U.S. patent application number 15/086680 was filed with the patent office on 2017-10-05 for weldless support beam for rack shelving.
This patent application is currently assigned to WHIRLPOOL CORPORATION. The applicant listed for this patent is WHIRLPOOL CORPORATION. Invention is credited to Thomas I. Buckley, Patrick J. Duffy, Zachary A. Lownds, Matthew E. Pennington.
Application Number | 20170280875 15/086680 |
Document ID | / |
Family ID | 58461252 |
Filed Date | 2017-10-05 |
United States Patent
Application |
20170280875 |
Kind Code |
A1 |
Buckley; Thomas I. ; et
al. |
October 5, 2017 |
WELDLESS SUPPORT BEAM FOR RACK SHELVING
Abstract
A shelving support member includes a unitary member of a bent
sheet material and defining a support portion extending along an
axis to a first end and a retention portion disposed at the first
end of the support portion. The retention portion defines a base
extending congruently with the support portion at least partially
along the axis and to a first fold in the member. A reinforcement
portion extends from the first fold along and in contact with the
base. A first punched area is defined in an aligned manner through
both the base and the reinforcement portion of the retention
portion.
Inventors: |
Buckley; Thomas I.;
(Stevensville, MI) ; Duffy; Patrick J.; (St.
Joseph, MI) ; Lownds; Zachary A.; (St. Joseph,
MI) ; Pennington; Matthew E.; (St. Joseph,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WHIRLPOOL CORPORATION |
BENTON HARBOR |
MI |
US |
|
|
Assignee: |
WHIRLPOOL CORPORATION
BENTON HARBOR
MI
|
Family ID: |
58461252 |
Appl. No.: |
15/086680 |
Filed: |
March 31, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47B 47/021 20130101;
A47B 57/34 20130101; A47B 57/50 20130101; A47B 96/1441 20130101;
A47B 57/40 20130101; B21D 47/01 20130101; A47B 57/482 20130101 |
International
Class: |
A47B 96/14 20060101
A47B096/14; A47B 47/02 20060101 A47B047/02; B21D 47/01 20060101
B21D047/01; A47B 57/34 20060101 A47B057/34 |
Claims
1. A shelving support member, comprising: a unitary member of a
formed sheet material and defining: a support portion defining a
C-shaped cross section of the sheet material and extending along an
axis to a first end; and a retention portion disposed at the first
end of the support portion and defining a base extending
congruently with the support portion at least partially along the
axis, the base further extending to a first fold in the member, a
reinforcement portion extending from the first fold along and in
contact with at least a portion of the base; wherein a first
punched area is defined in an aligned manner through both the base
and the reinforcement portion of the retention portion.
2. The shelving support member of claim 1, further including a
first attachment rivet coupled with the unitary member through the
first punched area.
3. The shelving support member of claim 2, wherein a second punched
area is defined through both the base and the reinforcement member
of the retention portion, the support member further including a
second attachment rivet coupled with the unitary member through the
second punched area.
4. The shelving support member of claim 2, wherein a second punched
area is defined through both the base and the reinforcement member
of the retention portion, the support member further including a
retention tab coupled with the unitary member within the second
punched area.
5. The shelving support member of claim 2, wherein the unitary
member further defines a second fold at an end of the reinforcement
portion opposite the first fold and an stabilizer tab extending
from the second fold perpendicular to the axis.
6. The shelving support member of claim 5, wherein upper and lower
flanges within the C-shaped cross section define respective edges
extending along an upper and a lower edge of the stabilizer tab,
respectively.
7. The shelving support member of claim 1, wherein the punched area
is defined by three cut edges and one folded edge, the folded edge
joining a coupling tab with the retention portion.
8. The shelving support member of claim 7, wherein the coupling tab
includes a first portion extending congruently from the base and a
second portion extending congruently from the reinforcement
portion, the first and second portions of the coupling tab
contacting each other.
9. A shelving system, comprising: a first vertical member; and a
shelf support beam, including: a unitary member defining: a support
portion including sheet material extending along an axis from a
first end; and a retention portion disposed at the end of the
support portion and defining a base extending congruently with the
support portion and at least partially along the axis, the base
further extending to a first fold in the unitary member, a
reinforcement portion extending oppositely from the first fold
along and in contact with at least a portion of the base, a first
punched area being defined in an aligned manner through both the
base and the reinforcement member of the retention portion; wherein
the shelf support beam is coupleable with the first vertical member
at the retention portion thereof such that the shelf support beam
extends perpendicularly from the first vertical member.
