potential
use. Tapered washers with one flat side are also believed to be
commercially available and suitable for use as latch 32.
[0057] While less desirable, it is believed suitable to manufacture
the desired washers by stamping them out of metal sheet with the
desired flat side and large opening 34 to form latch 32 with a flat
edge suitable for easy fastening to the deck beam 14.
Alternatively, a commercially available round washer may have a
flat side cut or ground by known means to form the latch 32. As
desired, the hole in the washer may be enlarged to form a suitable
opening 34 for the mating hook 30.
[0058] Because standard washers and nuts have circular holes in the
center, a larger diameter washer or nut is needed to accommodate
the passage of an inclined hook 30. The diameter increases as the
length of the hook 30 increases. It is believed possible to deform
commercially available, standard nuts by squeezing them from
opposing sides to form an elongated hole or opening 34 in the
deformed nut, and opening that is not circular but that has a
length greater than a width of the opening 34, with the long axis
of the opening 34 being perpendicular to a flat side of the nut. If
the long axis of the opening 34 is perpendicular to the deck beam
14 then the hook 30 may fit within the opening 34--if the portion
of the hook 30 passing through the opening 30 has a circular, oval
or similarly elongated shape with any long axis aligned with the
long axis of the opening 34 of latch 32. Thus, it is believed
suitable to deform standard square nuts (FIG. 6) or rhombus nuts
(FIG. 8) or rectangular nuts (FIG. 7) by squeezing opposing sides
to deform the original circular opening in the nuts into an
elongated opening having a long axis perpendicular to the sides
that were not squeezed. It is also believed suitable to squeeze two
opposing corners of a hexagonal nut to deform the original circular
opening in the hex nuts into an elongated opening having a long
axis perpendicular to two opposing, sides. It is further believed
suitable to deform opposing flat sides of the nut away from each
other to create the elongated opening with a long axis of the
opening perpendicular to a straight side of the nut. The elongated
opening 34 should be sized and shaped to allow use with the hook 30
of cross-brace 28. An elongated opening 34 may be especially suited
to allow use with a hook 30 having a circular cross-sectional shape
or an elongated cross-sectional shape at least on the portion
passing through the elongated opening of the deformed nut. The nut
may be deformed by placing appropriate portions in compression by
engaging devices with conforming shapes. The nut may be deformed by
placing opposing portions in tension by clamping opposing faces of
the nut and pulling the clamped faces in opposing directions, or by
placing two pull-bars through the opening 34 of the nut and moving
the pull bars in opposing directions away from each other.
Deformation by compression is believed to be easier to implement
than deformation by tension even though the compressive strength of
metal is greater than its tensile strength.
[0059] The use of one or more cross-braces 28 provides some
advantages not previously appreciated. Normal shelving units 10 for
home use have the deck beams 14 and end frame members 16 that are
sized to withstand a specified load on the shelf 18 supported by
the beams and members 16 supporting that particular shelf. But by
making the deck beams 14 and end frame members 16 thinner and
compensating for the decreased strength using cross-brace 28 made
of a rod having circular cross-section, the shelf load capacity can
be maintained while the weight can be reduced. To the extent it was
previously known to use cross-braces to increase the load
capability of a shelf 18, there are still surprising advantages.
Using a rod with a circular cross-sectional shape maximizes the
tensile strength while reducing the weight, whether the rod is a
solid cross-section or a tubular cross-section. Thus, using a
cross-brace 28 formed of a rod having a solid circular
cross-section or a tubular circular cross section increases the
effectiveness of the cross-brace while reducing weight. Using a
cross-brace allows reducing the thickness of the deck beams 14 and
end frame members 16 for each shelf. For a conventional sized
shelving unit 10 having four rectangular shelves and a
corresponding number of eight deck beams 14 and eight end frame
members 16 and four posts 12, sufficient to form a shelving unit
four feet wide and six feet high and 12 inches deep, the beams 14
and members 16 can be reduced in thickness by 1-2 mm for shelves 18
rated to hold 1,000 pounds per shelf, using cross-braces with solid
rods of circular cross-section at the center of each pair of deck
beams. The weight of the shelf can be reduced and more shelving
units can be shipped. As a specific example, reducing the wall
thickness from 1.5 mm to 0.9 mm on the deck beams 14 reduces the
weight from 105 pounds to 89 pounds for a 16 pound weight savings
for a shelf unit having five shelves. U.S. shipping limits trailers
to 44,000 pounds, so that weight savings allows loading 480 units
in a 40 foot High Cube container rather than 390 units. That allows
more shelves to be shipped.
[0060] In addition to the advantageous increase in strength and
load capacity provided to the shelves and shelving unit, there is
also provided an improved method of manufacturing shelving units
and parts. The improved methods include placing a latch having a
flat side adjacent a flat surface of deck beam and fastening those
parts together by a process using heat or adhesives which form or
provide a material 33 joining the latch and deck beam. Processes
using heat include welding, soldering, brazing, friction welding
and spot welding that heat the material of the deck beam 14 and the
latch 32 and any third material (e.g., soldering or brazing), and
that preferably melts the material of at least one of the latch and
deck beam to bond the melted materials. As used herein, the term
"solidified metal" refers to the adhesive joining the deck beam to
the nut or washer, the at least partially melted and then
solidified metal from one of the deck beam, nut and washer arising
from the above described joining operations, or a third material
that is melted and bonded to the deck beam, nut or washer while
hot.