10. The shelving system of claim 9, wherein: the shelf support beam
further includes a first attachment rivet coupled with the unitary
member through the first punched area; and the vertical member
includes at least one slot along a portion thereof, the slot
receiving the attachment rivet to couple the shelf support beam to
the vertical member.
11. The shelving system of claim 10, wherein: a second punched area
is defined through both the base and the reinforcement member of
the retention portion of the shelf support beam; and the shelf
support beam further includes a second attachment rivet coupled
with the unitary member through the second punched area.
12. The shelving system of claim 9, wherein: the unitary member
further defines a second fold at an end of the reinforcement
portion opposite the first fold and an stabilizer tab extending
from the second fold perpendicular to the reinforcement portion;
the reinforcement portion is positionable along a first surface of
the first vertical member when the shelf support beam is coupled
therewith; and the stabilizer tab extends along an edge of the
first vertical member adjacent the first surface when the shelf
support beam is coupled therewith.
13. The shelving system of claim 12, wherein the support portion of
the unitary member defines a C-shaped cross section of the sheet
material, upper and lower flanges within the C-shaped cross section
defining respective edges extending along adjacent upper and lower
edge of the stabilizer tab.
14. The shelving system of claim 9, wherein: the first punched area
is defined by three cut edges and one folded edge, the folded edge
joining a first coupling tab with the retention portion; and the
vertical member includes at least one slot along a portion thereof,
the slot receiving the first coupling tab to couple the shelf
support beam to the vertical member.
15. The shelving system of claim 14, wherein a second punched area
is defined in an aligned manner through both the base and the
reinforcement member of the retention portion, the second punched
area being defined by three cute edges and one folded edge, the
folded edge joining a second coupling tab with the retention
portion.
16. The shelving system of claim 14, wherein the first coupling tab
includes a first portion extending congruently from the base and a
second portion extending congruently from the reinforcement
portion, the first and second portions of the first coupling tab
contacting each other.
17. A method for making a shelving support member, comprising:
bending an extension tab extending from a support portion, the
support portion defining a C-shaped section of sheet material and
extending along an axis to a first end, and the extension tab
initially extending along the axis beyond the first end of the
support portion and being bent to form a first fold separating the
extension tab into a base extending congruently with the support
portion and a reinforcement portion extending oppositely from the
first fold along and in contact with at least a portion the base;
and forming a first punched area in an aligned manner through both
the base and the reinforcement member.
18. The method of claim 17, further including coupling an
attachment rivet with the base and the reinforcement portion
through the punched area.
19. The method of claim 17, further including subsequently bending
the reinforcement portion to form a second fold and defining a
stabilizer tab extending perpendicularly from the reinforcement
portion and extending along respective upper and lower flanges of
the C-shaped cross section.
20. The method of claim 17, wherein the punched area is formed
through the base and the reinforcement member by forming three cut
edges and folding respective sections of both the base and the
reinforcement member within the three cut edges into a coupling tab
spaced from the reinforcement member and having a portion extending
generally parallel thereto.
Description
BACKGROUND
[0001] The present device generally relates to a support member for
use in a shelving system. In particular, the support member
includes ends thereof that are reinforced for retaining the support
member in the related system without the use of welding.
[0002] Rack-type shelving systems are used in heavy-duty storage
scenarios. These types of shelving systems typically use elongated
metal components that are assembled together to give the resultant
shelving units their shape, mechanical support, and to position the
associated shelves. Typically, these components are assembled at
90.degree. angles that extend relative to each other in various
directions, depending on the particular component. Variations of
this shelving include components that can be assembled together
without separate fasteners or tools by use of interlocking tabs,
slots, and the like. Further, the components of these types of
shelving are often fabricated from bent sheet material or various
extrusions, to give the desired strength at a reduced weight and
cost compared to solid or cast materials.
[0003] Because of the structure of the assembled shelving units, in
which various components are relied upon in the assembly for
providing strength along the various axes, relatively thin
materials can be used with profiles that generally resist bending
along the lengths of the components. However, in the areas where
the components are assembled together, such thin material may not
be able to withstand the loads imparted thereon due to shelf
loading or the like. Accordingly, coupling ends of these
components, particularly longer shelving support members or beams,
are often made of thicker material that is welded onto the ends of
the component. The additional material and components associated
with this construction can add to manufacturing time and overall
cost. Accordingly, further advances may be desired.
SUMMARY
[0004] According to an aspect of the present disclosure, a shelving
support member includes a unitary member of a bent sheet material
and defining a support portion extending along an axis to a first
end and a retention portion disposed at the first end of the
support portion. The retention portion defines a base extending
congruently with the support portion along the axis to a first fold
in the member. A reinforcement portion extends from the first fold
toward the first end of the support portion in contact with the
base. A first punched area is defined in an aligned manner through
both the base and the reinforcement portion of the retention
portion.
[0005] According to another aspect of the present disclosure, a
shelving system includes a first vertical member and a shelf
support beam. The shelf support beam includes a unitary member
defining a support portion including sheet material extending along
an axis from a first end and a retention portion disposed at the
end of the support portion. The retention portion defines a base
extending congruently with the support portion along the axis to a
first fold in the member. A reinforcement portion extends
oppositely from the base along the axis in contact with the base. A
first punched area is defined in an aligned manner through both the
base and the reinforcement member of the retention portion. The
shelf support beam is coupleable with the first vertical member at
the retention portion thereof such that the shelf support beam
extends perpendicularly from the first vertical member.
[0006] According to another aspect of the present disclosure, a
method for making a shelving support member includes bending an
extension tab extending from a support portion along an axis to a
first end. The extension tab initially extends along the axis
beyond the first end of the support portion and is bent to form a
first fold separating the extension tab into a base extending
congruently with the support portion and a reinforcement portion
extending oppositely from the base along the axis in contact with
the base. The method further includes forming a first punched area
in an aligned manner through both the base and the reinforcement
member.
[0007] These and other features, advantages, and objects of the
present device will be further understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the drawings:
[0009] FIG. 1 is a perspective view of a shelving support beam
according to an aspect of the present disclosure;
[0010] FIG. 2 is a perspective view of a shelving system including
the shelving support beam of FIG. 1;
[0011] FIG. 3 is a perspective detail view of the shelving support
beam of FIG. 1;
[0012] FIG. 4 is a top detail view of the shelving support beam of
FIG. 1;
[0013] FIG. 5 is a perspective detail view of the shelving system
of FIG. 2, including the shelving support beam of FIG. 1;
[0014] FIG. 6 is a perspective detail view of the shelving system
of FIG. 2, including the shelving support beam of FIG. 1 in a step
of assembly with an associated vertical member;
[0015] FIG. 7 is a perspective detail view of the shelving system
of FIG. 2, including the shelving support beam of FIG. 1 in a
subsequent step of assembly with an associated vertical member;
[0016] FIG. 8 is bottom elevation detail view of a variation of a
support beam shown in the assembly of FIG. 2;
[0017] FIG. 9 is a perspective view of an alternative shelving
support beam according to another aspect of the present
disclosure;
[0018] FIG. 10 is a rear detail view of the shelving support beam
of FIG. 9 during a stage of assembly with an associated vertical
member of a shelving system;
[0019] FIG. 11 is a perspective view of a further alternative
shelving support beam according to another aspect of the present
disclosure;
[0020] FIG. 12 is a rear detail view of the shelving support beam
of FIG. 10 during a stage of assembly with an associated vertical
member of a shelving system; and
[0021] FIG. 13 is a perspective view of a further alternative
shelving support beam according to another aspect of the present
disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
[0022] For purposes of description herein the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," and derivatives thereof shall relate to the device as
oriented in FIG. 1. However, it is to be understood that the device
may assume various alternative orientations and step sequences,
except where expressly specified to the contrary. It is also to be
understood that the specific devices and processes illustrated in
the attached drawings, and described in the following specification
are simply exemplary embodiments of the inventive concepts defined
in the appended claims. Hence, specific dimensions and other
physical characteristics relating to the embodiments disclosed
herein are not to be considered as limiting, unless the claims
expressly state otherwise.