[0061] The latch has formed therein an opening suitable for
engaging a hook on a distal end of a cross-brace extending between
opposing latches and deck beams. The latch may be formed by using a
threaded nut with flat side and a suitable opening and thickness to
allow use with the hook and cross-brace. Referring to FIG. 18, the
latch 32 may be custom formed by using a threaded nut with flat
side and an elongated opening 34 formed by deforming opposing
portions of the nut toward each other to create the elongated
opening with a long axis of the opening perpendicular to a straight
side of the nut, which elongated opening is suitable to allow use
with the hook and cross-brace, and which is especially suited to
allow use with a hook having a circular cross-sectional shape or an
elongated cross-sectional shape at least on the portion passing
through the deformed nut. The latch may be custom formed by using a
threaded nut with flat sides and an elongated opening formed by
deforming opposing portions of the nut away from each other to
create the elongated opening with a long axis of the opening
perpendicular to a straight side of the nut, which elongated
opening is suitable to allow use with the hook and cross-brace, and
which is especially suited to allow use with a hook having a
circular cross-sectional shape or an elongated cross-sectional
shape at least on the portion passing through the deformed nut.
[0062] The latch 32 may also be formed by using a flat washer with
flat side and a suitable opening and thickness to allow use with
the hook and cross-brace. The latch may also be custom formed with
a flat side as by punching or cutting the latch from sheets of
metal in the form of a washer with a flat side and a hole suitable
for use with a hook 30 of cross-brace 28. The latch may also be
custom formed by using a commercially available washer with a flat
side and pulling opposing sides of that washer apart so as to
create an elongated opening with a long axis of the opening
perpendicular to a straight side of the washer, which elongated
opening is suitable to allow use with the hook 30, and which is
especially suited for use with a hook 30 having a circular
cross-sectional shape or an elongated cross-sectional shape at
least on the portion passing through the deformed washer.
[0063] There is also advantageously provided a kit for forming a
shelving unit 10. The kit has at least two shelves 18 and four
posts 12. For each shelf the kit has two deck beams 14 and two end
frame members 16. The posts 12 have a plurality of post openings 22
configured to receive connectors 26 located on the deck beams 14
and end frame members 16. At least the deck beams 14 and optionally
the end frame members 16 have a shelf support 20 located to support
a shelf 18, preferably in a horizontal plane, but sometimes in a
slightly inclined plane to better position items placed on the
shelves 18. The deck beams have latches 32 fastened to them
adjacent a bottom side of the beams and below the shelves. The
latches 32 are preferably formed by using threaded nuts or washers
with at least one flat side that are fastened to the deck beams
adjacent to the bottom edge or bottom side of the deck beam, at
corresponding locations on the deck beams so the latches are
directly opposite to each other during use of the deck beams. The
kit also includes at least one cross-brace for at least one pair of
deck beams, and preferably includes a cross-brace for each pair of
deck beams that has directly opposing latches. Additional latches
may be provided on the deck beams and advantageously an additional
cross-brace is provided for each pair of directly opposing latches
during use of the kit. The latches are located at about the center
of the deck beams if there is only one latch on each deck beam. The
latches are located equally spaced about the center of the deck
beams if there are more than two latches for each pair of deck
beams.
[0064] There is also provided an improved method of assembling
shelving units and parts, especially using the parts included in
the kits. Four posts 12 are connected to two deck beams 14 and two
end frame members 16 (via post openings 22 and connectors 26) to
form a generally planar rectangle. A cross-brace 28 is affixed to
opposing deck beams 14 by engaging hooks 28 on opposing ends of the
cross-brace 28 with a latch 32 on each of the opposing deck beams
14. The latches 32 are located on the deck beams 14 so the latches
are directly opposite each other and the cross-brace 28 engaging
the latches 32 is perpendicular to the deck beams 14. A shelf 18 is
then placed in that rectangular arrangement of the deck beams and
end frame members to rest against shelf supports 20 and stabilize
the partial assembly. It is preferred that the first shelf and
supporting deck beams 14 and end frame members 16 be near the
bottom or top end of the posts 12 and shelving unit 10. A second
set of deck beams 14, end frame members 16 and a cross member 28
are then then attached to the posts 12 as described above, with the
shelf 18 being added thereafter. Successive shelves are attached as
described above. \
[0065] It is preferable that the second shelf be located at the
opposing end of the posts 12, but it could be adjacent the first
shelf. It is very desirable that the shelf 18 be placed on the
first set of deck beams 14 and end frame members 16 as the
rectangular shelf 18 aligns the beams 14 and members 16 to conform
to the rectangular shape of the shelf 18. While it is desirable
that the shelf 18 be placed on each set of deck beams 14 and end
frame members 16 as they are attached to the posts 12, that is
optional as the shelves 18 may be placed in position after some or
all of the deck beams 14 and end frame members 16 are attached to
the posts 18. Similarly, it is desirable to attach the cross-braces
28 to the opposing sets of deck beams 14 before installing further
beams and frame members, but that could be delayed and several
cross-braces 28 attached at the same time. It is desirable that the
cross-braces 28 be installed before the shelves 18 are placed on
the deck beams joined by the cross-brace(s) 28 since that makes
installation easier. But if the latches 32 are a sufficient
distance below the ledge/shelf support 20 to allow a user to
install the cross-brace 28 after the shelf is in place, then the
cross-braces 28 could be installed after the shelves 18 are resting
on the shelf supports 20 of the deck beams 14 joined by the
cross-brace(s) 28.