[0023] Referring to the embodiment illustrated in FIGS. 1-7,
reference numeral 10 generally designates a shelving support
member. Shelving support member 10 includes a unitary sheet
material member 12 that is bent or otherwise formed to define a
support portion 14 extending along an axis 16 to a first end 18.
Unitary member 12 further defines a retention portion 20 disposed
at the first end 18 of the support portion 14. Retention portion 20
further defines a base 22 extending congruently with the support
portion 14 along the axis 16 to a first fold 24 in unitary member
12. A reinforcement portion 26 extends oppositely along axis 16
from the first fold 24 in contact with base 22. A first punched
area 28 is defined in an aligned manner through both base 22 and
reinforcement portion 26 of the retention portion 20.
[0024] As illustrated in FIGS. 1 and 3, the punched area 28
included in the retention portion 20 of the present embodiment is
defined by a generally U-shaped or C-shaped cut through both
retention portion 20 and reinforcement portion 26. In particular,
the cut defining punched area 28 includes a first cut edge 72 and
respective upper and lower 74 and 76 cut edges extending away from
first cut edge 72. In this manner, a coupling tab 78 can be formed
integrally with retention portion 20 by bending the remaining
portions of base 22 and reinforcement portion 26 defined within
punched area 28 along a folded edge 80 extending between ends of
cut edges 74 and 76 opposite cut edge 72. Further, coupling tab 78
can be bent back toward reinforcement portion 26 such that at least
a portion thereof extends generally parallel with reinforcement
portion 26. Coupling tab 78 can facilitate coupling of support
member 10 with an associated component of a shelving system 34
(FIG. 2), as discussed further below.
[0025] As shown in FIG. 4, coupling tab 78 includes a first portion
82 extending integrally with reinforcement portion 26 and a second
portion 84 extending integrally with base 22. In this manner, the
inclusion of coupling tab 78 integral with retention portion 20 can
serve to at least partially secure reinforcement portion 26 against
base 22 due to the presence of folded edge 80 and the additional
end of coupling tab 78 itself (or at least increase the resistance
of retention portion 20 from being un-bent at fold 24). Further, as
shown in FIGS. 3 and 4, folded edge 80 can be angled with respect
to, for example, first fold 24. This arrangement may further
facilitate retention of reinforcement portion 26 against base 22.
By providing retention portion 20 with two material layers (base 22
and reinforcement portion 26) that together retain coupling tab 78,
support member 10 can be strengthened in the area of connection
with a related vertical shelving member 32 (FIG. 2) without the
need for an additional welded component. Accordingly, support
member 10 can include a single sheet material comprising unitary
member 12, as described above, while providing desired strength in
the area of coupling tab 78.
[0026] Referring now to FIG. 2, a shelving system 34 is illustrated
that includes a number of support members 10 coupled with a set of
four vertical members 32. As illustrated, support members 10 can
extend horizontally between two respective vertical numbers 32 and
can be arranged in horizontally-aligned pairs between respective
sets of such vertical members 32. In this arrangement, the
horizontally-aligned pairs of support members 10 can support a
shelf 33 thereon. As depicted, additional structural elements can
extend perpendicularly to support members 10 between adjacent
vertical members 32 to fully retain system 34 together. These
structural elements can include, for example, braces 35, shelf
supports 37, additional braces, or the like. As further shown in
FIG. 2, the vertical members 32 can include a plurality of slots 36
arranged along a height thereof at regular intervals. Such slots 36
can be spaced apart at intervals to allow for varied, user-selected
spacing between the pairs of horizontally-aligned support members
and, accordingly, the shelves supported thereon.
[0027] As further shown in FIGS. 5-7, the plurality of slots 36
included in vertical member 32 can be shaped to receive coupling
tab 78 therethrough by movement of support member 10 toward
vertical member 32 in a generally horizontal direction. Slots 36
can further provide an interengaging arrangement, in which a
portion of vertical member 32 is captured between reinforcement
portion 26 and coupling tab 78 when support member 10 is moved in a
generally vertical direction 70 along vertical member 32. As shown
in FIGS. 6 and 7, slots 36 are generally angled to match the angle
of folded edge 80 and may include a tapered portion 86 to a lower
end thereof to guide a portion of vertical member 32 between
reinforcement portion 26 and coupling tab 78 during the
above-described vertical movement of support member 10 with respect
to vertical member 32.
[0028] FIG. 8 shows another support member 11 that is shown in the
assembled shelving system 34 of FIG. 2 along the top and bottom of
the system 34 in place of the beams 10 discussed above with respect
to FIGS. 1 and 3-7. In particular, support member 11 includes a
unitary sheet material member 13 defining a support portion 15 and
retention portions 21 on opposite ends thereof, including first end
19. As illustrated, retention portion 21 includes a two part-base
including a first portion 23a that extends from support portion 15
along axis 17 and a second portion 23b joined with the first
portion 23a at a bend 25a such that second portion 23b is
approximately perpendicular to and extends away from first portion
23a. Fold 25b is positioned along the end of second base portion
23b with reinforcement portion 27 extending therefrom back toward
first portion 23a in a doubled-over manner similar to reinforcement
portion 26 and base 22 of support member 10, discussed above. As
further shown in FIG. 8, a coupling tab 79 that is generally
similar to coupling tab 78 is present within retention portion 21
extending from a punched area 73 through second base portion 23b
and reinforcement portion 27. Coupling tab 79, accordingly,
includes respective portions 83 and 85 extending congruently from
reinforcement portion 27 and second base portion 23b.
[0029] As shown in FIG. 2, the positioning of coupling tab 79 along
second base portion 23b and the associated reinforcement portion 27
can position coupling tab 79 so as to engage with one of the slots
36 positioned toward the outside of the support member 11 (i.e.
ones of slots 36 that are perpendicular to those of slots 36
engaged by the coupling tabs 78 of support members 10). This may be
advantageous for the joining of vertical members 32 in the
locations in which support members 11 are illustrated, including
for structural and assembly purposes. Further, variations of
assembly 34 are possible with support members 11 in place of one or
all of the support members 10. Conversely, an assembly 34 with
additional ones of support members 10 in place of support members
11 is also contemplated.
[0030] As discussed above, support member 10 comprises a bent or
otherwise formed structure of metal (such as steel, for example)
sheet material. Accordingly, in a method of fabricating support
member 10, a blank of sheet material of metal having appropriate
properties, and of appropriate size for the particular support
member 10 being fabricated, can be cut into a shape that can be
bent and folded in the form shown in FIGS. 1, 3, and 4. Suitable
materials may include galvanized or stainless steel, various
aluminum alloys, or the like. In general, the cut form will include
a two-dimensional shape with areas thereof corresponding to
vertical portion 48, upper flange 50, and lower flange 52 of
support portion 14, as well as areas for base 22 and reinforcement
portion 26. The cut material may be formed using stamping, sawing,
laser cutting, or the like.
[0031] Subsequently, the material can be bent to form upper flange
50 and lower flange 52 of support portion 14, including by bending
the designated area corresponding thereto with respect to vertical
portion 48 such that upper flange 50 and lower flange 52 extend
inwardly away therefrom at the desired angle (e.g., 90.degree.).
Additionally, if desired, shelf recess 54 can be bent into upper
flange 50. Subsequently, retention portion 20 can be formed by
bending the cut material along the desired area of first fold 24 to
define base 22 and reinforcement portion 26. Subsequently, the
above-described punched area 28 can be formed through retention
portion 20 by stamping or punching of base 22 and reinforcement
portion 26 in a single operation, according to the various
techniques described above. Coupling tab 78 can be defined within
punched area 28 by forming folded edge 80 between cut edge 74 and
76 by bending, stamping, or the like, with coupling tab 78 being
further shaped by bending or folding. In one embodiment, punched
area 28 and coupling tab 78 can be simultaneously formed by a
combined punching and stamping operation in which a single tool and
die arrangement is used to form cut edges 72, 74, and 76 in a
single operation in which the portion of retention portion 20
defined within cut edges 72, 74, and 76 is then bent to define
folded edge 80 and the desired shape of coupling tab 78. Support
members 11 can be fabricated in a similar manner, with an
additional fold 25a being incorporated between respective portions
23a and 23b.