[0066] The opposing ends of the cross-member 28 preferably have the
same shaped hook 30. But optionally, and referring to FIG. 4, one
end may have a hooked end 30' that has a smaller acute angle B than
the acute angle A on other end, and if so the more angled end 30'
is installed first. For installation, the cross-member 28 may be
angled downward with the more acute angled end 30' above the latch
32 to pass through the opening 34, with the cross-member 28 being
rotated as needed to pass the acute-angled end 30 through the
opening 34 and to bring the less-acute angled hook 30 into position
above the latch 32 on the opposing deck beam 32, for normal
insertion.
[0067] The hook 30 is shown in several figures as a substantially
straight end inclined at an acute angle relative to a horizontal
plane that is parallel to the shelf 18 above the hook, and inclined
at a complementary obtuse angle with respect to the plane of the
deck beam 18 where the latch 32 is fastened. The hook 30 need not
be straight and preferably has a recurved end portion on it as
shown in FIG. 5. The recurved portion makes it easier to engage the
edge of the opening 34 in the latch 32 and push the hook 30 through
the opening in the latch. The cross-brace 28 is preferably a rod
having a circular cross-section or a hollow, tubular cross-section,
with the ends bent to form hooks 30. Since the cross-brace 28 is
placed in tension to prevent the latches 32 and deck beams 14 from
splaying apart, the cross-brace 28 may be a flexible member such as
linked members (e.g., a chain) or braided wire cord that can be
repeatedly wrapped and unwrapped into compact shapes for compact
shipping, with the hooks 30 attached to the ends of the cord or
linked members or chain. Metals are preferred for the cross-brace
28 because plastics may creep and gradually increase in length when
a constant tension load is applied over time.
[0068] As shown in FIGS. 12-15, the latch 32 may be affixed to deck
beams 14 of various cross-sectional shapes. The end frame members
16 preferably have the same cross-sectional shape. The end frame
members 16 are optional but are preferred. The depicted
cross-sectional shapes are open sections, but use of the latch 32
is not limited to such open sections and may be used with various
closed sections, such as box sections or stepped sections as in
U.S. Pat. No. 2,815,130, the complete contents of which are
incorporated herein by reference. The latch 32 may also be used
with two open sections mated to form a closed section, as shown in
U.S. Pat. No. 4,955,490 and U.S. Published Patent Application
2009007520, the complete contents of which are incorporated herein
by reference.
[0069] The post openings 22 and the connectors 24 used on the deck
beams 14 and end frame members 16 may vary in shape. The openings
22 and connectors 24 may include various shaped fingers or fittings
on the ends of one or both of the deck beams 14 and frame members
16 and posts 12. Illustrative connections include those found in
U.S. Pat. Nos. 2,815,130, 3,601,432, 4,074,812, the complete
contents of which are incorporated herein by reference. The
specific type of connection between the posts 12, deck beams 14 and
end frame members 16 may thus vary.
[0070] Additionally, because the load on the shelves is usually one
or a few thousand pounds, and because metal (especially steel) is
relative strong and inexpensive, the cross-brace 28 may behave a
small cross-sectional diameter even if it is a solid metal rod. But
the small diameter makes the cross-brace flexible and that allows a
user to install a first hook 30 of the cross-brace by advantageous
positioning of the first hook and movement of the cross-brace as
described above to engage the first hook with the first latch 32,
and then resiliently flexing the thin cross-brace to better align
the distal end of the second hook 30 of cross-member 28 with the
opening 34 through the latch 32. Thus, the method of assembling the
shelves may include the step of resiliently bending the cross-brace
28 to align the distal end of at least one hook 30 with the opening
34 of the latch 32 and facilitating the connection of that hook
with that latch. The same applies if the cross-member 28 is a
braided cord or linked members such as a chain. As used herein,
resiliently bending means bending without exceeding the yield
strength of the cross-brace 28 so as to cause a visually
perceptible, permanent deformation.
[0071] As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention, which
may be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure. Thus, the above description is
given by way of example, and not limitation. Given the above
disclosure, one skilled in the art could devise variations that are
within the scope and spirit of the invention disclosed herein,
including various sectional shapes of the cross-brace 28 and
various cross-sectional shapes for the deck beams 14 and end frame
members 16. Further, the various features of the embodiments
disclosed herein can be used alone, or in varying combinations with
each other and are not intended to be limited to the specific
combination described herein. Thus, the scope of the claims is not
to be limited by the illustrated embodiments.
* * * * *