[0032] Turning now to FIG. 9, a variation of a support member 110
that is generally similar in some respects to support member 10
discussed above with respect to FIGS. 1-7 is shown. Support member
110 includes a general structure, as described above, including a
unitary sheet material member 112 defining a support portion 114
and retention portions 120 on opposite ends thereof, including
first end 118. As illustrated, retention portion 120 includes a
base 122 having a first fold 124 on an end thereof opposite support
portion 114, such a fold 124 joining base 122 with a reinforcement
portion 126 extending generally therealong in a doubled-over
manner, thereby providing additional support for retention portion
120 in the same manner as discussed above.
[0033] As further shown in FIG. 9, shelving support member 110 can
include at least one attachment rivet 130 coupled with the unitary
member 112 through the first punched area 128. In this manner,
rivet 130 is secured through both base 122 and reinforcement
portion 126, thusly helping secure reinforcement portion 126 in
contact with base 122. Further, rivet 130 may be configured to a
facilitate coupling between retention portion 120 and a vertical
support member 132, as part of a shelving system 134 that is
generally similar to that which is discussed above with reference
to FIG. 2. Thusly, the doubling over of unitary member 112 within
retention portion 120 can provide beneficial additional structural
strength. Particularly, in a similar manner to that which is
discussed above, this reinforcement helps prevents deflection,
weakening, or even rupture of retention portion 20 due to load
concentration thereon due to the coupling and support provided by
rivet 130.
[0034] With additional reference to FIG. 10, the present embodiment
of support member 110 is shown having a second punched area 138
beneath first punched area 128, second punched area 138 having a
second attachment rivet 140 extending therethrough to couple with
both base 122 and reinforcement portion 126 of retention portion
120. This arrangement can give additional support and stability for
the coupling between retention portion 120 and vertical member 132,
and can also facilitate an arrangement in which support member 110
extends from vertical member 132 in a generally horizontal manner
(i.e. generally perpendicular to vertical member 132). As shown in
FIG. 10, first rivet 130 and second rivet 140 can be spaced apart
vertically at an interval generally equal to an interval between
slots 136 in vertical member 132. This arrangement can provide for
an adjustment interval of support member 110 that is equal to the
spacing between first rivet 130 and second rivet 140.
[0035] As further shown in FIG. 9, the present embodiment of
support member 110 can include a second fold 142 at an end of
reinforcement portion 126 opposite first fold 124, the second fold
142 positioning a stabilizer tab 144 in a generally perpendicular
relationship with reinforcement portion 126 and with base 122.
Stabilizer tab 144 can provide additional rigidity for retention
portion 120. In particular, stabilizer tab 144 can make retention
portion 120 further resistant to bending along axis 116.
[0036] Further, as shown in FIG. 9, within support portion 114
support member 110 can define a generally C-shaped cross-sectional
profile 146. In such a profile, support portion 114 can define a
generally vertical mid portion 148, from which base 122 extends
congruently, as discussed above. An upper flange 150 and a lower
flange 152 can extend away from vertical mid portion 148, thereby
providing structural rigidity for support portion 114 and, further,
providing an area 154 that is recessed to receive, for example, a
substrate used to form the associated shelf (similar to shelf 33 in
FIG. 2). As shown in FIG. 9, upper flange 150 and lower flange 152
can define respective edges 156 and can be arranged such that
adjacent upper and lower edges 158, 160 of stabilizer tab 144
extend, at least partially, therealong. As shown, this arrangement
can include stabilizer tab 144 being inset with respect to upper
flange 150 and/or lower flange 152, which can help resist twisting
or other deformation of support member 110, particularly at a
junction between support portion 114 and retention portion 120. It
is to be understood that a second retention portion may be present
along support member 110 at an end of support portion 114 opposite
first end 118, such second retention portion 120 being generally a
mirror-image of retention portion 120 depicted in FIG. 9.
[0037] As shown in FIG. 10, support member 110 can be assembled
with respective vertical members 132 in a shelving system that may
be similar to that which is described above with respect to FIG. 2.
In particular, vertical member 132 can include slots 136
appropriately sized and positioned to receive and retain rivet 130
therein. As shown in FIG. 10, when retention portion 120 is coupled
with vertical member 132, reinforcement member 126 generally
contacts a first surface 162 of vertical member 132. In some
embodiments, stabilizer tab 144 may contact an edge 163 of vertical
member 132 adjacent to first surface 162. In other embodiments, a
second surface of vertical member 132 may extend away from first
surface 162 such that stabilizer tab 144 is in contact therewith
when support member 110 is assembled with vertical member 132. In
particular, In this manner, a lower portion 136b of slot 136 can be
generally narrower than the upper portion thereof such that rivets
130 and 140, which can be generally T-shaped in a rotational cross
section, can capture a portion of vertical member 132 outside of
slot 136 after movement thereof in the vertical direction 170. The
relatively larger upper portion 136a can allow rivets 130 and 140
to pass through and into respective slots 136 during movement of
support portion 120 toward vertical member 132.
[0038] Support member 110 can be fabricated in a manner generally
similar to that used in fabricating support member 10, described
above with respect to FIGS. 1-7. Specifically, support member 110
can be bent into the general shape shown in FIGS. 9 and 10,
including support portion 114 and retention portion 120. In
particular, the portion of the unitary sheet material 112 within
retention portion 120 can be bent along first fold 124 to define
base 122 extending congruently with support portion 114 and
reinforcement portion 126 extending back along axis 126 in contact
with base 120. Further, second fold 142 can be formed prior to
formation of first fold 124, although the particular order may
vary. Further, in a variation, retention portion 120 can be formed
prior to formation of support portion 114.
[0039] After the desired forming of the sheet material has been
completed to form the unitary support member 110, first and second
punched areas 128 and 138 can be formed through retention portion
120, including by stamping or punching holes or the like through
both base 122 and reinforcement portion 126, simultaneously.
Alternatively, punched areas 128 can be formed by cutting holes
through retention portion 120 and reinforcement portion 26,
including by laser cutting or the like. Subsequently, first rivet
130 and second rivet 140 can be coupled, respectively, with first
punched area 128 and second punched area 138. Variations of support
member 110 including additional or fewer rivets 130 can be
fabricated by a similar process with the desired number of punched
areas and rivets being formed in and assembled with support member
110.
[0040] Turning now to FIGS. 11 and 12, a further embodiment of a
support member 210 is shown that is, similar to support member 110,
discussed above with respect to FIGS. 9 and 10, respectively.
Support member 210 includes a general structure, as described
above, including a unitary sheet material member 212 defining a
support portion 214 and retention portions 220 on opposite ends
thereof, including first end 218. As illustrated, retention portion
220 includes a base 222 having a first fold 224 on an end thereof
opposite support portion 214, such a fold 224 joining base 222 with
a reinforcement portion 226 extending generally therealong in a
doubled-over manner, thereby providing additional support for
retention portion 220 in the same manner as discussed above. A
second fold 242 can define a stabilizer tab 244 generally
perpendicularly arranged with respect to reinforcement portion 226.
This stabilizer tab 244 can extend along portions of an upper
flange 250 and a lower flange 252 that extend inwardly from a
vertical portion 248 of support portion 214.
[0041] As further shown in FIG. 11, retention portion 220 includes
a first punched area 228 and a second punched area 238 therein that
extend through both base 222 and reinforcement portion 226.
However, such punched areas 228 and 238 have generally rectangular
shapes. As further shown, retention tabs 266a and 266b can be
respectively coupled within first and second punched areas 228, 238
so as to extend generally inwardly from retention portion 220 (i.e.
in the same direction as stabilizer tab 244). Further, retention
tabs 266a, 266b can each have a hooked or bent shape such that at
least a portion thereof extends generally in the direction of axis
216 so as to be spaced apart from reinforcement portion 226.
[0042] As shown in FIG. 12, such a support member 210 can be used
in connection with a related vertical member 232 of a shelving
system that can be generally similar to that which is described
above with respect to FIG. 2. Vertical member 232 may be adapted to
receive both retention tabs 266a and 266b in specifically-adapted
slots 268 formed therein. Further, support member 210 can be
coupled with vertical member 232 by movement of support member 210
in the vertical direction 270 indicated in FIG. 12.
[0043] Tab slot 268 can be similarly configured with the respective
upper 268a and lower 268b portions receiving retention tab 266
therethrough during movement of support member 210 in a horizontal
direction toward vertical member 232. Further, lower portion 168b
can be narrower such that a portion of vertical member 232 is
captured between respective portions of retention tabs 266a and
266b and reinforcement portion 226 after movement of support member
210 in the vertical direction 270. In this arrangement, the
narrower lower portion 268b can be horizontally offset with respect
to the upper portion, as opposed to being centered in the case of
slot 136, discussed above.
[0044] A method for fabricating support member can be generally
similar to the above-described method of fabricating support member
10 and support member 110. However, retention tabs 266a and 266b
can be coupled with retention portion 220 as a separate element
with the use of mechanical fasteners, adhesives, welding, or the
like. Alternatively, first and second punched areas 228 and 238 can
be formed using a three-sided punch or cut through both base 222
and reinforcement portion 226 with retention tabs 266a and 266b
being bent from respective portions of base 222 and reinforcement
portion 226 and being defined within punched areas 228 and 238 in a
similar manner to that which is discussed above with respect to
coupling tab 78.
[0045] A further variation of a support member 310 with a doubled
over retention portion 320 is shown in FIG. 13. In such a
variation, the base 322 associated with retention portion 320 is
joined with portion 314 by first fold 324 in the unitary shape
material 312 such that base 322 extends generally perpendicularly
from support portion 314. The associated reinforcement portion 326
is then joined with base 322 by a second fold 242 such that
reinforcement portion 326 extends back along base 322 to generally
align with first fold 324 and support portion 344. A plurality of
punched areas 328, 338, can be formed within retention portion 320,
by cutting, punching, stamping, or the like through both base 322
and reinforcement portion 326, including through second fold 342.
Remaining portions of retention portion 320 outside of the punched
areas 328 and 228, including second fold 342 can, accordingly,
define retention hooks 388 and 390 that can engage with
corresponding slots in a vertical member similar to vertical
members 32, 132, and 232, discussed above.
[0046] It will be understood by one having ordinary skill in the
art that construction of the described device and other components
is not limited to any specific material. Other exemplary
embodiments of the device disclosed herein may be formed from a
wide variety of materials, unless described otherwise herein.
[0047] For purposes of this disclosure, the term "coupled" (in all
of its forms, couple, coupling, coupled, etc.) generally means the
joining of two components (electrical or mechanical) directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
components (electrical or mechanical) and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two components. Such joining may
be permanent in nature or may be removable or releasable in nature
unless otherwise stated.
[0048] It is also important to note that the construction and
arrangement of the elements of the device as shown in the exemplary
embodiments is illustrative only. Although only a few embodiments
of the present innovations have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter recited. For example, elements shown as integrally
formed may be constructed of multiple parts or elements shown as
multiple parts may be integrally formed, the operation of the
interfaces may be reversed or otherwise varied, the length or width
of the structures and/or members or connector or other elements of
the system may be varied, the nature or number of adjustment
positions provided between the elements may be varied. It should be
noted that the elements and/or assemblies of the system may be
constructed from any of a wide variety of materials that provide
sufficient strength or durability, in any of a wide variety of
colors, textures, and combinations. Accordingly, all such
modifications are intended to be included within the scope of the
present innovations. Other substitutions, modifications, changes,
and omissions may be made in the design, operating conditions, and
arrangement of the desired and other exemplary embodiments without
departing from the spirit of the present innovations.
[0049] It will be understood that any described processes or steps
within described processes may be combined with other disclosed
processes or steps to form structures within the scope of the
present device. The exemplary structures and processes disclosed
herein are for illustrative purposes and are not to be construed as
limiting.
[0050] It is also to be understood that variations and
modifications can be made on the aforementioned structures and
methods without departing from the concepts of the present device,
and further it is to be understood that such concepts are intended
to be covered by the following claims unless these claims by their
language expressly state otherwise.
[0051] The above description is considered that of the illustrated
embodiments only. Modifications of the device will occur to those
skilled in the art and to those who make or use the device.
Therefore, it is understood that the embodiments shown in the
drawings and described above is merely for illustrative purposes
and not intended to limit the scope of the device, which is defined
by the following claims as interpreted according to the principles
of patent law, including the Doctrine of Equivalents.
* * * * *